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  • @ sibun

    Okay. Got it.
    Avenger RR - Same AC/DC set up, but higher Amps, so 60W bulb.
    Ape Rectifier - Full DC.
    Wats wrong with the first setup..? ( coz that might save some valuable pocket money )

    And may I request you to put up a DIY thread, showing how to replace the RR..?
    MOTORCYCLING IS AS MUCH ART AS IT IS SCIENCE

    Comment


    • Originally posted by sibun View Post
      Thanks for the credit and your appreciation. Actually everything can be solved in a simple manner. It is we who makes the system complicated. Off-course it is not our fault. It is the education system which made us like this. While we are doing engineering, MBBS, e.t.c anything which can be explained simply and easily is made complicated. When we cannot understand anything our professors just advice us to mug them up and vomit on the exam paper. Nobody is interested in understanding and thinking practically. Everybody is studying with only the motive of scoring high percentage. We follow foreign authors books but similar or better books are written by our indian authors which helps in understanding the concept. So whole point is that we are ourself making the matters complicated. I always try to find the simplest of solution and do it in such a way that i can make the other person understand.


      What happened to your hunk. Just ask me for any help anytime.
      well, in a nut shell, i have ruined it bg time...

      the ring broke in 2 peices when i tried to open the block (improper method of opening the ring). luckily, the bike decided to do this exactly when i had decided to completely open the engine and check for other damage. so till the doberman is down, the pomerian has been happily pottering arround :P.

      currently, i am waiting for the original timing chain kit and the guides to come so that the bike runs only on a new timing chain kit with new guides and new piston seal kit.

      also, i could not check the clearence between the block and the piston so i have borrowed a dial guage and will update the results ASAP.

      Ps: i checked my blog after a long time... thanks for the words
      Suffering from Parked Motorcycle Syndrome

      Cant ride ? read this..
      http://MechMarvels.wordpress.com

      Repair manuals for Hero honda Hunk
      https://www.xbhp.com/talkies/do-your...eneration.html

      Comment


      • I dont own a Hunk/Extreme but I have done DC mod on other bikes.
        If anything is wrong,please correct me.

        Would like to add few more points and share something-
        APE RR is a regulator cum rectifier.
        A rectifier converts AC to DC,Regulator will regulate and stabilize the output voltage and current.

        140 watts is generated at more than 4.5k RPM.

        What may be the reason behind hero using AC-DC setup ?

        All of us don't drive at high RPMs all the time and there is a risk battery draining completely if the bike is driven in bumper to bumper traffic with headlights and other loads at night and DC CDI bikes don't take take well to low batteries.(Just My thought)
        OR
        Half-wave Rectifier/regulators are cheap to make,???
        OR
        Bike becomes more reliable with AC-DC setup due to above mentioned reason.
        Cant say anything.

        Here is the procedure which is pretty same to almost all bikes.

        Remove the old RR or Disconnect it.

        After un-grounding and making the entire coil continuous you should end up with the starting and ending of the coil winding.
        Test with a multimeter in continuity mode,there shouldn't be any continuity between the coils end and the ground or any unpainted metal part.
        (To remove the groundings you will have to remove the stator coil and un-ground the coil ends by de-soldering)

        Replace the stator cover gasket.

        Now take this two ends of the coil by soldering high temperature resistant wires(teflon wires) cover it with insulating sleeve and feed it to the two gray wires of APE RR(This will be the AC input to the APE RR).

        There are two output wires in APE RR.
        1.Yellow is positive,DC supply .
        2.Black is negative(To be grounded/earthed to any unpainted metal surface).

        Now Connect the APE RR's yellow wire to battery positive terminal parallel by splicing the existing positive wire to battery,if you don't do so then the bike wont start.
        You can either ground the APE RR's black output wire to any unpainted part of chassis or connect it to negative of battery.

        Double check all the connections.
        Switch off all the electrical possible to be on the safe side,hook up a Digital multimeter,start the bike and check if the voltage is less than 14volts and greater than 12 volts.
        Then check the total current generated by the stator at various RPMs and report it here.

        If anyone needs a simple diagram/schematic of this setup please tell me.
        Last edited by shoeb2015; 08-16-2012, 07:36 PM.

        Comment


        • This sucks big time .

          Hero has completely stopped selling over the counter spares.Today only i went to SC and they told me to leave the bike they will change the ring - only then they will give the clutch+bore packing. They are saying even if i want to change the air filter i have to leave the bike for service or i wont get any spares .

          This particular SC is run by a bunch of thieves so i called the head mech in vellore and he is saying they too have stopped selling over the counter .Without proper packing the head mech is not willing to touch the bike but he confirmed unicorns rings will work on xtreme - i will try to get it from some other SC but i am not sure if i will get the packing .

          can anyone confirm this ?

          OT - this forum needs to incorporate the "like" button thing i see on other forums i visit .
          Last edited by sarbanoxley; 08-16-2012, 08:46 PM.
          sigpic

          Awesome indian militaryIndiaEquator - Sir Winston Churchill

          Comment


          • Apart from the camshaft, carb jets everything is interchangeable with unicorn even the cdi.
            "Engine tuning is not an exact science, but with some practice and patience you'll get comfortable with your skill and be able tune for any conditions mother nature throws at you"


            Still the Boss -- RX 135

            Comment


            • Originally posted by psycho 98 View Post
              Apart from the camshaft, carb jets everything is interchangeable with unicorn even the cdi.
              Can i get the bore packing /clutch packing/head gasket from honda unicorn then ?
              sigpic

              Awesome indian militaryIndiaEquator - Sir Winston Churchill

              Comment


              • Originally posted by sarbanoxley View Post
                This sucks big time .

                Hero has completely stopped selling over the counter spares.Today only i went to SC and they told me to leave the bike they will change the ring - only then they will give the clutch+bore packing. They are saying even if i want to change the air filter i have to leave the bike for service or i wont get any spares .

                This particular SC is run by a bunch of thieves so i called the head mech in vellore and he is saying they too have stopped selling over the counter .Without proper packing the head mech is not willing to touch the bike but he confirmed unicorns rings will work on xtreme - i will try to get it from some other SC but i am not sure if i will get the packing .

                can anyone confirm this ?

                OT - this forum needs to incorporate the "like" button thing i see on other forums i visit .
                The counter sell is not stopped . Here you can get what you need if it's available . Why Hero will stop counter sell ? They getting money with it .
                I think it is by your ASC , may be they have shortage of spare or getting very less bike to work on . Contact HMC thro there web .

                Comment


                • Originally posted by psycho 98 View Post
                  Apart from the camshaft, carb jets everything is interchangeable with unicorn even the cdi.
                  Of course yes.
                  "Engine tuning is not an exact science, but with some practice and patience you'll get comfortable with your skill and be able tune for any conditions mother nature throws at you"


                  Still the Boss -- RX 135

                  Comment


                  • Originally posted by sarbanoxley View Post
                    This sucks big time .

                    Hero has completely stopped selling over the counter spares.Today only i went to SC and they told me to leave the bike they will change the ring - only then they will give the clutch+bore packing. They are saying even if i want to change the air filter i have to leave the bike for service or i wont get any spares .

                    This particular SC is run by a bunch of thieves so i called the head mech in vellore and he is saying they too have stopped selling over the counter .Without proper packing the head mech is not willing to touch the bike but he confirmed unicorns rings will work on xtreme - i will try to get it from some other SC but i am not sure if i will get the packing .

                    can anyone confirm this ?

                    OT - this forum needs to incorporate the "like" button thing i see on other forums i visit .
                    I had similar experience, I went to a big ASC (RAJ motors if am not wrong) and asked for indicator bulbs, they told they do not sell over the counter.
                    But, there is a small ASC in Nungambakkam, I used to get engine oil from there.
                    So, I think this is only followed by some idiots.
                    Also, I've seen Hero genuine spare parts dealers like "Focuz" in Kerala, they used to have all Hero genuine spares. There should be some dealers like that here as well, I think googling will help you....

                    Comment


                    • Originally posted by sibun View Post
                      ... I have a different plan. After warranty gets over i have the following plan:-
                      1. Convert to DC as i have explained.
                      2. The stock bulb will be there.
                      3. Fit two projectors on leg guards on both side using GI sheet tubes as mentioned in GS thread.
                      4.Then i will fit 25 watt H7 bulbs in both the projectors.
                      5. Each projectors will have individual switch. So that depending on the requirements i will switch the required light to assist the headlight.
                      Like this but instead of HID i will go 25 watt H7 bulbs which will assist the original headlight.
                      Since all will be running on DC i, they will provide best illumination....
                      This is a good idea , I have always been exasperated why a 6-cell flashlight(torch) is able to throw a clear compact beam at least 10 meters away while our bikes with all the alternator-battery-wiring-reflector-halogen-bulb setup can't do that .

                      Originally posted by sarbanoxley View Post
                      This sucks big time .
                      Hero has completely stopped selling over the counter spares.Today only i went to SC and they told me ...
                      Same thing here too . But I have found the way to bypass it .
                      See, for every Indian state HeroHonda has a statewide distributor/stockist for all their parts , usually located at the capital city . HeroHonda does not supply it's ASC's with parts , except for a warranty replacement item . The ASCs are supposed to buy all their parts requirement from this authorised statewide distributor . Like for West-Bengal the authorised distributor is Bansal-Motors in Kolkata .
                      Find out where your local HeroHonda ASC is buying their parts from , or otherwise who is the authorised distributor for your city - and they'll happily sell you all the parts you want and at the correct catalog rates too . This is what I do now .

                      Comment


                      • Originally posted by Above_All View Post
                        The counter sell is not stopped . Here you can get what you need if it's available . Why Hero will stop counter sell ? They getting money with it .
                        I think it is by your ASC , may be they have shortage of spare or getting very less bike to work on . Contact HMC thro there web .
                        Thanks i didnt know they had a form like that for complaints- just sent the complaint lets see what they do .
                        sigpic

                        Awesome indian militaryIndiaEquator - Sir Winston Churchill

                        Comment


                        • Originally posted by SatSon View Post
                          I had similar experience, I went to a big ASC (RAJ motors if am not wrong) and asked for indicator bulbs, they told they do not sell over the counter.
                          But, there is a small ASC in Nungambakkam, I used to get engine oil from there.
                          So, I think this is only followed by some idiots.
                          Also, I've seen Hero genuine spare parts dealers like "Focuz" in Kerala, they used to have all Hero genuine spares. There should be some dealers like that here as well, I think googling will help you....
                          Yeah they do have parts distributor just saw it after pinaki sir posted it .
                          sigpic

                          Awesome indian militaryIndiaEquator - Sir Winston Churchill

                          Comment


                          • Originally posted by Pinaki View Post
                            This is a good idea , I have always been exasperated why a 6-cell flashlight(torch) is able to throw a clear compact beam at least 10 meters away while our bikes with all the alternator-battery-wiring-reflector-halogen-bulb setup can't do that .
                            lol never thought of that .

                            Originally posted by Pinaki View Post
                            Same thing here too . But I have found the way to bypass it .
                            See, for every Indian state HeroHonda has a statewide distributor/stockist for all their parts , usually located at the capital city . HeroHonda does not supply it's ASC's with parts , except for a warranty replacement item . The ASCs are supposed to buy all their parts requirement from this authorised statewide distributor . Like for West-Bengal the authorised distributor is Bansal-Motors in Kolkata .
                            Find out where your local HeroHonda ASC is buying their parts from , or otherwise who is the authorised distributor for your city - and they'll happily sell you all the parts you want and at the correct catalog rates too . This is what I do now .
                            no parts distributor even in nearby kanchipuram town - have to run all the way to chennai to get hold of the parts distributor . I even told the head mech that i will getg the packing from outside stores but he refused .
                            sigpic

                            Awesome indian militaryIndiaEquator - Sir Winston Churchill

                            Comment


                            • Originally posted by psycho 98 View Post
                              Of course yes.
                              quoting your own post ? .
                              sigpic

                              Awesome indian militaryIndiaEquator - Sir Winston Churchill

                              Comment


                              • Originally posted by sibun View Post
                                From yesterday there is a great dilemma over electrical of bike.
                                So here i am clearing all your doubts.
                                Lets start with basics:-
                                1.What is RR?
                                A RR is nothing but regulator and rectifier.
                                2.Why is the name Regulator & Rectifier?
                                Well the unit has two functions. It regulates the AC current and converts a part of AC current to DC and rest regulated AC to electricals.So basically RR unit converts AC to DC and also regulates the AC current by capping the voltage.
                                3.How does a RR unit know how much to give for AC and how much to give for DC?
                                It is a function of coil to determine how much to give for AC and How much to give for DC.
                                Lets say for CBZ extreme.
                                WE know every thing except headlight runs on DC. So RR unit must send 3 amps to AC circuit and rest to DC. So what happens is that in coil the no. of poles are divided. Suppose there are 8 poles. So after three poles the coil will be grounded and rest five poles will also be grounded. One wire from 3 poles will feed the regulator and the ground will serve as negative. Similarly the 5 poles will feed the rectifier and the ground will serve as negative. Basically the grounding of coil varies with the ratio of AC and DC.
                                4. How can we make CBZ/HUNK full DC or RUN 60/55 WATT bulb?
                                From the above point you can easily understand how the current is distributed between AC and DC circuit. So what happens is that the RR unit sends only 3 amps to headlight and rest is wasted as heat. So direct fitting 60/55 bulb will not light because of regulator as it regulates the maximum current and voltage.
                                Hero has done the most foolish thing in giving the ac to headlight and rest all dc because it will cost more for ac and dc set-up and also the wiring gets complicated. Instead full DC would have been easy.
                                We know our extreme produces 140 watts of electrical power.
                                so 140/12= 11.67 amp.
                                Load-
                                Headlight- 35 watt- 35/12=2.9 amp.
                                tail light- 0.5 watt- 0.5/12=0.04 amp
                                stop light- 4.1 watt- 4.1/12= 0.34 amp
                                meter led- 4 watt(NA)- 4/12= 0.3 amp
                                Parking bulb- 5w- 5/12 = 0.4 amp.
                                so total= 3.98 amp.
                                Adding Indicators, DC CDI, e.t.c comes to around 6 Amps. Remember indicators are momentary loads so they are not important. Even starter motor is also not calculated as when operating the starter every thing else would be turned off.
                                So in a nut shell our stock coil is more than enough. But the problem is this AC and DC partition. So what we can do is we must remove the partition.
                                For this we must remove the coil from the ground and join together so that eight poles become a single unit. Now both the ends of the coil must be fed to a rectifier. We can use APE rectifier as it can take load up to 20 A without sweating. By this way we can get all 11 amps to battery.

                                Is that safe to let such high current to our battery ?? and how long it should take to charge the battery at such high current.not more than an hour i guess

                                Now regarding wiring just take the output from ape rectifier and feed the battery. Ground the negative wire to body as it will serve the negative for entire wiring.
                                Now take the wire to headlight and feed the wire to dc through the ignition.
                                Now your bike will be full DC.
                                It will take hardly 30 mins if you are well versed with the bike.
                                So what you have to do is:-
                                1. unground the coil negative and make the coil a single unit.
                                2. Feed the wires from coil to APE rectifier
                                3. Lead the wires from ape rectifier to battery.
                                4. Ground the negative from battery.
                                5. You can use the stock wiring, just cut the wire to headlight from the old RR unit connector and connect it to stock DC circuit. Your DC conversion will be complete.
                                Thanks for such an detailed explanation. desperately waiting for someone to do this DIY. will follow it very soon after that along with those Projectors setup.
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