Tools: Philips screwdriver, wire stripper/crimper, electrical tape, small flat screwdriver
Materials: 20-18 ga. crimp-on quick disconnects, 12v DC Piezo Buzzer
Cost: <$10
Time: 30 minutes or less
1. Open the glovebox and remove the 2 screws in the back which hold the horncast in place.
2. In the front of the scoot, at the top of the horncast, carefully pry the Genuine emblem up and off and remove it. It's very easy to break this. I use a very thin flat screwdriver to gently pry the emblem up at the right side. Then insert the head of the screwdriver and gently push the tab in to release the emblem. (See second pic below).
3. Unscrew the Phillips screw behind the emblem and remove the horncast.
4. The stock horn is located on the right side (if you're facing the scooter). If you just want to disconnect it (and not replace it), just disconnect the purple wire.
If you're replacing it, also pull the red/yellow wire.
The buzzer is held onto a bracket with a pair of tapered rubber fasteners. You can remove the signal with some pliers, pulling the fasteners to stretch them then wiggling the buzzer off. If you want to pull the whole bracket, it may be easier; it's held in place with an 8mm nut at the bottom. This also holds a bracket for the brake line, so keep an eye on that.
5. Crimp a pair of male connectors onto the ends of the wires on the replacement buzzer (below; also pictured is original buzzer).
6. If you want to use the original fasteners on the bracket, you may need to use a 1/4" drill bit to widen the mounting hole on the buzzer.
7. Connect the new buzzer to the wires in the horncast. Black wire on the buzzer goes to the red/yellow wire in the; red wire connects to purple in the scoot. Test the buzzer before installing it into the scooter.
8. Install the new buzzer using the original fasteners or bolting the signal onto the bracket. Tuck the wires back.
9. Replace horncast and screw it all back in.
Now, the first time I did this I used a pulsating buzzer. Because the signal is already on a relay, it sounded a bit like I was strangling a duck and was a bit too loud. (If you use an alternating/pulsating buzzer, you can disable the relay, which is under the cowl by the battery.) I then replaced it with another signal that beeps, just not as obnoxiously as the original. Unfortunately, I tried to make it a bit quieter by wrapping some tape around it and made it too quiet. So, I'll probably go back in eventually and pulling some of that off.
it's possible I'm underestimating the annoyance level of the stock buzzer. is it really so bad it makes you want to full on replace it and get a new one?
