Hello Eshwar

I've done whatever there is possible till date in bike's electricals.
Let me tell you, there's nothing that will give you peace of mind until and unless you rewind.

Basically if you follow the method of routing lighting coils to the battery, it will create parallel charging, and its not a safe thing.
As a personal experience a good friend of mine's bike literally caught fire as at higher revs the hand made rectifier conked off, and one of the rectifier's were working.

4 amp battery is small for the load of HID bulb, as its not re-winded, Your lucky your battery is still giving enough juice to keep breathing.

As i said earlier, you will have to re-wind with a 19 guage wire, unicorn has 8 poles and its one of the easiest stator to wind.
The more you delay, the more you'll spoil your bike's battery.

If you need any help or information about the same, you can PM me or reply here.

it's soo good of you. the xbhp guys here are really caring others.
first i'll buy the required things and then decide whether i am going to do the jod or get it done by a mech...
could you tell me the things that i hav to buy(including even small things)???

A fan coil winding guy would not do it, you'll have to find an auto electrical guy or simply try it yourself, its a piece of cake.

For rewinding a Unicorn's coil, you'll need the following things.

1. 19 awg enameled copper wire (200~250 grams)
2. Winding varnish (buy the smallest bottle you can)
3. 2mm Sleeve (buy a single one, it will be 1 meter long)
4. 5mm normal wire (to route the output outside the magnet cover)
5. Soldering Iron (To De-solder and solder back after completion)
6. Soldering wire (Same purpose)
7. Soldering Wax (To De-solder even more easily)
8. Wire cutter (as the name suggests)
9. Big and strong pair of forceps (to make it easier to hold the wire while unwinding)
10. A good 3 hours with a lot of patience.

Basically to start with you would need to De-solder all the soldering points on the stator, both front and back.




Once that is done, remove the winding holding one of its end with the forceps and keep unwinding.

P.S. While doing so, it will break and spray a lot of dried varnish everywhere which the copper wire was covered with, this is as good as small pieces of glass and pierce through the skin very easily, try doing it slowly as its dangerous because the thing is already in your hand.

Make sure you do it slowly and not very vigorously as it could break the wire midway and its very difficult to start again from that point.

Once the removal is complete, from any end start winding the new wire in one particular pattern, make sure the wire is tightly stacked and no overlapping is done.
Make sure to do it as much as possible and as tightly and neatly as possible.
Follow the next pole in the opposite direction and so on until the last pole is finished.

If in case an overlap happens, unwind a few turns and do it again to get a neat finish, always start from the bottom and end at the bottom, this will not only be easier but also pretty much help in consistency and you won't need to count the no. of turns or length of the wire again and again across every pole.

Make sure before starting, you leave at least 15~20 cm of free wire for soldering and sleeving purposes and same after finishing.
once this is done, put the sleeve on the start and the end, to avoid any kind of contact.

Pour oodles of varnish over the entire stator and give it 3 hours of drying time.

Cut the extra wire and solder it to any 2 separate points which are not connected to ground or to each other.
Also solder the 5mm wire on these points to route it to the ape RR unit.

Make sure you connect the pulse generator back which you would have De-soldered before and your done.

route both of these coil (the new 5mm wire) outputs to ape RR and ape RR's output to the battery directly without any other contact.

Go to a mech and ask him to route all the electricals through the battery.

While coming back home, get some beer and have fun with pals and brag about how you converted your bike to ALL DC yourself.

thank you sooo much
i"ll try to do that ASAP....

Be careful while using the Multimeter.
Check the current rating , probe connection and setings of the Multimeter.

I cooked up one of my meters when I was a kid.


Coil rewinding by a professional will make enough power delivery[electric] for your battery and lamps.

Re: serious help needed.......regarding DC conversion

This sounds like the most inexpensive and easiest way to convert Apache RTR into Full DC mod, I do not ride much at night but only sometimes. I use only charging coil of My rtr to make it full DC, I have been using like this for one year and it has not given any problem till now. Now I'm going to install HID on my bike and I'm gonna need to boost the charging with a correct charging voltage ie just more than 12volt but less than 14.5 volt. I will try to use light coil with another Regulator/Rectifier (may be of Apache rtr) to charge the battery in addition to charging coil. I think this will works, Will give feedback when done....

Re: serious help needed.......regarding DC conversion

Hi.. I've been using the DC Mod by R & D Motovil on my RTR190. So far so good but as Debraj Baskar of R&D Motovil said, this is not the complete mod. Battery seems to get a little strain during prolong night riding, esp at low revs. One needs to go for recoiling to ensure that the battery doesn't die down and also to get a higher wattage output. Recoiling is the solution for all strained-battery problems.

Sent from my GT-S7562 using xBhp Connect mobile app

Re: serious help needed.......regarding DC conversion

This sounds interesting Zonun. Any more details as to how u did it?

Sent from my GT-S7562 using xBhp Connect mobile app

Re: serious help needed.......regarding DC conversion

Not to sound negative, but unless you get a competitive auto electrician with prior experience on rewinding, it is most likely that the modification might work and instead might lead to other complications. Another option would be to replace the entire coil assembly from another bike. However, please study the auto electrician before handing him the job. Good luck!