bro this answer is just for the bold text

tht u can easily fix a 9ah battery in there coz both passion and ss have the same battery it feels tht it wont fit , but i will fit try it once and the best and cheapest battery to have is MINDA Or Amaron (maintenance free) they cost rs 1.5k

Thank you for the reply

Will open the coil aread & post its pictures . Dropping both 55 watt hid & Ape rr from my list , so it would be 35 watt hid with a p180 RR , but bro i think the battery in pulsars are of 9 ah , so its rr is giving some more current & i think after cutting the bracket i can fit atmost battery of 6 amp in passion ( considering no rewinding of coil ), so is that be good to use a rr from Karizma-R or ZMR as they have 6ah battery so it would provide limited charging current to battery & no worry about it being frying out .

for HID i will go for H4 bixenon type 3 , so no halo+hid combo & i am trying to get info about philips or osram single motorcycle HID H4 but all i found are pair for cars . Any info on that ?

@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.

So do all pulsar ug4 share the same RR unit ?

Its not just a P180 RR, it has to be UG4 RR with 4 wires, charging rates are 4-5A so u dont've to worry about it. So long as the RR is fine, ur battery will be safe from over charging, its u to use the load judiciously for not draining it. ZMA/R has got a 3 phase alternator and 7AH batt (IIRC) so, swapping with a 3 phase RR is not a good idea, it may work with that though, and cost wise also its on the higher side. If u r worried about the over charging rates then, ZMA/R has got a 200+W alternator which can pump out not less than 16A which is not at all required for ur case and coupling it with a single phase alternator u can't dream of getting such a whopping current rate.

Philips and Osram falling under premium range and its hard to get in single piece. Consider some other brand coming with 1 year warranty for ur peace of mind.

FIY, I've'nt done this on a smaller CC engine so far, its totally depends on the stator core, magnet power, quality of the elements used, number of turns and finally the neatness in winding. Sometimes it mat turn out to be a failure, one of our fellow member once tried to rewind on a Y Crux with APE RR which turned out to be a total failure as the pumping rates were lower than the stock. One more, rewinding on a smaller CC four stroke engine is overloading, u may loose some spirited sprints on signals.

Hi sajjt.
I have done full dc conversion on many 150cc bikes but never on a 100cc

I am free this week so I want to experiment on installing a Hid(I have a spare hid left from previous mod)
Also I will be comparing the charging rates of stock and re-wounded coil.

4.Can anyone provide me the part no. of pulsar 180 ug4rr or any distinct feature of it ?

Thank bro , so pulsar UG4 rr is complete dc with smart cutoff ( put battery charging on hold when it's full ) & mainly for single phase alternator so most suitable on hero honda passion . Today meet some garage mechanic's & they don't have any idea about ug3 / ug4 , they told the old pulsars are ac+dc while new one's are complete dc so it might be called as ug4 . The pulsar hold's a 9 ah battery as they said , so as you mentioned a current of 4/5 amp from rr is ok for 9 ah battery but isn't it gonna frying machine for a 5/6 ah battery ? What charging current is excepted for a 5/6 ah battery ?

Is in this free week you gonna do the mod on some 100 cc bike ?
Please after you DIY put the charging rates details .

4. And you got the pulsar ug4 rr give its part no. details to me too .

Like I said earlier, as long as ur RR is good condition, ur battery will be safe from overcharging. If the demand is more than ur battery capacity it will be shared from the alternator. Boost in battery charge is required to compensate the drain from the battery without much delay as it may get fried with insufficient charging rates. If the demand is 6A and that will be shared from Alt+battery and during this time if the battery level is going low, the RR will charge the battery if there's extra current available at the alternator if its not there that time, when the alternator is free from load, it will charge it. When the battery is full, it wont take more than 1A and the RR will become on trickle mode charging state.

U don't've to spent time with mechanics, instead go straight away to the Bajaj spares and ask for P150/180 UG4 RR, if they couldn't follow u, tell them the battery charger for UG4. Part No. is not a must as they will check with the Service manual and get that.

Sat and Sunday are holidays so I will be doing the mod tomorrow.
In the mean time till i get the RR ,I converted the rear tail lamp to led.
Yet to convert pilot lamps,cluster,indicators to led to .
reduce the load on batt.

@ above all
I request you capture the wiring diagram with a good camera at high res.
(need it for reference so that minimal changes can be done to the stock wiring).

Guys i have a relatively new battery which I bought it 6 months ago.(locally made,no brand)
I have to upgrade to a 7/9ah battery so support hid.
What do i do with it ?
Sell it off or make a emergency light out of it or something else ?

Ok will grab rr from bajaj showroom . Is it then necessary to make the ground wire unground from the alternator for ug4 rr ? or just remove the stock passion rr & change it with ug4 rr ? As i found its necessary for ape rr but can't found about pulsar ug4 rr .
& can you please provide some rough connection diagram if there it need to remove the ground wire & pulse generator as in first post ac to dc conversion universal thread .



Bro next time i will try to snap as clear as i can . Is there you going to unground the alternator grounded wire , & making some modifications with stock pulse generator . rr connection ? or just only replacing stock rr with pulsar ug4 rr ?



A local made battery on resale won't give you much price but instead of it if you make some switches to on stock rr & this local battery with a aux/ another light , it would be good in emergency if modified circuits burn out .

I am going to un-ground the coil and take it to the RR so that i get full wave dc.
The old RR will be remaining there but all the connections will be removed.

Whats the cap of your batt ?
Are you planning any hid setup or just full dc conversion ?
I have decided that I will not install hid as soon as I am on full dc,Instead I will use 35w halo.
First I will test the reliability of the setup for at-least two weeks,If everything is good then I ll install Hid w/projector.

Where do you live BTW ?

Ok will grab rr from bajaj showroom . Is it then necessary to make the ground wire unground from the alternator for ug4 rr ? or just remove the stock passion rr & change it with ug4 rr ? As i found its necessary for ape rr but can't found about pulsar ug4 rr .
& can you please provide some rough connection diagram if there it need to remove the ground wire & pulse generator as in first post ac to dc conversion universal thread.