why are waiting ?
just go and un-ground the coil ends and connect it to RR.
If any thing goes wrong you can solder it back.
(Make sure you use a high wattage iron,say 60watts)

Don't hesitate my friend just do it.
If you are a DIY ,you gotta take some risk.

Bro the thing as suggested earlier by sajit bro rewinding will make a much more difference , but sometime it will give bad results if not done properly , so for that i am looking for the old coil in garages to rewind & store this one stock coil comed with bike so that if anything goes wrong i have a backup .

DIY means do it yourself & as it will be my first time to rewinding the coil , so better to have a backup plan ready .

Btw today i went to ape showroom , headed to the spare store asked the person , "i need a part with number ED22158" , he looked at me as i asked a part which don't belong to ape , so after explaining him what is this part for , he asked what i want to do , then told a girl there to check price , she quoted 1050 , but the man said the part belong to old ape rikshaw , now there comes a new rr , he showned it to me costing 1350 rupees , it having total 6 wires , & upon asking is there any person on your service center who deals with wiring , he said they don't have any , upon need they get a private garage guy we have fitted these 6 wires rr in old ape rikshaw which has 4 wire rr , i got his garage address , will buzz him tomorrow .

I don't think u'll get a good coil from the scrap yard or garages, if its good then why they left around? There should be some reason for that, possibly the ignition coil would've burned or so. In that case, if u rewind on it will turn out to be waste of time and money.

I would suggest u to do the rewinding on the stock one and if it turns out to be a failure u can rewind it to a slighter thicker than the stock and bring it back to action. U don't need to go for a backup one at any case as long as u fiddle with the ignition & pulse coil.

The max u damage can expect from a rewinded coil will be less output than the stock/over loading the engine.

New APE RR's more smarter than the first version and its got 6 wires with a battery voltage monitor, so its better to have the details from a reliable source, I don't belive these foot path grease monkeys as mostly just don't know what they are doing. Best thing is fetch the old RR if they've stock.

As i know the magnet coils will stay stationary , while the covering magnet moves around it , then how after rewinding there is any load on engine ? Can you please throw some light .
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Here are some garages where they bought ( ? ) bikes from other big cities like mumbai or so & destruct them & sales the working spares & fetch good amount of money .

Ok bro will do the r&d on the present coil , but before rewinding i will test how much voltage & current i get from the stock winding after removing the ground connection .

As i know the magnet coils will stay stationary , while the covering magnet moves around it , then how after rewinding there is any load on engine ? Can you please throw some light

The magnet induces a magnetic field across the conductor and the changes in mag-field caused by rotation of magnet gives voltage.

If you either increase the power of the magnet or the coil more induction takes place as a result more power is required to spin/turn the magnet.
Hence power-loss but that's negligible if you rewind it with a slightly thicker wire.

don't go for junkyard pieces but rewind it on stock coil. If anything goes wrong then light coil of three pieces comes as a set for 188 rupees. It is available as a separate item and doesn't include the ignition coil.
I am waiting for the results because i have a HH JOY and it has exact same coil base as yours so based on the results i will go for this modification.

The magnet induces a magnetic field across the conductor and the changes in mag-field caused by rotation of magnet gives voltage.
If you either increase the power of the magnet or the coil more induction takes place as a result more power is required to spin/turn the magnet.
Hence power-loss but that's negligible if you rewind it with a slightly thicker wire.

don't go for junkyard pieces but rewind it on stock coil. If anything goes wrong then light coil of three pieces comes as a set for 188 rupees. It is available as a separate item and doesn't include the ignition coil.
I am waiting for the results because i have a HH JOY and it has exact same coil base as yours so based on the results i will go for this modification.

Yes, we do have such junk yards but the issue is with the quality.

Good thought, but make sure that the three coils are in CW & ACW pattern. Else u cant ahieve the full output from the coil. U can leave the center tap open with proper insulation.

Good one there, to be precise, if u load a smaller capacity engine with thicker wires the load presence will be significant AFAIK The manufacturer had designed the magneto assy in such a way that it should not load the engine to affect its perfo but at the same time ensuring the optimum output from the coils for adequate lighting.

Thanks for the update, now the job is going to be more easy if anything goes wrong. How does it installed to the stator plate, with screws?

Even the pulsar coil the white one can be opened individually and changed. Each and every coil is available separately and can be changed separately and that is is the beauty of HERO HONDA as every part is available.

@ sibun thanks for the detailing of coil.

Today opened up the the air filter box , so as to get idea how a battery cage is replaced , but the battery cage is not a seperate piece , it is complete package with air filter box . So i just gonna shift the packing clips of both sides to make a space for holding bigger battery there . Check the image attached .
So if anyone have a dimensions ( length , width & height ) of 7 ah & 9ah battery , please post so accordingly i will make a place there .

UPDATE

Just taken the mesurements of my ZMR battery & it needs 3 cm more place for length & 3 cm more for height than the current place.
It is possible to make a 3 cm space for height , but for length there is only possibility of making 2.5 cm . Damn if there is not enough space for 6 ah battery then i think fitting 7 ah or 9 ah battery is almost impossible . Will check for the 5 ah battery now .

UPDATE 2

Took the 5ah battery from scooty to measure its dimension , & found that its 4cm longer , check the pic attached . Is there any 5ah/7ah/9ah battery which is small in length , or any other place where i can fit the battery .

UTKARSH STUNTY SHARMA[/B];730072]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

This might sound funny but here is my idea,then I saw a similar post by UTKARSH STUNTY SHARMA.
Cut out the entire battery holder,and the mounting brackets.
Use metal ties/straps to hold the battery.

UTKARSH STUNTY SHARMA also installed a 9ah batt. check out his post(on 1st page of this thread)

Please post the exact dimensions in mm(Length X Breadth X Height) of both the battery and the holder so that other members can reply more precisely.

Let me remind you that ,
Its better to convert the bike to full dc and then upgrade the battery depending upon the charging rates and load.

From there turn to the bajaj showromm , asked them for Pulsar 150/180 UG4 rr , he asked me which 1 there are 2 rr in UG 4 as per he , he given me part numbers of both & asked to check on perticular pulsar ug4 for exact number .

DJ201202 : 425 rupees
DJ201164 : 380 rupees used on p200

Do you know which 1 is correct ? .

And after looking each post i found the thing you pointed out that the negative supply to battery is given for ignition coil , so in dc conversion is we need to remove that too.

No need to remove it.



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