Repaired a Wolo Bad Boy

[MiCarl]

I've got a pair of Wolo Bad Boy air horns on my 89. The left one is newer because it was replaced after a crash. The design of the left is a bit different than the right, it does not have that apparent intake hole like the right one and the Stebel horn has.

 

The left horn started sounding pretty weak. I tore into it expecting to find a nest of some sort in the intake hole, which I never found.

 

In my search I noticed that there are a pair of holes in the bottom which are apparently used to hold the brushes back during installation (at least that's what I used them for on reassembly).

 

Since I had the armature out I lubed the bearings. That solved the problem. My guess is some dirty water got in through the bottom holes which put some drag on the shaft. The last couple rides before it acted up were wet and sloppy.

 

The older horn has the same holes and I suspect is vulnerable to the same problem.

 

**EDIT**

Didn't mention: The armature can be removed by removing the brush plate at the bottom. There are a pair of phillips screws near the electrical terminals. Putting screws back is not fun because magnets pull them out of alignment with the holes. I stuck the ends of a paper clip through the holes to hold the brushes back during assembly.

Edited October 24, 2012 by MiCarl

[Flyinfool]

I haven't had either of my Bad Boys go bad, yet, but this is good info to be stored back in the cobwebs of my poor little brain.

[djh3]

My stebel was acting up. Sometimes work sometimes needed long time on the button then would work. I shot a little wd40 in it. Now seems to be ok. But I may attempt the lube of the armature. Good info.