@All..

Guys.. Thank you very much for your valuable inputs...!!!

I have once again taken my bike to two more Electricians (1st one doesnt know any thing, He said it is RMP (RPM) meter fault and said to bring a new one...!!! )

Coming to Second Electrician (Experienced), I explained the whole story (About AVY coil), but he said it may not be the reason for fault in Regulator..!! He also added that Regulator faults are common and some may even Burn without any changes in bike...!!!!
He also added that it is very often and quiet normal, and siad that my bike just showed that fault to me now..!!!

After testing the wiring and others, he said that either your battery/ Regualtor is fault..!!!

I said my battery is just 13 to 14 months old..!! He said it is Good to change the Regulator.....!!!!

I asked him i will change to AVY Regulator, but he said all Regulators are common and AVY will not fit to my Bike as the metal clamp which comes out from unit will be straight for AVY and my bikes Regulator is L-shaped..!!

I said him, i will check it out and wandered two to three big Bajaj's authorised spare parts Dealers...!!!

At last i have found AVY coil and to my surprise and my bad luck the metal clamp is straight

At that dealer, i said i had installed AVY stator and now i want to install this to my P150...!!! And i even enquired can i bend the clamp to fit it in my bike...??

He said it will damage the interior even if you slightly apply the pressure on it...!!!

He watched the Regulator(Green coloured) of my Bike and he brought my bikes model regulator (Green) and another Regulator which is Brown in colour...!!!!

He said this is new regulator for newer models (Both P150 and P180) and said it has the same configuration of AVY Regulator and said it can Handle the AVY stator output..!!

I doubted him many times and he said that he's sure about it...!!! I even said, i am not bothered about two to three hundreds but expressed my confusion about it...!!!!

But he said that no to take the same old Green Regulator (My bikes)...!!!!
(The difference between My bikes regulator and Newer models Regulator is just below 10 RS)

He said he is well experienced and said newer models are electronically quite complex with BCU, LCD Display, Lit switches and others and whereas my model bike is quite simple and said it can handle the AVY Coil in my bike...!!

Dont know whether my decision is right or wrong i bought the Brown coloured Regulator

Regulator Part number DJ 20 1164 (Brown coloured )
MRP 395 RS...!! Got it for RS 360





Avengers Regulator
Part number: DV 20 1009 (Blue coloured )
MRP: RS 453








(I think the AVY coil pic i have taken is the very first pic of it in our xBhp... )

The changes i have noticed after Brown coloured New Regualtor after fitting into my bike just after 5kms ride are as follows



While ignition on without starting bike...
RPM needle stopped flickering while horn
Neutal and side stand indicators blinkling decreased...!!!

In Idle after stating and while bike is running....
RPM needle stopped flickering while horn

The most observable change is my Horn working at full tone (Pulsar 2005 UG has got the horns which produce the sound that no bike in India will produce that much intensity....!!! (Not considering Bullets with car horns...))

I still doubt the Regulator which i have bought...!!! But surely wait to watch how it performs after installing 55/60 watt bulb...!!

Guys i have an idea...!!!

If at all my bikes Regualtor will go off..!! I will do the thing as below...!!! (It doesnt glowed while buying, the idea glowed into my mind after the whole process completed...!!! )

I will break My old Green Regulator and remove the Clamp (L- shaped Metal)..!! I will make two holes for it on the other side(same as the holes on opposite side..!!)

After making the two holes on other side, TWO BOLTS AND NUTS should be bought to fit the AVY regulator into the holes which i have made...!!!!

YES... now the L-shaped Regulator(Straight AVY regulator and L-shaped clamp) is ready to fit in Pulsar....!!!!!

One may have doubt that, will it fit in the bike with extra fitting..??

I have observed a gap after fitting the Regulator which is around 3/4 th inch...!!

But before doing it, I have to request the Dealer for checking AVY coil for fitting into the GAP with my idea infront of him without tearing the packed Regulator....!!!

It is my idea...!!!

Once again thanx for all your time in diagnosing the problem of my bike...! Very much appreciate all your help...!!!

I think my thread will help a lot of people who are struck with my kind of mod...!!

Guys: Can anyone redirect or post or give thread for a DC conversion which is GOOD..!! (I mean proved and working flawlessly..!!) Thanx in advance...!!

Guys... its been 4 days i had added my results! My bike is running good....!!!!!

I think this thread is one of the good threads when coming to AVY regulator discussions...!!!!

Guys... i need all of your COMMENTS on this....!!!!!

@MODS... As you watch the content here in this thread, i think the content is quite good and can be useful to those who are thinking of AVY stator coil to their Pulsars...!!

I sincerely request to stick this thread (Not because of my thread), and it will be quiet useful to many bikers....!!!!

I'm amazed that out of so many experts no one told you a proper way to troubleshoot your problem. The most easiest way would have been:
1. To connect the +ve lead of the multimeter to the +ve charging wire & connect the -ve lead of the multimeter to the GND (to check for charging voltage). Now, many transistorized regulators don't show reliable voltage without any load. For that you can follow the next method to get confirmation.
2. Open the +ve charging wire from the battery terminal & connect it to the ammeter's +ve lead & Connect the -ve end of the ammeter to the battery/headlamp (as load) & connect the GND directly to the battery/headlamp. Then start the bike and rev up upto 6k RPM & you would've seen the charging current flowing through the load, which would've helped you decide if your regulator was at fault.
But never-mind, atleast its been sorted.

Facts:
1. I had used AVY coil with a 55/60W headlamp with stock regulator without any problems whatsoever (you may say I'm lucky)
2. Pulsar 150/180 regulators are 'cement' colored not brown. I have it, Shoeb2012 had posted a pic as well (I have also checked with other pulsars). Check if yours is a genuine product.

No offence meant to anyone, just a piece of info that I wanted to share.

@Abhi...

Thanx for the info buddy....!!!!

You have mentioned your bike as Disco135 in your profile...??? (Dont mind about my question )

I went to a Dealer who is one of the biggest Bajaj's(only) genuine spares Dealer in Hyderabad...!!!!

I bought the AVY coil (previously) from him...!! He gave me it within seconds, when i asked about it...!!! (AVY 180 stator coil is bit difficult to find in most of the areas as far as i know)..!!!

As i told about two mechanics, both of them showed the Green regulators with them which were blown.. But none showed Cement coloured..!!!

Even the Dealer showed Green (My bikes), Blue (Avy) and Brown (Latest P150&180) coils...!!

Can i know which model Pulsar do you have..?? (Month and year)

Can i know since how many months you are using AVY coil in your bike...??? Can you lease share about info of your bike Regulator part number...??

Thanx in advance...!!!!

There's absolutely nothing to mind, yes, I own a 2007 Discover 135 analogue model. It has the same electrical wiring as the Pulsar UG3, only difference being that pulsar ug3 had BCU & discover doesn't have one.

I do not own a pulsar but I've checked with a acquaintance who has a 2007 Pulsar 150 UG3 & a friend who has a Pulsar 180 UG4 both had cement colored RR's, apart from Shoeb2012's UG4 RR which also happens to be cement colored.
I'm not sure about green regulators or whatever color they were upto UG2 model but I'm quite sure that UG3 & UG4 RR's were cement colored, hoping that they haven't come with a brown one lately.

Well, I've used AVY 180 coil for a year, before I went for a full DC mod.
Part No. for AVY coil - DV111005
Part No. for Pulsar UG4 RR - DJ201202

You can just ignore my post just because I don't own a pulsar but if I were you, I'd have been more concerned to know if the brown RR is a counterfeit part.

Edit:

From this, I can easily make out that its not a UG4 RR simply because, UG4 RR has 4 wires: white, black, and 2 blue wires. Where as this has 6, same as older AC/DC model pulsars (I can even tell you which wire is for what for both RR's )



This is what a Pulsar UG4 RR looks like


Make sure your RR is a genuine maal.

@Abhi...

Ohh.. I dont know that Cement coloured Regulators too exist...!!! As you have said i think they were for newer models with BCU....!!!

I have found Brown coloured Regulator pics in one of the threads...!! It is same part which i have got...!!!

But its from P200

Dont know whether i did wrong or right in purchasing that Regulator...!!!

Here is the link...!!!!

If its for a Pulsar 200 DTS-i then its absolutely fine, no worries

@Abhi...

Whats the current status of your bike buddy...???

AVY stator +Pulsar ug4 Regulator + DC setup...??? Am i right bro...???

I too want to go for a DC setup (Reliable and Good setup without any problems in that setup in future)

I want a DC setup with good 60/55 watt bulb...!! (Plain light not tube light focus)

(Also i want to know the best bulb, many are saying that Philips Xtreme vision is good..!! I dont know much about bulbs. )

I am not interested in HID and other stuffs as i have taken the pain when the battery gets down...

I want your suggestions buddy..!! Please help me in this issue...!!!

Thanx in advance...!!!!

currently using a rewinded AVY coil + custom made (by me) RR + 5Ah battey (stock) -> full DC with 7+ Amps current & 55/60 headlamp

Go for any 55/60W bulb illumination is more or less same.
For DC setup, rewind with 18AWG + ape RR is the best & most reliable option.

Ape RR outshines everything any day, nothing beats the output as well as the reliability...
There are many posts across xBHP mentioning detailed explanations about the same.
Check my old thread HID projector help in help-me section...

Hey Nano anything new cooking?

Hi Guys,

Which is the best battery in Amaron 9ah for Pulsar....???? Maintenance free or Regular battery...???

Two mechanics are saying that Regular batteries are better.... and adding to that they are saying that MF batteries will show problems....... I dont know what are that problems... Any light on that problems...???

In my experience Regular batteries oozes liquid, deposits sulphur/deposits and causes corrosion.. Already my bike had lot of corrosion because of it.....

But i dont know about MF batteries..

Exide had lot of problems and has very short span of life according to my experience(I maintain with regular distilled water topups and maintained it well)...... Really had bad experience with it.....

So Really inclined towards Amaron after reading many bikers opinions in our Xbhp.....

No one (Even single person) had given -ve response about Amaron in our forum......

So i want the price, warranty of the best variant (in Amaron)...

Also please rectify me if any.... with your experiences.....

Anyhelp is really appreciated.....

Thanks in advance.....

Re: Problem in battery charging.... PLZ help

Anyone plzz share their views on above post

Waiting for that......

Re: Problem in battery charging.... PLZ help

amaron MF sealed batteries with 4 year warranty are best.

Re: Problem in battery charging.... PLZ help



Thanks for the info

Installed new MF Amron 9Ah battery with 48 months warranty