Stebel Nautilus Installation on an MP3 400


Finding space for an air horn on the front end of the MP3 is a challenge, mostly because of the tilt mechanism. I had to relocate my Stebel twice because what had seemed like safe spots when the bike was upright, turned out to be in the way of suspension components while leaning. I finally settled on the area behind the front cover (the black plastic behind the windshield), just below the instrument cluster.

The shield (the main body of the front fairing) has a band running across the top. This is a convenient mounting place, but the thin plastic is not strong enough to support an air horn in a dynamic environment. I reinforced it with sheet aluminum (Figure 1) that attaches to existing mounting nuts on either side. The upper bracket assembly (Figure 2) is riveted though both the metal reinforcing strip and the plastic in front of it (Figure 3, upper right).


Figure 1


Figure 2
  
Figure 3


That setup worked pretty well until recently, when the horn stopped functioning. I discovered that the upper part of the tilt transmission's cable drive had been rubbing against one of the electrical spade connectors, eventually knocking it off its corresponding tang on the Stebel. I bent the tangs and connectors to increase clearance (Figure 4, top center).

At this point I decided that mounting the horn with only one bracket allowed too much free play, which could cause the horn to come into contact with another part, such as the instrument cluster, or perhaps result in metal fatigue in the upper bracket.

  
To that end, I created a lower bracket from 3/16" aluminum (Figure 5) that could attach to a conveniently located and unused factory bracket (Figure 4, bottom).
Figure 4
   Figure 5


I put a piece of protective foam on the underside of the bottom bracket where it contacts the horn's compressor, and secured them with a stainless steel hose clamp (Figures 6, 7). The horn now has no free play, and doesn't impinge on any other parts.


Figure 6
  
Figure 7