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**Samarth 619** · 06-28-2012, 03:34 PM

Topic Approved.

There are threads for this purpose, although not sure whether they are RE focused or not.

**princesirohi** · 06-28-2012, 04:24 PM

i don't think anybody has done a DC conversion on RE on xBhp. we will try to help as much as we can.

regarding battery, you can use amaron battery, as it has the longest warranty period.
why do you need a 14Ah battery, what is capacity of stock battery?
you want to use HID's or Halogen bulbs or both and of what wattage. we need to fix this first.
regarding how to connect headlight H/L wires to battery we will tell you in detail later, for now- it has to taken through ignition key switch and headlight switch through a relay.
buddy let us do it step by step.- first decide what wattage bulb you will be using and how many and of what type. then tell us RE stator winding is single phase or 3 phase..??
if possible post some pics of stock RR unit and stator plate.

**TheNoobGeek** · 06-28-2012, 05:39 PM

regarding battery, you can use amaron battery, as it has the longest warranty period.

Thanks

why do you need a 14Ah battery, what is capacity of stock battery?

I came to know from Dr vivek (drvtm) that battery is like water tank. Stock battery is 12V 5ah which won't be able to supply much power if I plonk 2 HIDs. Hence going for bigger battery, I'm not sure if a 9ah battery will be able to handle load of 2 HIDs + console, tail etc + (halogen - only for emergency)
I'll not be using both HIDs and Halogen together, halogen is only in case HID fails. Maybe for occassional flashing. Again, 2nd HID is only down the line, not now.

you want to use HID's or Halogen bulbs or both and of what wattage. we need to fix this first.

1 35w HID(as aux inside a projector) and existing 55/60w halogen as of now.
Maybe another HID in a good reflector down the line. Ignore the 2nd HID as of now, just that the extra power need is to be considerd.

regarding how to connect headlight H/L wires to battery we will tell you in detail later, for now- it has to taken through ignition key switch and headlight switch through a relay.

cool

RE stator winding is single phase or 3 phase..?? if possible post some pics of stock RR unit and stator plate.

I have no idea if its 3 phase or single phase. Sreeni said its three phase. Can it not be converted to single phase? Single wire + APE RR?

some pics I got off net. I'll try uploading mine, got them long back and stator is oil dipped can't remove at will

from bulletwala
pic courtesy nanotech

**lovish** · 06-28-2012, 06:20 PM

Veing a n00b Can I please ask one thing ??

What's is the need to convert it from ac to dc ?? I mean does that means better performance ??

**TheNoobGeek** · 06-29-2012, 10:55 AM

update: Mine is a 3 phase stator. Confirmed from RE service center.

Originally posted by lovish

What's is the need to convert it from ac to dc ?? I mean does that means better performance ??

my plan is to plonk an HID which can run only on DC hence the conversion. DC will give constant output compared to AC which makes the headlight dim/bright depending upon the RPM.

**princesirohi** · 06-29-2012, 12:09 PM

its good that you are also in touch with drvmtm and sreeni. if possible, invite them to this thread also.

if it is a three phase stator, i don't think you can convert it to single phase, because, its not just wiring but how magnets are provided.

looking at the picture you have provided, it seems there is not much space available for rewinding with a thicker wire.

plz post a picture of its RR unit also, it will help us understand better.

and planning for a halogen and 2 HID's will be overkill.

a single 55/60 w HID should be more than enough for any kind of riding. you can keep a halogen as a aux. but HID rarely fails as there is no filament involved. so chances of HID failure are minimum. still keeping a halogen as back up is ok.

tasks for you now.-

post a pic of RR unit
invite drvmtm and sreeni to this thread.

**TheNoobGeek** · 06-29-2012, 12:31 PM

Here's Picture of RR I found online.
Have asked sreeni, dr and nano to help here.

EDIT:Some more info

I cannot convert 3-phase to 1-phase and plonk an APE RR. I'll have to stick to 3 Phase RR. Now, newer classic bullets come with a 14ah battery so its RR would be the best bet. In case mine has the same RR then there's no point in changing the RR.

As of now the stator winding is cut in 3 portions : Ignition coil, lightning coil (to headlight), and charging coil (to battery).
If I get it rewound all except ignition coil and direct the stator coil o/p to RR then can everything be taken forward from here the normal way?
I know there will not be a single coil, there will be 3 outputs from stator which will go to RR. I guess I'll just tell Ruby electricals and he'll rewind and route all through RR thus making my bike full DC.

Am I missing something here?

Also, at which points should I measure the current ensuring that its within range (what is the range)?
Please don't reply with "depends" etc, reply with solid numbers.

**princesirohi** · 06-29-2012, 02:10 PM

both the RR's in above pic are different.
the left one is for single phase and full DC setup.

which one is yours ?

what is the wattage of stock headlight bulb ??

instead of internet, click a photo of your bike's RR and upload.

looking at the stator plate and the fact that your stock battery is 5Ah, i have doubt that it is a 3 phase system.

**TheNoobGeek** · 06-29-2012, 02:34 PM

what is the wattage of stock headlight bulb ??

it was 35/45w, I changed it to 55/65w.

instead of internet, click a photo of your bike's RR and upload.

Will do once I get my bike back from service center (hopefully today)

looking at the stator plate and the fact that your stock battery is 5Ah, i have doubt that it is a 3 phase system.

I called up ruby electrical and he said its a 3 phase, the service center guy also confirmed as 3 Phase.

**princesirohi** · 06-29-2012, 03:22 PM

ok, so i will be waiting for the actual pic of your bike's RR.

is ruby electricals ready to do all this job, conversion to DC and HID installation etc.?

**TheNoobGeek** · 06-29-2012, 04:01 PM

He just asked me call him back on saturday morning. He was in a hurry and just said "it is a three phase, call back on saturday morning at 10am"

Edit: Images added

confirmed with 2 more people at service center. They both said its a 3 phase stator.

**TheNoobGeek** · 06-29-2012, 11:17 PM

Cross reference to Sajjit and Prathin's posts

Originally posted by sajjt

U can't use APE RR on a bull, APE RR is for single phase alternators. Go for TBTS RR. I guess the stock lighting is AC,if then RR swap is a must.

2 HIDs will be an over kill setup IMHO Then u need to upgrade the battery like others said. Does ur bike got an amps meter by stock?

Can I use Classic's RR? It guess it'd be better than TBTS, correct me if I'm wrong.

Originally posted by rprathin

can it be done like this if we will remove all the old winding than again do the winding with the 19g wire on all poles than it will become single face and then we can use ape rr..

If you notice the pics in above post then you'll notice that my RR has only 4 wires. 2 for I/P and 2 for O/P, how the hell is it supposed to take I/P from a 3 phase stator then?

Even I'm wondering same. explained below.

Originally posted by rprathin

if its 3phase than pulsar 220 rr can also be used

P220 is a high revving machine ; Low amps / high Volts. Bullets are vice versa, I wonder if it will be good for a bullet.

Let me explain what I am understanding.My stator has 5 coils which can be used for charging battery. I think that 2 are lightning coils and 3 are charging coils

Case 1: (1 Phase ?) Wind with a single wire and use APE RR - I read somewher that 3 Phase to 1 Phase cannot be done this way since magnets are set up in different ways. I have no idea pon this. Maybe someone can help.
Case 2: (3 Phase) Wind in current fashion and use TBTS / Classic RR- Since a 3 phase power requires poles to be in multiples of 3, it means I can only use only 3 poles (same as existing setup) in which case 2 poles will remain unused. These 2 poles are providing power to H/L so post conversion whole power will be delivered only from 3 poles which I think will not be sufficient (40% drop due to use of only three wires Vs 10-15% increase due to rewind).
Using all 6 poles for charging the battery is out of question since it'll include removing the ignition coil and including it in the battery charging ciruit. This will make my bike not start on a dead battery. I've faced couple of times when a wire got burnt and the battery was not used, my bike still started.

**rprathin** · 06-29-2012, 11:18 PM

Originally posted by TheNoobGeek View Post

He just asked me call him back on saturday morning. He was in a hurry and just said "it is a three phase, call back on saturday morning at 10am"

Edit: Images added

confirmed with 2 more people at service center. They both said its a 3 phase stator.

but the rr which is in the photo shows that its is single phase rr as it has got only 4 wire inputs which means 2wire for inputs from coil and one for battery positive and other for battery negative
what d you say sajjt and princesirohi...

**princesirohi** · 06-30-2012, 05:37 AM

ok now i m going to ask a very stupid but logical question-

does your bike has two RR units ? one for battery charging and other for headlight ?

thanks for the images. one last thing we will require from you is wiring diagram of your bike.

in any AC + DC bike, more power is delivered to headlight and less to battery charging. so it may be that 2 coils are being used for battery charging and 3 for headlight.

wiring diagram holds the key.

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