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Converted my Pulsar 150 Classic to ALL DC

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  • #226
    abhijit i have wound wire but left 60gram wire so only 195gram 19G wire i can make it on plate!,can i switch to 100w helogen??
    all pole are some waht unevenly wound ,im attaching its picture so u can get idea of that,what effect can occure at out put when pole are wound more and less,i think its not that much diffrence but diffrence is there and can be seen in pics.
    rr unit make it Dc so is that en even ac out put cause any diffrence in Dc output?im not sure about winding theory so please educate me about winding things.

    Comment

    • #227
      Originally posted by Ramborider View Post
      work is in progress but in etween two coil there is very little gap at the bottom end of poles about 1mm but wire doesnt toiching each others is it ok or not???
      and how much power loss occure due to that 100w helogen?is it reduce perfomance in real life?
      Loss is not felt in real life. Gap seems to be ok.

      Originally posted by Ramborider View Post
      abhijit i have wound wire but left 60gram wire so only 195gram 19G wire i can make it on plate!,can i switch to 100w helogen??
      all pole are some waht unevenly wound ,im attaching its picture so u can get idea of that,what effect can occure at out put when pole are wound more and less,i think its not that much diffrence but diffrence is there and can be seen in pics.
      rr unit make it Dc so is that en even ac out put cause any diffrence in Dc output?im not sure about winding theory so please educate me about winding things.
      No pics seen. Did not get your question.
      Your biking tells a lot about the person you are!

      Comment

      • #228
        i mean i can only wound 195 gram of that 19G wire,all pole to brim!before work wire was 255gram but 60gram wire left! so can i connect 100w bulb??
        and quantity of wire wound in each pole are not same so is that create any problem???i wound as u said altarenate diarection after each pole.

        is it ok??what is you opinion about it????
        waitng for your reply!!!!!

        Comment

        • #229
          Its not too neat but will do fine. As for the winding per pole, the lower the difference between the poles the better. Its not like one full layer difference right?

          Now, connect the wires. Remove the old RR unit and use the APE as per the wiring I have explained.

          Next connect the h/l wire from the old RR unit to the battery.

          And yes, this coil will take 100W without any prob!
          Your biking tells a lot about the person you are!

          Comment

          • #230
            Originally posted by abhijeet080808 View Post
            Its not too neat but will do fine. As for the winding per pole, the lower the difference between the poles the better. Its not like one full layer difference right?
            im not getting you,that the lower the difference between the poles the better. Its not like one full layer difference right?
            Thanks im so happy to seen your reply!!!it will take 100W
            i have not applied varnish is it so nessesary??

            Comment

            • #231
              Originally posted by Ramborider View Post
              im not getting you,that the lower the difference between the poles the better. Its not like one full layer difference right?
              Thanks im so happy to seen your reply!!!it will take 100W
              i have not applied varnish is it so nessesary??
              All poles should have approx same length of wires winded.

              Yes varnish is necessary. Apply a layer or 2 before fitting it back.
              Your biking tells a lot about the person you are!

              Comment

              • #232
                I crosscheked the winding but im very confusing about that connection which i made! that black strip on coil plate which has two connection terminals,is that connection are shorted i mean in right connection and left are shorted??if yes then i have to remove that because i solder one end of winding to that soldering strip end and get out from that gap provided at near and other end of winding solder to second soldering point on that strip. so if that strip has short(both end are conected each other) then its wrong conection.do u have any pic of ur mod ?it will be vary helpful to me


                Comment

                • #233
                  ^^ See you just do 2 things -

                  1. Leave the igniton coil wirings alone.

                  2. Take 2 wires from you own coil and fit to APE RR unit. Do not solder the wires to the stator plate GND anywhere. Those 2 wires should not touch GND anywhere.
                  Your biking tells a lot about the person you are!

                  Comment

                  • #234
                    Im done it!! but doesnt make connection of headlight unit to battry,
                    winding are shorted in between poles!!!! so i have to remove that all winding and done new winding and that time i merk on wire to eqal amount of winding to be done on poles and also applied araldite on pole whre metal is nakked!!
                    i connect coil to RR unit and rr output too battry
                    and get that reading-
                    voltage at high rpm doesnt exid 14.7V
                    but cuurent are so less only getting 4.15amp at max rpm!!
                    is it bacause no light connection made??i only done on engine running condition no headlight nothing was on!!
                    4.1amp *12.5volt=51Watt so is that means i cant connect 100w bulb in it??
                    last time i done winding on same 197gram of 19G.
                    but i observed that ampere reading reached at lazy 3000rpm and get steady!!

                    Comment

                    • #235
                      Originally posted by Ramborider View Post
                      Im done it!! but doesnt make connection of headlight unit to battry,
                      winding are shorted in between poles!!!! so i have to remove that all winding and done new winding and that time i merk on wire to eqal amount of winding to be done on poles and also applied araldite on pole whre metal is nakked!!
                      i connect coil to RR unit and rr output too battry
                      and get that reading-
                      voltage at high rpm doesnt exid 14.7V
                      but cuurent are so less only getting 4.15amp at max rpm!!
                      is it bacause no light connection made??i only done on engine running condition no headlight nothing was on!!
                      4.1amp *12.5volt=51Watt so is that means i cant connect 100w bulb in it??
                      last time i done winding on same 197gram of 19G.
                      but i observed that ampere reading reached at lazy 3000rpm and get steady!!
                      Connect a 100W bulb temporarily to the batt. and then measure the voltage/current.

                      Also, wirings are shorted? How did you detect this? Winding wire to GND/plate resistance is not infinite?

                      Yes, use araldite/varnish. It seems you have read up most of this thread!
                      Your biking tells a lot about the person you are!

                      Comment

                      • #236
                        yes,im reading treads most of times, i had cheked buy using test lamp!! coil end and coilplate(ground are shorted)
                        actuly araldite are very time consuming!!takes 4Hours,we can use fevitite EXP, which dried instantly.
                        yes tomorrow will going to switch to amby sealed beam unit,and which type of cut out requred??and costing of that cut out?is that much needed?
                        where to source 60w H4 helogen?on 4wheelers spare parts or 2wheeler?
                        horn relay can work on that?

                        Comment

                        • #237
                          Originally posted by Ramborider View Post
                          yes,im reading treads most of times, i had cheked buy using test lamp!! coil end and coilplate(ground are shorted)
                          actuly araldite are very time consuming!!takes 4Hours,we can use fevitite EXP, which dried instantly.
                          yes tomorrow will going to switch to amby sealed beam unit,and which type of cut out requred??and costing of that cut out?is that much needed?
                          where to source 60w H4 helogen?on 4wheelers spare parts or 2wheeler?
                          horn relay can work on that?
                          Hmm... use anything as long it remains a bit soft and malleable. Is Fevitite EXP epoxy based?

                          Yes cut out is very much needed else you will blow your switch! Use it. Ask at car accessories shop. They will have it for 2 bulb holders. Use one and cut the other.

                          If you know how to, you can fabricate your own relay + wiring.

                          For halo, go to car shops.
                          Your biking tells a lot about the person you are!

                          Comment

                          • #238
                            Yes fevitite is epoxy based.
                            yes i got it its that relay which use in 4wheelers costing around rs700!!another bomb on poket!!can we use swiitch used for Hazard lamp,in our bike minda company(pull,push type),its costing around rs35,so its easy to replace than whole switch and can go further for relay!

                            Comment

                            • #239
                              Originally posted by Ramborider View Post
                              Yes fevitite is epoxy based.
                              yes i got it its that relay which use in 4wheelers costing around rs700!!another bomb on poket!!can we use swiitch used for Hazard lamp,in our bike minda company(pull,push type),its costing around rs35,so its easy to replace than whole switch and can go further for relay!
                              I got mine for 350! Dont look for quality brand etc, since they will be made for 2 h/l = 200W and we will only use it for 100W which it will easily support. You will get it under 400!
                              Your biking tells a lot about the person you are!

                              Comment

                              • #240
                                Cheked that current while 100w bulb on !!!its giving around 7.6amp of current at 6000 rpm and voltage was around 14.6v at 5-6rpm range??so 100watt bulb can i fit or 60watt???
                                is that using 100watt bulb will reduce that bvattry life???actuly after seen effect of 100watt at morning its like
                                im have not switched to relay so how much time it can be use without relay???

                                Comment

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