Modern Vespa

1) Remove the Piaggio crest. Pry straight up from the right side. I was able to do it with my finger nail, a thin blade screwdriver may be necessary.



2) Remove the screw that resides under the crest.



3) Remove the screw that holds the coolant reservoir cover in place.



4) Remove the coolant reservoir cover. This is a tight friction fit and requires a good tug to remove it especially the first time. Just get your fingers under the bottom and pull straight back. It may feel like your going to break something but you won't.



5) Remove the screw at the front of the reservoir area and the one on the other side of the bike.





6) Remove the two screws on either side of the fuel filler door.



7) Open the fuel filler door and remove the two visible screws at the top of the open compartment.



8) Now you can lift the entire plastic piece high enough to gain access to the hidden screws (one on each side) as shown below.





9) Remove the two screws from under the nose just above the front fender.



10) This shows where the Stebel will be mounted.



11) Using a hacksaw I cut off the mounting tab on the horn to allow clearance between the horn and the coolant reservoir hose.



12) This picture shows where I cut the mounting tab and the clearance for the coolant hose.



13) These next three shots show how I routed the ty-wraps to hold the horn in position. For the bottom ty-wrap i used the hole that the original horn was mounted to.







14) I used a ty-wrap to hold the relay in position on the right side of the bike (right side when facing the front of the bike) The light green wire that is disconnected from the stock horn goes to the horn button. The black is ground.



15) The next two shots show the Add-a-Fuse. The 15 amp fuse is the original and the 10 is the one I added. In the second picture the Add-a-Fuse is in position. It simply presses into place like a fuse. The Add-a-Fuse has a pig tail already installed for you to crimp an extension wire onto. I was able thread this wire through an existing hole in the glove compartment.





16) Here is a nice schematic on how to wire the relay. Note the light green wire from the stock horn will go to terminal 86. The black wire from the stock horn will go to terminal 85. The power wire from the Add-a-Fuse will go to terminal 30. The positive position on the horn goes to terminal 87. You will have to run a ground wire from the horn to a chassis ground on the bike. I used one of the screws holding the rubber mat covering the electrics.



17) To install the body panel back on I first loosely put the center screw from under the Piaggio badge in place, then the two lower hidden screws, then the two top screws and finally the two screws under the nose and the two that hold the fuel filler piece .

Dave

I don't have a BV but this was a excellant post with photo's.
This is how all how to's should be posted.
Super Job!!!!!!

Great post. This may finally inspire me to put the Nautilus in my BV250.

Follow instruction, we will power Stebel horn direct from existing ciruit of scooter instead from battery. Is it overload the circuit? Thanks.

Bravo Dave! Top flight post. How'd you like it now that you got it installed? Is this something I just can't live without? BTW...our scoots are the same color.
-Arjen

Chetwynder,
Based on this posting, I ordered a horn and installed it. Your pictures and especially your schematic was super helpful. I did basically what you did, except I made a metal bracket that allowed me to install the horn rotated 180 degrees from the way you did it. That oriented the horn right behind the opening in the front bezel. Man, is it loud! Thanks.
-pdxscoot

I'm glad my post was helpful. I wish I all my tools and paraphernalia so I could have done a bracket as well. It's still plenty loud though! I still can't believe that these bikes aren't more popular than they are. Every time I ride mine I'm impressed.

Dave

Thanks for the post! I plan on doing this mod and this will help me a bunch. I plan on trying to keep my original horn. Did you remove yours to put the stebel in its place? Also on the piaggio badge is it held on by clue or clips?

Thanks again

Oh and the reason they aren't more popular here is you don't see them in person much. I bought the first of two my dealer got in a 3 month period.

Yes I removed the original horn, I can see no good reason (and actually I think room is going to be a factor) to have both. As for the badge, it is a clip arrangement.

In Canada the BV 500 has been discontinued - I'm guessing the only reason is due to poor sales. In the greater Vancouver area with a population of over 2 million I believe there are 3 BV 500's including mine .

Dave

I left the original horn in place. In the pic below, the original horn switch is at position 3. I hooked the new horn up to that switch. I ordered a new switch and installed it to the right of the original one and hooked the original horn to it. So I still have my silly beep beep for friendly hellos.

-Arjen

Just got my Stebel. Do I need to buy anything else to do this install?

Oh, and if I wanted to keep the original horn, where could I order a new switch?

Just should answer your questions: 2009 BV500 Stebel Horn Install Keeping Existing Horn

As for a new horn button, your local dealer should be able to order you one. Otherwise, you can order from Athens Scooter Company.

What happened to the photos, are they available anywhere else?