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Thread: Electrical Modification on Hero Honda Passion.

  1. #201
    Rusted Above_All's Avatar
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    Default Re: Electrical Modification on Hero Honda Passion.

    Quote Originally Posted by amit01 View Post
    I bought second (or many ) hand Hero Honda Passion June 2001 Model

    i took help from local mechanic...
    i did rewinding locally as well...
    i purchased DJ 201102 RR for 630/- as well but mechanic was unable to replace it with old RR... battery got discharged when he did it, also current was very little from new RR compared to 11-12.5 V from old RR ???
    mechanic was unable to do connections with the help of wiring diagram provided...

    so far, The mods i have already done are .

    Battery = 12V 5A 1100/-

    Turn Signal = 12 V 10W*4 to equivalent LED's 4 for 120/-

    Meter light / fuel indicator light = 12 V 1.7W*2 to equivalent LED's 2*20/-

    Neutral Indicator = 12 V 3W to equivalent LED's 1*20/-

    Turn signal indicator ( RH + LH ) = 12 V 1.7W*2 to equivalent LED's 2*20/-

    Position lamp = 12 V 3W to equivalent LED's 50/-

    Hi Beam Indicator = 12 V 1.7W 20/-

    and installed Cree Fog lamp for 1300/- a pair, which are really good in performance... connections are on key switch most of them... maybe all of them...

    what to do about RR? (wiring confusing to mechanic, I have no idea whats so ever about it... I don't know anything about bike electricals)

    Headlight (LED?)
    Break Light/Tail Light (no help nothing could be found at Lamington Road)

    Thanks a Lot for replying... awaiting for further advice...
    You got wrong RR. To convert to full DC you need Pulsar UG4 "DJ201202" RR, Its a 4 wire RR.
    Your rewinding works seems to be bad also. Is your passion has 3 pole charging coil ?
    If so & you have done rewinding of it then let it keep outside of this DC conversion.
    Get a new 3 pole coil. Now check it the poles have copper wire on it which is contineous for 3 poles.
    That is started from first pole continue to second & third.
    Starting Terminal of copper wire from first pole is left open to connect wire. Connect the required wire to it.
    On the middle pole there is one terminal out where normally yellow wire is connected. Don't connect yellow wire there just cover this terminal with tape.
    Last terminal from third pole is earthed/grounded there. Remove that grounding connection & connect yellow wire to it.
    Use good taping to both connection wire connection.
    Now remove petrol tank. You will find Stock RR. Remove its connection. Good thing is the socket connecting to stock RR is direct fit to Pulsar UG4 "DJ201202" RR.
    Just the wiring is different. So remove the clips from UG4 RR from its socket & rearrange them in same socket as per our new connection.
    That is if i remember correctly then 2Gray wire in pulsar RR will be connected to Stator Wires ( the one from first pole of coil & other is yellow from last pole of coil.)
    Remaining 2 wires will be to battery connection which are present in stock RR socket. After rearranging wires in Pulsar UG4 "DJ201202" RR then only connect it to Passion RR connection socket.
    Now open Headlight assembly & locate 3 wire socket which has headlight supply wire IIRC its yellow wire coming from RR connection . Disconnect it & tape it. Now get +ve supply from Switch & fed it to that headlight supply socket.
    Additionally you can disconnect the Resistor connection which is under the seat near tail grab rail bolts.
    And now i hope you will get sufficient voltage across battery terminals.

    For brakelight you can get led one from lamington road. I purchased from there. Check my last 2/3 post in Let there be light thread i have posted pic of it along with LED headlights.
    amit01 likes this.

  2. #202
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    Icon4 Re: Electrical Modification on Hero Honda Passion.

    Quote Originally Posted by Above_All View Post
    You got wrong RR. To convert to full DC you need Pulsar UG4 "DJ201202" RR, Its a 4 wire RR.
    My mechanic still could not understand about RR's... I think I will note down these points and show it to him so that he can understand...

    about stop light to convert in LED... there are no ready made solutions available, not I could find at Lamington road... mechanic says that stop light has two filaments in single enclosure so it is not possible to change it to led....

    any suggestions on how to fix this....

  3. #203
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    Default Re: Electrical Modification on Hero Honda Passion.

    Quote Originally Posted by Above_All View Post
    I have a Hero Honda Passion 2002 model . I want to make some electrical modifications to it .

    The Electrical & lights details of it are

    Battery = 12V 2.5 AH

    Alternator = Flywheel A.C. generator

    Headlight ( High / Low ) = 12 V 35/35W

    Tail/Stop light = 12 V 5/10W

    Turn Signal = 12 V 10W*4

    Meter light / fuel indicator light = 12 V 1.7W*2

    Neutral Indicator = 12 V 3W

    Turn signal indicator ( RH + LH ) = 12 V 1.7W*2

    Position lamp = 12 V 3W

    Hi Beam Indicator = 12 V 1.7W


    The mods i have already done are .

    A pair of Roots Vibrosonic Horns with relay .

    A pair of rainbow lamps .

    I wanted to make it completely DC , to get a good strong focus from my headlight instead of the candle light .

    ================================ UPDATE ================================

    Thanks to sajit , shreeni , utkarsha , shoeb & all who cleared the doubts i got it done .
    For the new comers to this thread what we need to done is 4 things for complete DC conversion .

    1) In alternator / coil unground the grounded wire , remove the center tap yellow wire & connect that yellow wire to the ungrounded terminal. If you do rewinding with a higher guage wire then it would be good .

    2) Change the stock RR to a complete DC RR . I used a pulsar UG4 rr part no. DJ201202 .

    3) Reroute the ac supply wire of headlight to key switch dc connection .

    4) Change the battery to higher one , i used a 12v 5ah battery .

    *) Additionally it is good if you can change all other pilot light , meter lights , brake light etc to led's / smd led's .

    For getting clear on this 4 things check this thread .
    ================================================== =========
    The Below Modification done more than 10 bikes as off now and running fine for past 1 years.

    Upgrade / Modify the 35/35W to 60/55W headlight running from alternator itself with more brightens for Hero Honda splendor / super splendor / passion / Hunk

    Default HeroHonda Rectifier wiring or connections


    Red --> To Battery
    Green --> To Ground
    White --> From Coil / Alternator
    Yellow --> To Headlight


    Bajaj Pltanina / Boxer / CT 100 Rectifier wiring or connections for 55/60W Headlight

    White --> To Battery
    Blue & White --> From Charging Coil / Alternator
    Yellow --> To Headlight
    Yellow & Red --> From Lighting Coil / Alternator
    Black & Green --> To Ground


    The Modification need to do

    1 - Join Green (Of default regulator) with " Balck & Green " (of Bajaj Regulator) and Green wire from bike à Common Ground for Both regulator
    2 - Join White (Of default regulator) with " Yellow & Red " (of Bajaj Regulator) and white wire from bike à Common AC input from Coil for Both regulator
    3 - Join Red wire from bike to red wire connection only of default regulator --> Input to battery from Default Hero honda Regulator
    4 - Join Yellow wire from bike to Yellow wire of Bajaj regulator only --> Input to 55/60W Headlight from Bajaj regulator
    5 - Don't connect Yellow from default regulator to any thing
    6 - Don't connect " Blue & white " & White from Bajaj regulator to anything


    Two Diagram/picture attached: for the same.
    Attached Images Attached Images   

  4. #204
    Surely heaven waits for you. Bismaya's Avatar
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    Default Re: Electrical Modification on Hero Honda Passion.

    OP, how did you get the Pulsar switch gear working on the bike, especially the kill switch?
    [My Motorcycles]

    2016 - Current: Honda Unicorn 150
    2017 - Current: Splendor Pro
    2019 - Suzuki Shogun (The Boss)

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