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Bajaj Pulsar 220 Twin Beam HID Modification

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  • Bajaj Pulsar 220 Twin Beam HID Modification

    Most of us are not satisfied with the level of illumination our bikes provide. For some few, who possess a Pulsar 220, the headlight is really good, and most of them are satisfied with it.

    But for the lot, which includes me, there nothing know as enough light! Even before buying my 220, I had thought of using both the beams together, and finally, I have successfully tried and tested, such setup.

    The usage idea is simple. The low beam works as a single beam, but when switchover to high beam, my low beam remains on, along with the high beam. (With a toggle switch to go back to stock setup)

    The modification makes use of a relay, because the 220’s BCU does not simply allow both the bulbs to work, simply by shorting the two. Still, the mod is simple, and is fully reversible and does not need any kind of wire cutting, hence no problem with warranty with the bike or HID. The BCU is not all bad, as it automatically switches of the light in case of overload or severe battery drain.

    This mod applies only to HIDs. As combined load of 2 HIDs is just 70W. We need to replace the Pilot Bulbs to LEDs saving 10W. So in stock mod our bulb setup consumes 2X5=10W + 55W = 65W. Where’s as twin HID’s consume 35W X 2 = 70W.


    Setup is simple. The (+)Ve of the Low beam Bulb, goes to the relay at A. When the Low beam is selected the relay is not activated and low beam completes the circuit through point B and goes to the socket of Low Beam. When the High Beam is selected, the High Beam glows as well as the Relay get activated, and hence the low beam completes the circuit at C, and the low beam gets power through High Beam Socket. A Toggle switch, keeps the Relay deactivated even if high beam is selected.

    So go ahead and have the best possible illumination on any Indian Stock Bike!

    I have been testing it for last few days, and it does not affect the battery. In case of a problem with the relay, the bike simply returns to stock system (Single Beam HID not Halogen).

    BTW my HID is Raylux (CAR) 35W x 2, 6000K bought for 7000/- Rs.
    Last edited by rahuldevnath; 09-16-2009, 09:56 AM.
    Been There, Done That; Better!

  • #2
    Topic Approved.

    I am not merging this thread with the exisiting light thread as I know, many of us would LOVE to keep it as a separate thread. This is a tremendous job, I say!

    As it was, the headlights of the P220 are the most powerful of the Indian motorcycling lot, and now this! Amazing, really. Rahul, thanks a lot for the detailed post. I am sure it would benefit many of the P220 owners out there.

    Topic also made Sticky!
    :)

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    • #3
      Wow! I see you have started modding your brand new P220 too! Great post there.

      Edit - Can you make the connections at the relay clearer? I am not sure what A,B,C,D,E means. Specific names like Ground, Relay Coil +ve etc would help.

      Let me try and guess -

      E - Coil +ve
      D - Coil GND

      B - Common
      A - NC (Normally Closed)
      C - NO (Normally Open)


      And why not use a diode in place of the relay? It would have a much simpler 2 wire connection. Does it cause any problem with the BCU?
      Last edited by abhijeet080808; 09-15-2009, 11:47 PM.
      Your biking tells a lot about the person you are!

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      • #4
        great work dude. Amazing illumination.[Any such ideas possible for the humble MFR headlamp of a ZMA? maybe someone could answer on the original light thread.]

        Lets hope we get some innovative responses for the P220 atleast.
        Kudos Rahul!
        10 Commandments:
        1)Thank thy God for being alive.
        2)Thou shalt respect one's own life and the live's of other road users.
        3)Thou shalt respect one's own bike.
        4)Love thy bike as thy self.
        5)Always wear safety gear.
        6)Alcohol is a strict NO!
        7)Thou may lust after thy neighbour's bike specially if its of the R1 kind!
        8)Thou shalt ride with 'ultra-most' care and caution when on Indian roads.
        9)Thou shalt never leave the engine running at long traffic halts.
        10)Thou shalt follow all of the above.

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        • #5
          amazing mod .. will surely do it as soon as i get my hands on it
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          The fast became faster[RTR] and now is the FASTEST[220] !!

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          • #6
            Originally posted by Aryan View Post
            Topic Approved.

            I am not merging this thread with the exisiting light thread as I know, many of us would LOVE to keep it as a separate thread. This is a tremendous job, I say!

            As it was, the headlights of the P220 are the most powerful of the Indian motorcycling lot, and now this! Amazing, really. Rahul, thanks a lot for the detailed post. I am sure it would benefit many of the P220 owners out there.

            Topic also made Sticky!
            Thanks a ton Aryan..for quick approval! And wo.. double thanks for making it sticky. I'm hope all 220's of XBHP, one day will not run without both beams on highway!
            Been There, Done That; Better!

            Comment


            • #7
              Wow, thats quiet a lot for a bulb.

              I am saving up to buy that same amount of money for a new silencer which is busted and gives a very frustrating sound!
              sigpic

              Comment


              • #8
                Originally posted by abhijeet080808 View Post
                Wow! I see you have started modding your brand new P220 too! Great post there.

                Edit - Can you make the connections at the relay clearer? I am not sure what A,B,C,D,E means. Specific names like Ground, Relay Coil +ve etc would help.

                Let me try and guess -

                E - Coil +ve
                D - Coil GND

                B - Common
                A - NC (Normally Closed)
                C - NO (Normally Open)


                And why not use a diode in place of the relay? It would have a much simpler 2 wire connection. Does it cause any problem with the BCU?
                Well I made it that way, so that people without any technical knowledge can correlate better, as with our previous experience with "D.C Conversion"

                Come to think of it.. yes it seems confusing to me also. I will try elaborate it

                You got most of it right though...but..


                E - Coil +ve
                D - Coil GND

                B - NC (Normally Closed)
                A - Common

                C - NO (Normally Open)

                And why not diode? Well, I used diode initially, made use of two diodes. But they were unnecessarily getting heated! So, I would suggest, it's the best way. BTW used miniature relay.

                Originally posted by 46wannabe View Post
                great work dude. Amazing illumination.[Any such ideas possible for the humble MFR headlamp of a ZMA? maybe someone could answer on the original light thread.]

                Lets hope we get some innovative responses for the P220 atleast.
                Kudos Rahul!
                I think same thing can be applied to ZMA, the second HID of course has to be in separate housing.

                Originally posted by sam92 View Post
                amazing mod .. will surely do it as soon as i get my hands on it
                Been There, Done That; Better!

                Comment


                • #9
                  Originally posted by 46wannabe View Post
                  great work dude. Amazing illumination.[Any such ideas possible for the humble MFR headlamp of a ZMA? maybe someone could answer on the original light thread.]

                  Lets hope we get some innovative responses for the P220 atleast.
                  Kudos Rahul!
                  BRO !!!! do you want to blind Indias population PERMANENTLY ??
                  FACEBOOK

                  HYDERABAD XBHP VIDEO
                  http://www.youtube.com/watch?v=nTMF0soJCI8

                  The fast became faster[RTR] and now is the FASTEST[220] !!

                  Comment


                  • #10
                    Originally posted by rahuldevnath View Post
                    You got most of it right though...but..


                    E - Coil +ve
                    D - Coil GND

                    B - NC (Normally Closed)
                    A - Common

                    C - NO (Normally Open)

                    And why not diode? Well, I used diode initially, made use of two diodes. But they were unnecessarily getting heated! So, I would suggest, it's the best way. BTW used miniature relay.
                    Are you sure? I thought B is common and gets power from A normally and from C when on High Beam. Maybe I got it wrong though!

                    And the 6A4 diodes heated up? They are rated at 6A and 35W is hardly 3A!

                    Anyways if the diode ckt would have worked, it would have been even simpler. Just a diode between the 2 bulbs +ve.
                    Your biking tells a lot about the person you are!

                    Comment


                    • #11
                      Originally posted by abhijeet080808 View Post
                      Are you sure? I thought B is common and gets power from A normally and from C when on High Beam. Maybe I got it wrong though!

                      And the 6A4 diodes heated up? They are rated at 6A and 35W is hardly 3A!

                      Anyways if the diode ckt would have worked, it would have been even simpler. Just a diode between the 2 bulbs +ve.
                      Ah..
                      The Low Beam bulb +Ve goes to common. Draws power from B, (noramally closed, ie: Relay not activate). As you switch on High beam, Relay activated, and Low Beam +Ve via Common gets power from C (Now Closed, as Relay activated), from High Beams +ve.

                      Yes, tried with 3 6A4 in parallel, they heat up. HID in initial stage draws as high as 9Amps! Secondly in case Diodes conks off, there would be reverse flow to Socket, hence problem with BCU!

                      We need 2 diodes even in that case. In high beam when Diode will allow current flowing to Lower Beam, but the current cannot be allowed to reverse flow to the Low Beam Socket. (Read STUPID BCU ) But a second Diode can solve the problem.. still heating issue!
                      Been There, Done That; Better!

                      Comment


                      • #12
                        Excellent mod
                        though it will blind other people in the opposite direction.

                        Comment


                        • #13
                          Ok, so diodes will work with normal bulbs but not HIDs (high initial draw)

                          And thanks for labeling that diagram! I thought the bulbs were at the bottom and the BCU connections at the top while actually it is the reverse. Hence my confusions!
                          Your biking tells a lot about the person you are!

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                          • #14
                            Originally posted by rahuldevnath View Post
                            mod applies only to HIDs
                            @Rahul: Can you put both the diagrams showing what was the original circuit and what did you change!
                            " Nothing Z Forever,Except D Change "

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                            • #15
                              Originally posted by abhijeet080808 View Post
                              Ok, so diodes will work with normal bulbs but not HIDs (high initial draw)
                              I thought HID meant HIGH INTENSITY DISCHARGE..


                              Rahul bro tonnes of thanks for making things easier for me!
                              Soon I would be running on 4 projectors with 2 Hids and 2 halogens on my R15..
                              Thanks once again!!

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