Electrical Modification on Hero Honda Passion. - xBhp.com : The Global Indian Biking Community

Above_All · 11-05-2011, 10:30 PM

I have a Hero Honda Passion 2002 model . I want to make some electrical modifications to it .

The Electrical & lights details of it are

Battery = 12V 2.5 AH

Alternator = Flywheel A.C. generator

Headlight ( High / Low ) = 12 V 35/35W

Tail/Stop light = 12 V 5/10W

Turn Signal = 12 V 10W*4

Meter light / fuel indicator light = 12 V 1.7W*2

Neutral Indicator = 12 V 3W

Turn signal indicator ( RH + LH ) = 12 V 1.7W*2

Position lamp = 12 V 3W

Hi Beam Indicator = 12 V 1.7W

The mods i have already done are .

A pair of Roots Vibrosonic Horns with relay .

A pair of rainbow lamps .

I wanted to make it completely DC , to get a good strong focus from my headlight instead of the candle light .

================================ UPDATE ================================

Thanks to sajit , shreeni , utkarsha , shoeb & all who cleared the doubts i got it done .
For the new comers to this thread what we need to done is 4 things for complete DC conversion .

1) In alternator / coil unground the grounded wire , remove the center tap yellow wire & connect that yellow wire to the ungrounded terminal. If you do rewinding with a higher guage wire then it would be good .

2) Change the stock RR to a complete DC RR . I used a pulsar UG4 rr part no. DJ201202 .

3) Reroute the ac supply wire of headlight to key switch dc connection .

4) Change the battery to higher one , i used a 12v 5ah battery .

*) Additionally it is good if you can change all other pilot light , meter lights , brake light etc to led's / smd led's .

For getting clear on this 4 things check this thread .

Noor · 11-07-2011, 10:12 AM

Query approved

Above_All · 11-07-2011, 09:16 PM

Quote:

Originally Posted by Noor

Query approved

Thanks for Approval

UTKARSH STUNTY SHARMA · 11-08-2011, 09:45 AM

Quote:

Originally Posted by Above_All

I have a Hero Honda Passion 2002 model . I want to make some electrical modifications to it .

The Electrical & lights details of it are

Battery = 12V 2.5 AH

Alternator = Flywheel A.C. generator

Headlight ( High / Low ) = 12 V 35/35W

Tail/Stop light = 12 V 5/10W

Turn Signal = 12 V 10W*4

Meter light / fuel indicator light = 12 V 1.7W*2

Neutral Indicator = 12 V 3W

Turn signal indicator ( RH + LH ) = 12 V 1.7W*2

Position lamp = 12 V 3W

Hi Beam Indicator = 12 V 1.7W

The mods i have already done are .

A pair of Roots Vibrosonic Horns with relay .

A pair of rainbow lamps .

I wanted to make it completely DC , so that i can run a 55 watt HID or a 55 watt halogen bulb .
As per the AC to DC conversion thread . I enquired rewinding shops here but no one has any idea about rewinding the bike's magnet coil .
So is it possible to proceed further without rewinding ? If so then if anyone has any picture of Hero Honda Passion Coil please post & make clear which wire need to be remove from grounding & where to connect it .
How much current & voltage excepted at RR ? As there is no RPM meter so how to calculate ? Just on ideal & on full throttle ?
I have measured the voltage at battery terminal by alternator after removing battery it is around 3.9 v at idling & 8.5 volt on full throttle ( no light is on , so no load on alternator . )
So how big AH battery i can get charged after making it complete DC . 5 AH ? 6 AH ? or 7 AH ?

What is the thing on left side of battery as marked in attached picture . Is it RR ? or pulse generator ? & what is pulse generator ?

There is something like resistance under the left rear cowl , it is marked in the another picture attached . It's wire is disconnected from a long time , i recently connected it & it results in draining of battery . Asked several mechanics they said its something related to headlight , SVC mechanic saying it stores power in day time from alternator when no light is on .

So overall i wanted to get a strong good focus from my headlight instead of the candle light by making bike complete DC without coil rewinding . Is i need to change all other bulbs like meter console , positioning , neutral , turn signal , high beam indicators , tail/stop lamp , indicators to led's / smd led .

Bro though im not tht experienced but i would like to give in my suggestion here as i had the same problem a year ago....i have a HH Super splendor 2004 (without self) i was bored with the light as it just wasnt enough...so i decided i firstly installed tht blue bulb but it was of no good....then i decided i want a HID on it so i went to a local shop....then i got a hid installed on my bike by using the dc relay setup(no idea how it is done as same is in my aache 180 too) then when i was back on the way to home after runin 2k kms with hid i pressed the horn and the problem started the hid stopped while horn was operatiing and the other time the horn got killed...

...then i went to the same shop next day....he told me to upgrade the battery so i went on with his suggestion and installed a minda 9Ah maintanence free(dry) battery... the installation needed the cutting of the batt holder but it was afterwards tied with 2 metal strips .....then the mech told me tht the problem was solved and believe me it was solved......

then i used to ride it for 2-3 hours with hid on and no problem was there and my horn installed was roots windtone.....both were easy to use at night so i would say try this at it dosent costs much

Hid 6000k- 800rs
Minda battery- 1500
labour- 200 rs

Above_All · 11-08-2011, 04:09 PM

Quote:

Originally Posted by UTKARSH STUNTY SHARMA

Bro though im not tht experienced but i would like to give in my suggestion here as i had the same problem a year ago....i have a HH Super splendor 2004 (without self) i was bored with the light as it just wasnt enough...so i decided i firstly installed tht blue bulb but it was of no good....then i decided i want a HID on it so i went to a local shop....then i got a hid installed on my bike by using the dc relay setup(no idea how it is done as same is in my aache 180 too) then when i was back on the way to home after runin 2k kms with hid i pressed the horn and the problem started the hid stopped while horn was operatiing and the other time the horn got killed...

...then i went to the same shop next day....he told me to upgrade the battery so i went on with his suggestion and installed a minda 9Ah maintanence free(dry) battery... the installation needed the cutting of the batt holder but it was afterwards tied with 2 metal strips .....then the mech told me tht the problem was solved and believe me it was solved......

then i used to ride it for 2-3 hours with hid on and no problem was there and my horn installed was roots windtone.....both were easy to use at night so i would say try this at it dosent costs much

Hid 6000k- 800rs
Minda battery- 1500
labour- 200 rs

Thank you for information . But is your stock super splendour alternator & RR able to maintain 9 AH battery charged ? & can you please give some wiring details or photo of dc conversion done by mechanic . Here i talked with some they say just give a connection from battery directly to headlight . They have no idea about dc conversion .

Shreeni0403 · 11-09-2011, 09:11 AM

Putting bigger battery just gives better back up. But end of the day, battery needs to be charged sufficiently to keep the HID running.

@Utkarsh - Try riding for 3 hours on 2 consecutive days without riding the bike during day time.

There is no way you can run a 55w Halogen or 55w HID without rewinding the coil. Even if you rewind, for the passion coil I guess the max you can use is 35w HID which is more than sufficient for a Passion.

For ZMR if you want put a 55w HID

UTKARSH STUNTY SHARMA · 11-09-2011, 09:48 AM

Quote:

Originally Posted by Above_All

Thank you for information . But is your stock super splendour alternator & RR able to maintain 9 AH battery charged ? & can you please give some wiring details or photo of dc conversion done by mechanic . Here i talked with some they say just give a connection from battery directly to headlight . They have no idea about dc conversion .

For my setup it was able to handle it as i rode for around 3 hrs during daytime and around 2 hrs in the night tht too in traffic of a place like patna.....i say tht on the stock charging setup u can run hid for atleast 2 hrs in the night......

and regarding the photo sorry bro i cant upload them now as the bike is still in patna and i have come to pathankot and got my menace....

UTKARSH STUNTY SHARMA · 11-09-2011, 09:51 AM

Quote:

Originally Posted by Shreeni0403

Putting bigger battery just gives better back up. But end of the day, battery needs to be charged sufficiently to keep the HID running.

@Utkarsh - Try riding for 3 hours on 2 consecutive days without riding the bike during day time.

There is no way you can run a 55w Halogen or 55w HID without rewinding the coil. Even if you rewind, for the passion coil I guess the max you can use is 35w HID which is more than sufficient for a Passion.

For ZMR if you want put a 55w HID

1.Thts why i mentioned the riding time with Hid on as i knw the charging aint good and my aim was to just tell him my "Jugaad"

2.I knw it wont work but as i said its enough for 2-3 hrs riding with hid in normal conditions(i.e bike is ridden during day too)

3.Minw was a 35 wat 8000k Moto Hid (chinese ones) cost was just 800rs 1 year back

Above_All · 11-09-2011, 08:19 PM

Today i was in Hero Moto ASC for my ZMR servicing . Talked with the workshop manager on this thing making Passion complete DC . He is kind enough shown me wiring diagram of HH bikes . I took snaps of HeroHonda Passion Plus wiring Diagram ( No HH Passion Wiring Diagram available there ) & others . Passion+ wiring diagram is as in this image .

Sorry for quality its my Nokia C7 HD Snap.

Quote:

Originally Posted by Shreeni0403

Putting bigger battery just gives better back up. But end of the day, battery needs to be charged sufficiently to keep the HID running.

@Utkarsh - Try riding for 3 hours on 2 consecutive days without riding the bike during day time.

There is no way you can run a 55w Halogen or 55w HID without rewinding the coil. Even if you rewind, for the passion coil I guess the max you can use is 35w HID which is more than sufficient for a Passion.

For ZMR if you want put a 55w HID

Thank's bro , dropping 55w HID . So without rewinding just using a RR like ape or GC1000 can 35 w HID will run ?
Or if i use a Karizma or Karizma ZMR RR is it gonna work ?
Is there any complete DC Bike RR which can maintain battery voltage ? Like charge it when low & cut charging when full .
& How much Voltage & Current should be excepted from RR to battery ?

Quote:

Originally Posted by UTKARSH STUNTY SHARMA

For my setup it was able to handle it as i rode for around 3 hrs during daytime and around 2 hrs in the night tht too in traffic of a place like patna.....i say tht on the stock charging setup u can run hid for atleast 2 hrs in the night......

and regarding the photo sorry bro i cant upload them now as the bike is still in patna and i have come to pathankot and got my menace....

Ok bro so it mean the charging period is require more than load period . ( 3 hour charging , 2 hour HID lighting . )

sajjt · 11-09-2011, 09:33 PM

@above all, Sorry for the late reply

Like Shree said u've to compromise with a 35W HID max with the three pole coil. U can expect a max of 5A out of this puny coil.

Typical HH Splendor lighting coil:

Being the current generation is limited, u don't've to go for APE RR, instead u can use Pulsar UG4 RR which can push 5A and its more cheaper than APE RR (Rs 400/ approx) I don't think after rewinding it will give much difference as with a single coil, it wont take much thicker coil, so the low rpm drives will strain the battery I would say try with the stock coil after isolating the grounding and feed it to the new RR and check for the charging rates. (Make sure that all three coils are not splitted for lighting and charging) If its lower than 4A, try to source a spare coil and rewind that and check for the improvement. Try with the next thicker size from the stock winding so that it will take almost near to the stock turns.

There are mechanics who are simply putting the HID on the battery which is not enough for feeding a HID, it may run for some time, but remember u can't drive in high rpms always. Low battery will flicker HID which will lessen its life span. If u r planning to go for HID, upgrade the battery as well as ur coil is just near to the required rates, so chances are more to fry it in no time.

When going for DC conv, its always good to route the wires separate than depending on the stock loom as there can be internal tappings in that.

Do not settle with a cheaper kit as it will not last long, invest in 1.5-2K range kit which will offer 1 year peace of mind and more than that cheaper kit will sip the battery juice faster.

Also do not go for HID+Halo combo as the halogen will be normally of 55W which is again another battery eater and its hard to get a 35W halogen replacement. Each time when u swap the beam, the ballast will take more current and will worse the battery condition and many are disappointed with this combo as the sudden change of low/high:HID to halo low/high will litterally blind u for a few secs which is very dangerous.

11-05-2011, 10:30 PM	#1 (permalink)
Above_All ¯\_(ツ)_/¯ Join Date: Mar 2011 Location: MH 18 Posts: 657	Electrical Modification on Hero Honda Passion. I have a Hero Honda Passion 2002 model . I want to make some electrical modifications to it . The Electrical & lights details of it are Battery = 12V 2.5 AH Alternator = Flywheel A.C. generator Headlight ( High / Low ) = 12 V 35/35W Tail/Stop light = 12 V 5/10W Turn Signal = 12 V 10W4 Meter light / fuel indicator light = 12 V 1.7W2 Neutral Indicator = 12 V 3W Turn signal indicator ( RH + LH ) = 12 V 1.7W2 Position lamp = 12 V 3W Hi Beam Indicator = 12 V 1.7W The mods i have already done are .* A pair of Roots Vibrosonic Horns with relay . A pair of rainbow lamps . I wanted to make it completely DC , to get a good strong focus from my headlight instead of the candle light . ================================ UPDATE ================================ Thanks to sajit , shreeni , utkarsha , shoeb & all who cleared the doubts i got it done . For the new comers to this thread what we need to done is 4 things for complete DC conversion . 1) In alternator / coil unground the grounded wire , remove the center tap yellow wire & connect that yellow wire to the ungrounded terminal. If you do rewinding with a higher guage wire then it would be good . 2) Change the stock RR to a complete DC RR . I used a pulsar UG4 rr part no. DJ201202 . 3) Reroute the ac supply wire of headlight to key switch dc connection . 4) Change the battery to higher one , i used a 12v 5ah battery . ) Additionally it is good if you can change all other pilot light , meter lights , brake light etc to led's / smd led's . For getting clear on this 4 things check this thread . Last edited by Above_All; 01-02-2012 at 08:59 PM.*

11-07-2011, 10:12 AM	#2 (permalink)
Noor Administrator Join Date: Mar 2003 Location: Mumbai, Maharashtra, India. Posts: 2,336	Query approved __________________ Happiness is finding you have another Gear left.... Join xBhp On

11-09-2011, 09:11 AM	#6 (permalink)
Shreeni0403 Biking In Veins Join Date: Nov 2008 Location: Mysore/Bangalore Posts: 1,365	Putting bigger battery just gives better back up. But end of the day, battery needs to be charged sufficiently to keep the HID running. @Utkarsh - Try riding for 3 hours on 2 consecutive days without riding the bike during day time. There is no way you can run a 55w Halogen or 55w HID without rewinding the coil. Even if you rewind, for the passion coil I guess the max you can use is 35w HID which is more than sufficient for a Passion. For ZMR if you want put a 55w HID __________________ ●▬╡‹¦[«-̲̅■̲̅■̲̅■̲̅ ̲̅S̲̅ђ̲̅я̲̅є̲̅є̲̅ ̲̅■̲̅■̲̅■̲̅-»]¦›╞▬●

11-09-2011, 09:33 PM	#10 (permalink)
sajjt DIY Hobbyist Join Date: Aug 2009 Location: Cochin Posts: 1,077	@above all, Sorry for the late reply Like Shree said u've to compromise with a 35W HID max with the three pole coil. U can expect a max of 5A out of this puny coil. Typical HH Splendor lighting coil: Being the current generation is limited, u don't've to go for APE RR, instead u can use Pulsar UG4 RR which can push 5A and its more cheaper than APE RR (Rs 400/ approx) I don't think after rewinding it will give much difference as with a single coil, it wont take much thicker coil, so the low rpm drives will strain the battery I would say try with the stock coil after isolating the grounding and feed it to the new RR and check for the charging rates. (Make sure that all three coils are not splitted for lighting and charging) If its lower than 4A, try to source a spare coil and rewind that and check for the improvement. Try with the next thicker size from the stock winding so that it will take almost near to the stock turns. There are mechanics who are simply putting the HID on the battery which is not enough for feeding a HID, it may run for some time, but remember u can't drive in high rpms always. Low battery will flicker HID which will lessen its life span. If u r planning to go for HID, upgrade the battery as well as ur coil is just near to the required rates, so chances are more to fry it in no time. When going for DC conv, its always good to route the wires separate than depending on the stock loom as there can be internal tappings in that. Do not settle with a cheaper kit as it will not last long, invest in 1.5-2K range kit which will offer 1 year peace of mind and more than that cheaper kit will sip the battery juice faster. Also do not go for HID+Halo combo as the halogen will be normally of 55W which is again another battery eater and its hard to get a 35W halogen replacement. Each time when u swap the beam, the ballast will take more current and will worse the battery condition and many are disappointed with this combo as the sudden change of low/high:HID to halo low/high will litterally blind u for a few secs which is very dangerous. __________________ Do it Yourself, what so ever, if Possible ----------------------------------------- http://www.xbhp.com/talkies/desi-bik...sar-150-a.html Last edited by sajjt; 11-09-2011 at 09:41 PM.

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