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Thread: Bajaj Pulsar 220 Twin Beam HID Modification

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    Default 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 at 09:56 AM.
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    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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    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 at 11:47 PM.
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    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!
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    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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    Quote 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!

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    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][/SIGPIC]

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    Quote 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.

    Quote 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.

    Quote 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!

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    Quote 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!
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    Quote 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!

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