Installed Stebel Nautilus air horn, a.k.a. Wolo "Bad Boy" horn

[FrugalNinja250]

Bought it a year ago, decided to finally install it. Rummaged through my random hardware and found a steel angle brace. I drilled out the holes in it to fit the various bolts holding the relay and horn on, and to allow the stock Ninja horn screw to fit, then bent it around a little. The relay shown is what came with the kit, the stock horn wire terminals fit it perfectly. I ran two new wires back to the battery to power the horn itself as it draws up to 20 amps.

All in all it was a pretty straight-forward installation, and it is loud as heck.

The bracket, almost done. Just need to flatten out the kink in the vertical leg:



View showing the horn and relay mounted, still have to finish insulating terminals:



View from the front:



Final view from the side, everything clears through the full range of fork travel:

["A"]

Will the front fender hit the horn when the fork is compressed?

[Snake]

Originally Posted by N Ja

Will the front fender hit the horn when the fork is compressed?

He answered that above the last pic.

Great job Frugal Ninja250. I.m sure that will get some attention. When I use my horn every one just turns and laughs.

[FrugalNinja250]

Update, I had to remove it for the time being. I didn't check for suspension travel, just rotational clearance, and it never occurred to me that the forks had that much travel, so yes, the fender hit the horn. Now have a 1/2" crack in the fender.

The horn is pretty bulky and has specific mounting orientation requirements, so it's going to be a challenge to find some place to mount it. If I do remount it I'll leave the relay in the old location because it's convenient to the OEM horn wire connection.

To say I'm disappointed having to go back to the lame meep meep horn would be an understatement.

[CynicalC]

There are some mounting ideas for that specific horn here:

http://faq.ninja250.org/wiki/I_want_a_louder_horn

[FrugalNinja250]

Followup: The horn sustained a small dent on top, enough to prevent the impeller from turning. It's toast. Took it apart to verify the failure mode theory, unfortunately the top cap had a machine-swaged attachment so no way to repair. Off to the store to get another one, lesson learned about front suspension travel.

[CynicalC]

Originally Posted by FrugalNinja250

Followup: The horn sustained a small dent on top, enough to prevent the impeller from turning. It's toast. Took it apart to verify the failure mode theory, unfortunately the top cap had a machine-swaged attachment so no way to repair. Off to the store to get another one, lesson learned about front suspension travel.

In that link, there are also some different horn suggestions that can be mounted in the stock location.

["A"]

Originally Posted by Snake

He answered that above the last pic.

Great job Frugal Ninja250. I.m sure that will get some attention. When I use my horn every one just turns and laughs.

I saw it in the 3rd picture and thought the clearance would be problematic when the fork if compressed.. That horn seems way too big and heavy for the extra sound that it produces. I'd op for the slimmer profile and lighter weight 'freeway blaster' horn at 130+ db. Which has no need for a relay.

[FrugalNinja250]

Finished installing the Wolo adjacent to the left coil per one option posted, works great! I will note that though the Wolo and Stebel appear similar at first glance, they are very, very different horns though laid out identically. I'll post some pictures next week.

I also ordered the high and low tone FIAMM Freeway Blasters, $10 each shipped off Amazon was a good deal. At some point I'll do a comparison between the two.