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Thread: Converted my Pulsar 150 Classic to ALL DC

  1. #1
    Rusted abhijeet080808's Avatar
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    Default Converted my Pulsar 150 Classic to ALL DC

    Hi guys! My Pulsar 150 now runs on all DC. In stock condition, the headlight, tail lamp and pilot lamp (parking), console lamps runs on AC. Rest of the stuffs - horn, indicators, tachometer, brake lamp, tell tale lamps, fuel meter and the starter motor runs on DC through the battery. I converted all the AC stuffs to run on DC.

    Advantages -
    1. Nil Flickering at idle - constant brightness of headlight.
    2. HID ready - can directly install HID in place of my 60/55W light. No battery draining issues.

    The procedure is described below. Can be potentially adapted to any bikes.

    Step 1

    Prepare the AC to DC rectifier circuit. The circuit diagram is given below.



    The above circuit is a standard bridge rectifier circuit. Use only parts mentioned above. Check for correct polarity of the diodes and the capacitors.

    Thanks to rahuldevnath for helping me confirm the basic idea and provide the design of the circuit including choosing the exact components needed to build the circuit. He has this rectifier on this UGIII Pulsar 180.

    My completed circuit -



    Look at the circuit - the extra soldering is done so that it may dissipate some heat from the diodes. I recommend a 5K resistor between the capacitor pins to ensure safe discharge of the capacitor charge when not in use. I will be connecting the resistor shortly.



    Make 2 DC wires.

    Step 2

    Now connect the wires as shown below.
    You need to modify the wiring at two places -



    At the first place separate the yellow wire from the connector of the RR unit. Now connect the wires from the custom built rectifier as shown below.



    Step 3

    Connect GND to the RR unit mounting bolt.

    Step 4

    At the second place, connect the another DC wire to the brown wire shown in the picture below. I used the brown wire at the relay. You can use the brown wire at any available point in the wiring. This brown wire is connected to the battery when the ignition is switched ON.



    Step 5

    Mount the rectifier as shown.




    That's it. Look at my console! The engine is OFF.



    Any questions - feel free to ask!
    Last edited by abhijeet080808; 05-25-2009 at 11:39 PM.
    Samrat Gupta likes this.
    Your biking tells a lot about the person you are!

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    SlowMotionInfinity Sunny's Avatar
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    Topic Approved
    Join xBhp On


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    Rusted insanebiker's Avatar
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    Nice info there buddy.
    When everything comes ur way, u r in the wrong way ;)


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    Rusted Puneet1's Avatar
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    well explained

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    Rusted Shreeni0403's Avatar
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    Congrats on completion

    And thanks a lot to Rahul Devnath who helped in completion

    Oops, you haven't used a Heat Sink??
    Last edited by Shreeni0403; 05-25-2009 at 11:49 PM.
    ●▬╡[-̲̅■̲̅■̲̅■̲̅ ̲̅S̲̅ђ̲̅я̲̅є̲̅є̲̅ ̲̅■̲̅■̲̅■̲̅-]╞▬●

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    Rusted abhijeet080808's Avatar
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    Quote Originally Posted by Shreeni0403 View Post
    Oops, you haven't used a Heat Sink??
    Will test for a few days with this set up.

    And cost of the circuit - below Rs. 200.
    Your biking tells a lot about the person you are!

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    Rusted rahuldevnath's Avatar
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    Just In Case of Pulsar UG3 variants of 150, 180 and 200.

    The BCU in these bike do not allow the bike to be on DC and make use of self starter simultaneously. Only way out is put a switch or a relay.



    Last edited by rahuldevnath; 05-26-2009 at 01:20 AM.


    Been There, Done That; Better!

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    Rusted rahuldevnath's Avatar
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    Same Setup on my 180 UG3, with heat sinks. After final assembly. This box houses the above shown rectifier plus a relay specifically for UG3



    Been There, Done That; Better!

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    Rusted Devilpulsarian's Avatar
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    Nice info ther....
    2002 - Pulsar 150 Classic (Still owned)
    2005 - Pulsar 150 Dtsi (Still owned)
    2006 - Eterno (sold)
    2008 - Dio (Owned)
    2009 - Pulsar 220 DTSi

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    Quote Originally Posted by abhijeet080808 View Post
    And cost of the circuit - below Rs. 200.
    It didn't cost me even 50rs.

    To be precise

    6A4 - 3rs X 4 - 12rs
    Capacitor 25v 4700uf - 15rs
    Heat Sink - Plucked it from blown SMPS of my desktop
    Plastic Tape and other things - 20rs
    __________________________________________________ ______
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