Re: upgrading headlight of pulsar 180 UG4

Ug5?? When was that released? Use a lower gauge wire since the current required will be high. I think you may have to rewind the stator coil...

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Re: upgrading headlight of pulsar 180 UG4

One bajaj mechanic told that pulsars without BCU in 2014 are UG5. And about wire, guage lower or higher? Single copper is better or multi copper is better?
The wire which i used had 30-50 thin wires in it.
Thats why asking. I wont go for rewinding which i will void warranty. And during night drives i will keep headlamp off during fogs usage.

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Re: upgrading headlight of pulsar 180 UG4

AFAIK, p180 is ug4 till date(silver engine cover). Lower gauge is thicker wire which can handle higher current. Multiple wire is better since it fares better with motion. But the individual wires should not be too thin. Or try using double wires per polarity which improves current carrying capacity. I think you should also monitor the current being drawn by the bulb to ensure battery is able to handle the discharge rate..

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Re: upgrading headlight of pulsar 180 UG4

Here are some pics of my P180 with fogs attached. They are not yet powered. Because I am searching for separate switches to light them. It may take 4-5 days to complete since I get free time only in evening.
1. Side View

2. Front View

3. The Clamp

Re: upgrading headlight of pulsar 180 UG4

The lights do look good. Though the yellow glass does look a bit odd.. Still, if it does the job, then no worries.. Do you use blue coated headlights? I heard they are actually less bright compared to normal halogens.. Do post pics once it is completed. I'd like to see how the lights compare to stock headlights. Do keep the circuit readily accessible for easier adjustments..

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Re: upgrading headlight of pulsar 180 UG4

It was suggested to me by the shopkeeper that a dark yellow light will easily breakthrough fog. If it its white or light yellow, then focus will be less because the fog us also white. I have brought a seperate key switch. Finding waterproof switches is a difficult job. I have planned to use the switches used in discover costing 280 INR. It is cheap compared to honda/hero.


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Re: upgrading headlight of pulsar 180 UG4

Discover switches? How do you plan to fit them on the bike? Is the circuit for these lights independent or is it fitted with the stock wiring?

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Re: upgrading headlight of pulsar 180 UG4

It can be easily fitted on the leg guard. I have already bought a ignition key switch and a fuse box. Will try to fix today if time permits.
And i am not messing with the stock wiring

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Re: upgrading headlight of pulsar 180 UG4

Project Success. First attempt had failed due to faulty bulb which shorted itself. I have attached some photos. Complete review on Fog lamps with all pics I shall post tomorrow. And BTW sorry for Shaky photos.
My 35W OSRAM 90% ( Price - 580 INR) in Low Beam


With High Beam


Right Fog ON


Left Fog ON


Both Fog ON


Fog + High Beam


Fog + Low Beam


What I found is that Headlamp Bulb is almost negligible.
I will do a Battery load Test tomorrow and post the results.
Thank You.

Re: upgrading headlight of pulsar 180 UG4

That is truly awesome dude. What's with the headlights?? Do post the new switchgear set..

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Re: upgrading headlight of pulsar 180 UG4

Attempt:1
Previously I had fixed Fog directly on the Leg Guard as in my Previous Photos. The Problem I faced is that the light was very close to Front Tyre which was blocking its Projection.
I was testing the setup with voltmeter. I raised the for 8500RPM. Suddenly the Left fog bulb itself got shorted. Fused. I thought it was the switch. Because I used a CD100 Switch which has a capacity of 3A, Where I am supplying 9A. My suggestion is not to use this. Better go with any Pulsar switch. I thanked god because I didn't mess with my electricals and were completely safe even by shorting. Got upset that I damaged the switch which I paid 200 INR for that.

Attempt:2
Reconstructed the Setup and found bulb to be the culprit. Replaced with other one. Checked the switches which were in perfect working condition. Only one wire had melted due to heat from the bulb which shorted with the body of the bulb where it was grounded ( negative).
To be frank Both Fogs + Headlamp induces much load on battery.
For the focus issue, I fixed a horn Clamp on the leg Guard. Now I am having retractable Fog lamp with 360x120 degree rotation which can be focused anywhere like a spot lamp or a torch.
During night drive people really confused for my bike as the couldn't identify it. The thing had twin lamps too close to each other, not an Auto, Not a car, then what?. While they get close they used to stare at the vehicle, which I felt proud of myself.

Some Photos:
1. Key set.



2. CD100 Switch gear.



3. Key fixed in the front fairing.



4. Clamp Mounted to Right leg guard



5. Switch gear on Left Guard



The white thing in the first photo is the thermal glue which I used to prevent short circuit during rains.
Second Photo: I used the H/L beam switch and Headlamp ON/OFF switch. Still Indicator and horn switches are free and can used for some-other purpose in future.
Third: Finding space for the key set was difficult Job. I have made a wrong hole in the fairing. Now covered with Carbon Vinyl Paper. But will replace the whole set in future ( around 200 INR).
Fourth: Clamp Contains rubber Bushes to ease my job. Also they prevent rusting. I got that clamp from my friends garage.
Fifth: Switchgear of CD100 sits perfectly. All the wiring's are hidden under the tank. I had removed the tank to ease the job.

Re: upgrading headlight of pulsar 180 UG4

Beautiful stuff... Now, for the load test alone.....btw, the design looks good and neat

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Re: upgrading headlight of pulsar 180 UG4

In my bike, the headlight is running without any problems so far. No battery draining issues.. Have to check it in the long runs...

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Re: upgrading headlight of pulsar 180 UG4

Battery load test completed today.
Very bad result.
1. Bike completely off - 12.6V
2. In idle 1000RPM- 14.25V
3. Headlamp in idle - 13.2V decreases unless engine throttled.
4. Only 1 Fog ON - Eng. Idle (Pilots ON) - 13V Decreases unless RPM maintained at 3000.
5.1 Fog+ Headlamp - 12.5V Cannot be regained even at 5000 RPM.
6. Fog1+ Fog2 + Headlight.- 11.5V Decreases drastically. Voltage can never be regained.
7. Just Fogs with bike running and lights OFF - 12V. Still goes on decreasing. Cannot be maintained.:banghead:
8. Result: Pulsar 180 can only be loaded to a maximum of 25 watts more than the stock setup.
Alternator is very weak in charging battery. I will go for rewinding or will replace coil with that of Avenger 180. However we can use a 55 watt halogen without any battery issues, just the reflector heats up much. And anybody having/seen 35watt H3 bulb, please inform me.

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Re: upgrading headlight of pulsar 180 UG4

Hella Part H83135241 - H3 35w Standard Halogen Bulb - 4 Wheel Parts - http://www.4wheelparts.com/Lighting-...n=HLAH83135241

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