The Yamaha Road Star Warrior Forum

Overview & Explanation of this modification:

For several years i've been running with just the single Fiamm Low Note Freeway Blaster horn w/o a horn relay using the factory wiring:

http://rswarrior.com/forums/p/28179/391266.aspx#391266

http://rswarrior.com/forums/p/16823/274515.aspx#274515

Not happy with the single horn performance from day one (possible voltage drop thru button contact) i recently decided to reinstall the left OEM high note horn to compliment the Fiamm and was concerned about overloading the Factory Horn Button contact. I didn't want to get involved with rewiring the OEM harness to the horns and concocted this circuit as an simple and secure way to support this mod.

I've rationalized this modification based on the following:

The Horn Button now operates a low current draw miniature sealed automotive relay rated @ 180 ohm, 800mW located in the headlight housing.

The new sealed relay contact is rated @ 20A, 12V and i've increased the wire size to 16 ga

The existing signal circuit, 10A fuse, will protect any possible overdraw or short circuit. My current signal lighting is all LED's although i do use a LEQ that restores or duplicates the original load of the factory turn signals.

The existing horn wiring, altough 20ga, is parallel wiring in most cases so it isn't being overloaded

Reduced load through the Hitachi Pin Connector from the Horn Button

The headlamp ground conductor was established as the best and largest source for the new ground to the relay N.O. contact to feed the horns and wouldn't be a drain to the lamp as the horns are not used continuously

While accomplishing this mod i uncovered the undocumented factory ground bus connector in the headlight housing and have included a couple of photos for those that are interested

Electrical Schematic in Adobe Format: http://www.fileden.com/files/2008/1/1/1673654/My%20Documents/Horn%20Schematic%20Warrior%20Model.pdf

SlideShow Presentaion of the completed Mod: http://flickr.com/photos/15071518@N07/sets/72157605298482469/show/

Wiring Method: Tap/Branch connection means i skinned the insulation only and soldered the new wire as a branch and double shrink wrapped. Spliced connection is severed or cut with soldered and double shrink wrapped. The 16 ga tap to the headlamp ground is mechanically crimped and soldered.

Timely info Alan....I'm just getting ready to install a Stebel Nautilus horn on mine....they supply a 30 amp relay with it. Is that overkill or should I just use it with your method?

Once again, you've clarified another important mod!

Thank you! 

Alan,

Unbeatable, as always. When are you doing your PhD on the Warrior...?

SuicideD_45:

Timely info Alan....I'm just getting ready to install a Stebel Nautilus horn on mine....they supply a 30 amp relay with it. Is that overkill or should I just use it with your method?

I'm sure you can reroute the existing LH or RH existing horn wiring to trigger the new 30 amp relay coil from the signal circuit

The N.O. contact to power the horn will require 14 ga wire because of the increased 18A load. The positive lead should be fused as close as possible to the battery terminal per their pnstructions. The Grnd should be 14 ga too.

 Good enough....thanks for the insight! I'd already decided to use the heavier gauge wire for the Stebel!

Dan 

I mounted my Stebel Nautilus horn in the Speedstar air cleaner housing and fitted the relay under the fuel tank on the coil relocation plate. I took heavy guage wire, plus fuse in the live line, directly from the battery to power the horn. I unwrapped the harness and took the wires for the front horn to the relay and then re-wrapped the harness. I hope this helps.

 Cool, it does help...thank you!

I've mounted the horn in the relocated left side AIS cover I have on the right side, with a mod to the bracket so I could stuff that behemoth horn inside the inner bracket. We should be tackling that this afternoon once I pick up the new rear rotor bolts for the Carrozzeria wheel. I'll try and snap a pic or two of the install for anyone that may be interested in doing the same thing. 

Alan, Top notch workmanship and documentations as usual.

I thought you were tired of working on the ol Warrior and going to trade it in on a VMax?...LOL.

Jim

youngja:

Alan, Top notch workmanship and documentations as usual.

I thought you were tired of working on the ol Warrior and going to trade it in on a VMax?...LOL.

Jim

Badger:

I mounted my Stebel Nautilus horn in the Speedstar air cleaner housing and fitted the relay under the fuel tank on the coil relocation plate. I took heavy guage wire, plus fuse in the live line, directly from the battery to power the horn. I unwrapped the harness and took the wires for the front horn to the relay and then re-wrapped the harness. I hope this helps.

When i unwrapped the main harness to accomplish the coil relocate plate earlier last year, i went into a week long depression before i could complete the job  ... that's why i rationalized this short-cut modification 

 I'm game to see an easy, sensible way to tap into, run and mount the Stebel horn.  I had thought about trying to fit it in the AIS cover also.. but not sure I can make it work.  seems like when I looked at the instructions for the install, it HAS to be mounted a certain way for the compressor to work.. or something like that.

Pictures would help me TREMENDOUSLY.. :)

Thanks!
 

RRUFAST:

 I'm game to see an easy, sensible way to tap into, run and mount the Stebel horn.  I had thought about trying to fit it in the AIS cover also.. but not sure I can make it work.  seems like when I looked at the instructions for the install, it HAS to be mounted a certain way for the compressor to work.. or something like that.

Pictures would help me TREMENDOUSLY.. :)

Thanks!
 

I'll snap a few pics of the revised AIS bracket/horn install for you tomorrow Keep watching! 

And you are right, the horn does have to be mounted within 15 degrees of vertical axis...the way I have mine set, it's perfect, with the breather tube exiting at the back.

 Dan

AlanH:

....When i unwrapped the main harness to accomplish the coil relocate plate earlier last year, i went into a week long depression before i could complete the job  ... that's why i rationalized this short-cut modification 

I must admit that it is not a job for the faint hearted but definitely worth it in the end

 Hey Suicide.. any pictures for me? :)