I was able to unscrew it effortlessly using an Impact screw Driver.
I would recommend every one to have this indispensable, incredible tool.

Thank You PSR ji for advising me to use an Impact Driver.

Yeah Yeah , now I gotta buy one too ...
3 cheers for him as always ..

Thats good. Can you please post the photos of impact screwdriver. And with the right method and force( you cannot go wrong with 17 inches biceps my mechanic and i both compete in the gym) you can open any nut with a plain screwdriver. For me any nut is not tight courtesy the above mentioned reason.
on a serious note post the differences in light as i am seriously thinking of going for the same as after riding my extreme my joy light feels inadequate.

Even my extreme's light is inadequate , it's spread out too much and does not focus exactly where it's needed . Potholes , wet roads , oil leaked by other vehicles, crashed & broken down vehicles, suddenly dug up road work, stray cattle , drunken guys, construction material(sand), unexpected police check naka(barriers) ... you name it and it occurs everyday here and riding home at night I've had all kinds of bad spills and narrow escapes. I'm pretty frustrated with all bike makers in India about this ... none of them have been able to design and build a perfect headlamp in all these years , despite so much technology being developed in this area upto now . This life-saving component seem to be build with fashion in mind and function as an afterthought on all bikes . Very deserving of a solid kick in the you-know-where .

Extreme light is very bright but its the new bulb with the separator plate in between with decreases the intensity and spreads the light in dipper.
But HS 1 bulbs do not come without separator plate. In my joy which uses M 5 bulb its halogen do not posses the plate thus its dipper is good but the light is not bright as old hero hondas had very bad light. After riding my extreme the JOY light feels as if it is lacking in intensity not in spread.

Installed the coils,took the ends to Pulsar UG4 RR and Re-Routed all the necessary cables.

Output
2.5 Amps (with no load and 60% charged 2.5ah battery)
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Coming Soon


I will wire the headlights(tomorrow) though the ignition switch so that if the key is in "Off" position the headlights will also turn off.
Reason-The stock setup provides direct connection to headlight.


@ALL
I don't know whether the stock RR can withstand the load of a 55-60 watt bulb on AC.
What do you think ?

NOW SOME CALCULATIONS

Stock setup

1.Headlight 35w
3.Brake light 5w
3.Hi-beam indicator 3w
4.Instrument cluster back-light 5watt
5.Dc current to stock battery 6watts

Total current generated is 54watts.

Even if the re-winded coil generates about 70 watts at max Rpm,it is not possible to plonk in a 60watt bulb unless all the other bulbs are changed to LED.

SO what can be done if you dont want to use led's for auxlillary bulbs?

Option 1(Slightly expensive)
A good 25watt 4300k temperature Hid on stock coils or a 35watt hid on re-winded coils can be used with a projector.
Both the setups cost about Rs.4000/-

Option 2(Inexpensive but requires lot of work)

I did no go for Hid as my new bulb glows with full intensity and reflector adjustment is very-very good and light throw is better than many 150cc's out there.
To increase the intensity I had changed
1.the stock bulb to Phillips premium 35watt(Stock is Phillips essential)
2.High beam indicator to LED
3. Neutral Indicator to led
4.Pilot/parking light to Led.
5.Rear brake lights to led.
Hence I saved almost 15watts which was utilized by the Headlight as a result the headlight glows to max even at low RPMs.

Hence I request everyone to change the headlight bulb to Phillips premium,Replace all the other bulbs with LED,slightly lower the headlight reflector position and then see the huge change in lighting

Two questions ,
This is output amps measured at idle rpms ?

This improvement may be obtained after rewinding the coil or with stock coil and RR itself ? I may try this first as it will be very painless for me . How to replace all other bulbs with LEDs , one by one please shoeb'jee .

Are you not forgetting the tail-lamp in both instances ? The brake light and tail light are separate bulbs nahi ? There is also one light that back-lights up the speedometer console ? What about the horn and blinkers, they don't draw any current from the alternator at all ?

Sorry for creating any confusions.

Replies in Bold.

I will post the difference in light soon.
17 inches biceps,Can you post a picture of yourself.

Here are the pictures of the Impact driver.

Thanks for posting photos of impact screwdriver. Can you tell me how much it cost. And regarding DC conversion if the current is so low then i doubt if DC conversion will be successful.These old hero Honda bikes has so pathetic headlights that it becomes difficult to view if dog, human being or something else is crossing the road at night. Thank god the new pro, CD deluxe are coming with better alternator and far better than our bikes. Between how can we know the jet needle size from its number.
Slightly OT- I will post my photo soon but let me find someone who will take my photo after gym.

Impact driver costs somewhere around Rs.350/-.(It cost me less than 300 because I got some discount as I had purchased few other tools also)

Its my mistake,I should have posted the details of output with full load.

2.5amps without any load is excellent. Why ?
The Bajaj Pulsar UG4 RR is a Smart Charger.
It senses the presence a battery,its charge level and load and then it regulates the amount of current output.
Suppose the RR pumps more than 2.5amps without load,the battery will die in no time.

The output will be more than 4-5 amps with full Load.

The complete Guide to better Lighting

After lots of trials and errors,mistakes and hard-work and difficulties,
I have come to a conclusion that The best Way to Increase the Light output is by Following this method.

1.Remove the top black covering/sticker from the headlight assembly.
2.Clean the inside of the HL assembly with water and let it dry .
3.Change the HL bulb to Phillips Premium.
4.Slightly lower the headlight position/focus depending upon the speed.(Slightly low for low speed riding and slightly high position for high speed ridging)
5.Change the rear brake lights to LED.
6.Change the parking/pilot lamp to LED.
7.Change the instrument cluster back-light bulbs to LED.
9.If the Lighting is Still not satisfactory,rewind all the poles.

Full Dc setup on a Splendor/passion/CD/joy is not recommended as you will have to make many changes in the wiring ,It requires a new RR,A 7-9 Ah battery,modification to the battery holder etc....

can passion pro's console be swapped with passion plus?

Ok , shoeb'Jee ... first, a big kudos for all the hard work ... BRAVO .

Can you tell us the gory details that made you reach this conclusion .. I want to follow your experiment steps .
Also tell us how to replace each of those lamps with LED , one by one .. along with the other necessary circuit (resistance, diodes and capacitors) necessary . Pics if possible ,all can benefit from it .
A big thanks for the brave effort again .

Pinaki ji , some T10 parking bulbs are available in markets , you need to remove the front visor , then remove the meter console, under the bottom part of it you would find rubber socket , pull them & remove those bulbs & put the led bulbs & refit all.

Check this for the bulbs i ordered http://www.xbhp.com/talkies/help-me/...tml#post761792

Green one is not reached yet , so changing is on hold , once when get all will post pics of process.