The Ultimate Stebel Location... tickler thread - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 30 Old 10-25-2006, 09:46 PM Thread Starter
Join Date: Oct 2006
Posts: 19
The Ultimate Stebel Location... tickler thread

Where to mount that damn STEBEL horn....

ok.. during tech day I helped Irelage mount his on the back of the bike using the Decalifornication bracket... clean install.. easy to access.. worked great...
the sound was coming from behind you.. and in my case with future hard bags it would have been muted somewhat...

ok.. how about under the right side... this is where people usually put it... great location... room for it and the relay.. sound works well... all in all a great location..
for me this is exactly where Ive been installing my centech fuse block and 3 20a relays... no room for Mr Stebel....

Where next.. no room on the left side... no room behind the kickstand safety switch...
What about all the room behind the fairing... my weldor's eye said heck.. it SHOULD fit...
Unbolted the fairing.. moved the wiring out of the way... tried using one of the healdight to stem bolts.. my original idea... damn.. too close.. hits the tubes,,, but.. not by much.. how to move it forward an inch or so..

bam.. made a bracket out of 3/8 (needs to be stout) welded it to the miain fairing brace... bolted the horn on.. WOW it fit.. with about 1/16 " all the way around.... cool...
went to put on the fairing..darn.. it hits

now what.,,

Hey this is KLR fab time not beauty school...
The light went on.. TRIM ONE OF THE TRUMPETS!!!!!
7 tries later it fits in snug as a bug and looks factory..
YOU cant see it... its fully protected.. its up high.. the trumpets and sound come out the vented bottom of the fairing.... the sound is projected in front of you.. exactly where you want a horn to blast....

Ok granted.. you need to know how to weld.. and you shouldnt be afraid to cut on a brand new Stubel....


not yet.. this is just a tickler thread...
Im so damn excited I had to post up...

Ill shoot some tomorrow

We now have a third place to mount that damn horn

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post #2 of 30 Old 10-25-2006, 09:54 PM
Join Date: Jun 2006
Posts: 595
Guess I'll repost here too!

Excellent! That's where I orignally wanted to mount mine, but I too noticed that there was some clearance issues... just barely. I knew it would fit, but would take some modification. But I was at a Tech Day myself and wasn't about to impose my will with someone else's tools and welder. Besides, I kinda figured that if I put it in the easiest location that most regular folks could do themselves, well, more people would be willing to buy them. I consider it a safety device, and I was taking pictures that day of the install specifically for the forum gang.

I'm waiting with bated breath to see how much you had to hack to get it to fit! :si0008
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post #3 of 30 Old 10-26-2006, 08:59 AM
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Cam, do I need to stop by your place Saturday and take some pictures for you?? :smile:
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post #4 of 30 Old 10-26-2006, 12:07 PM Thread Starter
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Craig.. what an awesome offer.. youre ALWAYS welcome KLR brother.. but I have pictures under control thanks

ok Stebel Thread continues

Work with me guys.. I was born long before computers.. I figured out an image host.. lets see if I can get this to work

Stebel Horn Fairing Mount Install "HOW-TO"

1) Removed fairing, remove light plug/turn signal plugs/ mark and get out of the way

2) Place Stebel on fairing bracket (drivers side) for fitup.. note that a new bracket, (3/8" x 1" w x 2" long), 3/8 is necessary for strength as the stubel is heavy but also for "spacing" the horn away from the fairing bracket for clearance) ,will need to be welded to the fairing headlight mount. This requires some trial and fitup. Make sure you have clearance, minimum 1/16" from alll contact points

3) After getting the right location and drilling a hole (5/16") through your new mount (in my case I had to clearance the existing factory center brace so I could get a socket on the stebel nut) Bolt on the stubel for trial fit.

In my case the cast body of the stubel just touched the fork tube when I tightened everything up.. not good.. so I ground off some of the excess cast housing. Bulders note... IT IS VERY IMPORTANT not to have any part of the horn touch the fork tube (or anything for that matter).. the vibration would wear the tube and while the casting of the horn is softer there is no way you would want it abraiding any part on the bike

4) After some more fitup I tried the fairing plastic.. it hit enough to be an issue ..hitting on the front trumpet of the stubel... so out came the cutoff saw.. several fitups and cuts had the horn fitting perfectly.. with clearance all the way around. The excess trumpet cut off wont affect any sound. The horn points at the mesh in the front fairing.

5) I took a picture after I bolted the fairing on.. there is about 1/2" clearance between the compressor and the fender... so electrical wiring lugs need to be bent at a 90 degree angle.. then waterproofed. Build note: The headlight fairing bracket bolts onto the KLR neck with two bolts.. they are a sloppy fit and you can make the headliight go up or down depending on where you elect to have the bracket during tightening phase... MAKE SURE you locate it in the upward most position.. i.e. pull up on it while tightening it.. This gives you an extra 1/8-3/16" to play with for the install.. you'll need it

Your light harness now has to go over the top of the bracket and needs wire ties, as the stock wire holder will no longer be used.

Im happy with the way it fits... its concealed..looks factory stock... puts the sound where it needs to be,, off the ground /projected forward

Hopefully someone can lead me about posting pictures and I can get them here directly next time
Next Ill post up how-to wire this and put a new fuseblock in.. that makes it all go together...

comments.. critique,,

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post #5 of 30 Old 10-26-2006, 12:15 PM
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You forgot to put the image tags before and after your links. I fixed it for you.

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post #6 of 30 Old 10-26-2006, 12:24 PM
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Nice write up Cam. I want to do this before too long.


[B]2005 [COLOR=red]KLR [/COLOR]685[/B]
[B]2015 Yamaha Super Tenere ES, 5/23/2015[/B]
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #7 of 30 Old 10-26-2006, 12:26 PM Thread Starter
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Posts: 19
and tim.. you just happen to know a friendly weldor that will do it for you!!!

Heres the final pic..

um.. Im still dumb biker scout.. not sure how to get them driectly here

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post #8 of 30 Old 10-26-2006, 12:34 PM
Join Date: Jun 2006
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There's little buttons at the top of the "Post A Reply" page that says "Img"

You can either type [img] then paste your link the type [/img] right after it.


You can paste your link, then highlight it and click that "Img" button at the top. That's what I do, it's faster.
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post #9 of 30 Old 10-26-2006, 12:38 PM
Join Date: Jun 2006
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As for the horn placement... good work! Actually, that's a lot of work. However, I'm still wondering if you are not going to get a lot of sound bouncing back at your face. Because technically, the horn outlets are facing the side of the fairing, which act like a concert shell and project the sound back towards you.

Was there no way to get that horn facing flat towards the front?

My original idea was to fab an insulated bracket that aligned the tubular body of the horn with the upper fork tube. At first inspection it seemed to me like it would then be allowed to rotate on the fork tube getting the horn outlets facing forward and near the lower grill. Did you look into that at all, since you had everything apart? Or was the headlight bracket too much into the way? (That could probably be abreviated somewhat... I'm not crazy about Kawasaki's design on that piece)
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post #10 of 30 Old 10-26-2006, 12:42 PM
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I cant hear you... your horn is too loud.

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