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Thread: Electrical Modification on Hero Honda Passion.

  1. #21
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    Quote Originally Posted by shoeb2015 View Post
    So do all pulsar ug4 share the same RR unit ?
    AFAIK it shares
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    Quote Originally Posted by sajjt View Post
    Its not just a P180 RR, it has to be UG4 RR with 4 wires, charging rates are 4-5A so u dont've to worry about it. So long as the RR is fine, ur battery will be safe from over charging, its u to use the load judiciously for not draining it. ZMA/R has got a 3 phase alternator and 7AH batt (IIRC) so, swapping with a 3 phase RR is not a good idea, it may work with that though, and cost wise also its on the higher side. If u r worried about the over charging rates then, ZMA/R has got a 200+W alternator which can pump out not less than 16A which is not at all required for ur case and coupling it with a single phase alternator u can't dream of getting such a whopping current rate.

    Philips and Osram falling under premium range and its hard to get in single piece. Consider some other brand coming with 1 year warranty for ur peace of mind.

    FIY, I've'nt done this on a smaller CC engine so far, its totally depends on the stator core, magnet power, quality of the elements used, number of turns and finally the neatness in winding. Sometimes it mat turn out to be a failure, one of our fellow member once tried to rewind on a Y Crux with APE RR which turned out to be a total failure as the pumping rates were lower than the stock. One more, rewinding on a smaller CC four stroke engine is overloading, u may loose some spirited sprints on signals.
    Thank bro , so pulsar UG4 rr is complete dc with smart cutoff ( put battery charging on hold when it's full ) & mainly for single phase alternator so most suitable on hero honda passion . Today meet some garage mechanic's & they don't have any idea about ug3 / ug4 , they told the old pulsars are ac+dc while new one's are complete dc so it might be called as ug4 . The pulsar hold's a 9 ah battery as they said , so as you mentioned a current of 4/5 amp from rr is ok for 9 ah battery but isn't it gonna frying machine for a 5/6 ah battery ? What charging current is excepted for a 5/6 ah battery ?

    Quote Originally Posted by shoeb2015 View Post
    Hi sajjt.
    I have done full dc conversion on many 150cc bikes but never on a 100cc

    I am free this week so I want to experiment on installing a Hid(I have a spare hid left from previous mod)
    Also I will be comparing the charging rates of stock and re-wounded coil.

    4.Can anyone provide me the part no. of pulsar 180 ug4rr or any distinct feature of it ?
    Is in this free week you gonna do the mod on some 100 cc bike ?
    Please after you DIY put the charging rates details .

    4. And you got the pulsar ug4 rr give its part no. details to me too .

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    Quote Originally Posted by Above_All View Post
    Thank bro , so pulsar UG4 rr is complete dc with smart cutoff ( put battery charging on hold when it's full ) & mainly for single phase alternator so most suitable on hero honda passion . Today meet some garage mechanic's & they don't have any idea about ug3 / ug4 , they told the old pulsars are ac+dc while new one's are complete dc so it might be called as ug4 . The pulsar hold's a 9 ah battery as they said , so as you mentioned a current of 4/5 amp from rr is ok for 9 ah battery but isn't it gonna frying machine for a 5/6 ah battery ? What charging current is excepted for a 5/6 ah battery ?

    Is in this free week you gonna do the mod on some 100 cc bike ?
    Please after you DIY put the charging rates details .

    4. And you got the pulsar ug4 rr give its part no. details to me too .
    Like I said earlier, as long as ur RR is good condition, ur battery will be safe from overcharging. If the demand is more than ur battery capacity it will be shared from the alternator. Boost in battery charge is required to compensate the drain from the battery without much delay as it may get fried with insufficient charging rates. If the demand is 6A and that will be shared from Alt+battery and during this time if the battery level is going low, the RR will charge the battery if there's extra current available at the alternator if its not there that time, when the alternator is free from load, it will charge it. When the battery is full, it wont take more than 1A and the RR will become on trickle mode charging state.

    U don't've to spent time with mechanics, instead go straight away to the Bajaj spares and ask for P150/180 UG4 RR, if they couldn't follow u, tell them the battery charger for UG4. Part No. is not a must as they will check with the Service manual and get that.
    Do it Yourself, what so ever, if Possible
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    Sat and Sunday are holidays so I will be doing the mod tomorrow.
    In the mean time till i get the RR ,I converted the rear tail lamp to led.
    Yet to convert pilot lamps,cluster,indicators to led to .
    reduce the load on batt.

    @ above all
    I request you capture the wiring diagram with a good camera at high res.
    (need it for reference so that minimal changes can be done to the stock wiring).

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    Guys i have a relatively new battery which I bought it 6 months ago.(locally made,no brand)
    I have to upgrade to a 7/9ah battery so support hid.
    What do i do with it ?
    Sell it off or make a emergency light out of it or something else ?
    Last edited by shoeb2015; 11-11-2011 at 06:15 PM.

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    Quote Originally Posted by sajjt View Post
    Like I said earlier, as long as ur RR is good condition, ur battery will be safe from overcharging. If the demand is more than ur battery capacity it will be shared from the alternator. Boost in battery charge is required to compensate the drain from the battery without much delay as it may get fried with insufficient charging rates. If the demand is 6A and that will be shared from Alt+battery and during this time if the battery level is going low, the RR will charge the battery if there's extra current available at the alternator if its not there that time, when the alternator is free from load, it will charge it. When the battery is full, it wont take more than 1A and the RR will become on trickle mode charging state.

    U don't've to spent time with mechanics, instead go straight away to the Bajaj spares and ask for P150/180 UG4 RR, if they couldn't follow u, tell them the battery charger for UG4. Part No. is not a must as they will check with the Service manual and get that.
    Ok will grab rr from bajaj showroom . Is it then necessary to make the ground wire unground from the alternator for ug4 rr ? or just remove the stock passion rr & change it with ug4 rr ? As i found its necessary for ape rr but can't found about pulsar ug4 rr .
    & can you please provide some rough connection diagram if there it need to remove the ground wire & pulse generator as in first post ac to dc conversion universal thread .

    Quote Originally Posted by shoeb2015 View Post
    Sat and Sunday are holidays so I will be doing the mod tomorrow.
    In the mean time till i get the RR ,I converted the rear tail lamp to led.
    Yet to convert pilot lamps,cluster,indicators to led to .
    reduce the load on batt.

    @ above all
    I request you capture the wiring diagram with a good camera at high res.
    (need it for reference so that minimal changes can be done to the stock wiring).
    Bro next time i will try to snap as clear as i can . Is there you going to unground the alternator grounded wire , & making some modifications with stock pulse generator . rr connection ? or just only replacing stock rr with pulsar ug4 rr ?

    Quote Originally Posted by shoeb2015 View Post
    Guys i have a relatively new battery which I bought it 6 months ago.(locally made,no brand)
    I have to upgrade to a 7/9ah battery so support hid.
    What do i do with it ?
    Sell it off or make a emergency light out of it or something else ?
    A local made battery on resale won't give you much price but instead of it if you make some switches to on stock rr & this local battery with a aux/ another light , it would be good in emergency if modified circuits burn out .

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    Quote Originally Posted by Above_All View Post
    Ok will grab rr from bajaj showroom . Is it then necessary to make the ground wire unground from the alternator for ug4 rr ? or just remove the stock passion rr & change it with ug4 rr ? As i found its necessary for ape rr but can't found about pulsar ug4 rr .
    & can you please provide some rough connection diagram if there it need to remove the ground wire & pulse generator as in first post ac to dc conversion universal thread .



    Bro next time i will try to snap as clear as i can . Is there you going to unground the alternator grounded wire , & making some modifications with stock pulse generator . rr connection ? or just only replacing stock rr with pulsar ug4 rr ?



    A local made battery on resale won't give you much price but instead of it if you make some switches to on stock rr & this local battery with a aux/ another light , it would be good in emergency if modified circuits burn out .
    I am going to un-ground the coil and take it to the RR so that i get full wave dc.
    The old RR will be remaining there but all the connections will be removed.

    Whats the cap of your batt ?
    Are you planning any hid setup or just full dc conversion ?
    I have decided that I will not install hid as soon as I am on full dc,Instead I will use 35w halo.
    First I will test the reliability of the setup for at-least two weeks,If everything is good then I ll install Hid w/projector.

    Where do you live BTW ?

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    Quote Originally Posted by shoeb2015 View Post
    I am going to un-ground the coil and take it to the RR so that i get full wave dc.
    The old RR will be remaining there but all the connections will be removed.

    Whats the cap of your batt ?
    Are you planning any hid setup or just full dc conversion ?
    I have decided that I will not install hid as soon as I am on full dc,Instead I will use 35w halo.
    First I will test the reliability of the setup for at-least two weeks,If everything is good then I ll install Hid w/projector.

    Where do you live BTW ?
    Ok so it is needed to unground the wire . What about other connections like pulse generator . Any changes in them too ?

    My current battery is 2.5 ampere 5 years old but still strong , driving the vibrasonic & windtones horns with rainbow lights on .
    But for making complete DC will put a 5/6 amp battery or even 7/9 amp battery which is available & within budget .
    Not gonna put hid immediately will continue with the 55/60 watt halogen which i have already plonked from a month .
    I live in Dhule , Maharashtra .
    Please keep posted with details & photos once you done dc conversion .

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    Will that puny stator be able to support a 55/60 halo ? It alone draws about 4.5 -5 amps.+ other loads.
    I suggest you to change the acc. bulbs to led so that you will be saving a lot of power.
    Don't touch the pulse generator.

    @ sajjt
    Can I connect the two wires from lighting coil and two wires from battery coil together and then connect it to new RR ?
    (haven't opened the stator coil yet).Pls clarify.

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    Quote Originally Posted by Above_All View Post
    Ok will grab rr from bajaj showroom . Is it then necessary to make the ground wire unground from the alternator for ug4 rr ? or just remove the stock passion rr & change it with ug4 rr ? As i found its necessary for ape rr but can't found about pulsar ug4 rr .
    & can you please provide some rough connection diagram if there it need to remove the ground wire & pulse generator as in first post ac to dc conversion universal thread.
    I guess there's some confusion, u've rewinded the alt coil with fresh wire and both the ends should be connected to the new RR. Both ends are free from the stator body right? Or did u connect one end to the body like in the stock coil? It has to be floated ie; both ends to the RR only, no groundings, no tappings to anywhere. No play around the pulse coil, it should be as it is in the stock, if u do something out of the way, ur bike wont fire.

    Typical wiring diagram can be found in the universal thread for DC conv. Shreeni had given my wiring diagram there too.

    http://www.xbhp.com/talkies/universa...ke-all-dc.html




    With ur 3 pole alternator and a small battery, 35W halo is the best bet for testing, 55W will be an overkill for ur system. If the system can take 55W halo, surely it can take a 55W HID too.
    Do it Yourself, what so ever, if Possible
    -----------------------------------------
    [SIGPIC][/SIGPIC]
    After Market HID Projector Mod for Pulsar 150
    Flasher Enabled Head Light Flash for Just Rs.1/-

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