question about cylinder side cover on S50

O

o no its mo

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Sorry if this is a duplicate post, I don't know if any one saw it on the Mechanics Corner thread.
I'm looking for a place to mount my Stebel air horn and I was thinking of making a short bracket and bolting it down under the front bolt on the left side of the front cylinder head chrome side cover. Before I do that, is there any problem in removing that bolt holding on the side cover and putting a piece of 1/8" aluminum under the bolt head and then tightening it down again? This is not the cylinder head, just the chrome side cover I'm talking about. I have a Clymer manual and it doesn't look like there will be any problem but I wanted to check with those of you who have taken this off before I decided to do that.
 
The cover is just decorative, so I see no problem with putting a thin bracket under the bolt. But remember, that bolt is not designed for any lateral or pulling forces, so you might want to swap it for a grade 3 bolt. Also, with only one mounting point, the horn is going to move forwards and back if you hit it, and will vibrate itself loose faily quickly. You might want to consider using a two-point mount directly to the frame. Or maybe it will fit inside that fake air cleaner on the right side.
 
I have cobra hwy bars and mine is mounted on the top right of the bars butting up against the frame. Also I took the horn apart and mounted the compressor separate from the horn. I have seen other mount them in near floor boards. Not too sure of the set up of the S50 though.
 
I've actually considered taking the right side fake air cleaner off which is the look of the older Intuders. That would give you a few bolt holes to use for adapting an air horn.
 
By fake right side air cleaner, you mean what they are using for the tool kit holder? That nice shiny piece of plastic? Then maybe the tool kit will fit inside the sissy bar compartment.
And, Frostbite- any problem taking the horn apart, the 2 parts just slide apart from each other? My bike has highway pegs mounted, not a full bar, and they are too thin and too low and at the wrong angle to mount anything to.
I also could drill a hole into the frame around the radiator and mount it to this, but I really don't want to drill any holes in the bike (rust, etc.). I just have to keep looking for an existing bolt or screw to use for the mount.
 
I think that's where the toolkit used to be on the Intruder where the sissy bar was standard equipment.

Before I'd drill any holes in the frame I'd buy some p-clamps or such and hang the horn off engine guards. The frame on the S50 is none too heavy to begin with and while it's unlikely the frame will bend or break at a hole, it is a potential stress riser for a fatigue crack. Probably not, but still possible.
 
There are already two factory holes in the frame just above that fake air cleaner, where they rivit some kind of ID tag for some countries- easier to just drill all the frames the same. So I see no worries with adding a couple more if you need to, on the other side. Use stainless screws and they will not rust, and if you ever remove the bracket just use a drop of touch up paint on each hole to prevent rust.
 
Just to be clear. I wasn't thinking of drilling a hole in the bike's frame. just in the metal frame or housing that surrounds the radiator, on the left side. I would remove the frame or housing around the radiator, drill a hole to put a bolt through it, and mount a bracket for the horn to the radiator housing..
But first, I'll see about removing the tool box housing and see what's under there, altho I sort of like the look of that.
Weird that Suzuki would make you use a Phillips head screwdriver to remove the cover to get to the tool kit. Wonder what genius thought that up.
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The screw to open the cover is at the 7 o'clock position and is a Phillips head with a thin slot all the way across it. You might be able to open it with a dime, I'll have to see if one fits and if if there's enough room to turn it with the coin. But then you always need to have a dime with you to get into the toolbox.
 
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