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Thread: Convert AC/DC bike to ALL DC.

  1. #1
    Rusted Shreeni0403's Avatar
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    Default Convert AC/DC bike to ALL DC.

    Well many have accomplished this successfully on their bikes and the entire source of information is available in xbhp itself but it is scattered through out in many threads so putting up all together in one place.

    Let me start this with bikes like Unicorn/CBZ/Xtreme and any other which has single phase coil. I will leave the explanation part of Pulsar’s to Sajan and Abhi who are good at it and also the back bone behind accomplishing this successfully .
    The job is pretty much simple on bikes mentioned above.
    First of all the coil rewind done from a reputed auto electrician. In Bangalore, Ruby electricals would be a better place. Ask them just to rewind the coil without RR Unit change.
    Once the rewinding is done, tell them to remove the ground from coil. Just have a look at the below image. The coil end will be connected to ground/body and green wire will be connected to body/ground. (Red Dots) De-Solder both the terminals from ground and connect it directly. i.e connect the coil wire and green wire directly removing the connection from ground (Yellow Line).





    Now once the ground is removed, figure out the Green wire coming from Pulse generator, disconnect it and ground it to body.Check stock diagram and changed diagram so that u can identify easily.
    Stock Wiring




    Modified wiring with APE RR



    Once this is done, don’t connect the Coil Connector to Wiring Harness; instead connect it to APE RR Unit connectors Grey color wire in APE RR picture. (Generally its direct fit connector atleast for Unicorn). Connect the yellow wire of APE RR to +ve of Battery and Black to –ve of battery. Remove the stock RR unit and preserve it safely or just disconnect it and leave it as it is. Check the above picture.

    That’s it..!! Voila you are done

    APE RR Unit.


    Complete Wiring for Headlight including relay. (Put up by Sajan)



    Approx Cost Involved.
    APE RR OEM - 1100rs
    APE RR Delhi Made (Not recommended) - 600rs
    Coil Rewinding - 600-800rs

    Regarding APE RR unit, people please do go in for an OEM RR unit of APE else you might face a serious problem somewhere in mid-road without lights !!
    Use of doing all DC -

    Hassle/flicker free riding at night with higher watt bulb/HID

    Last edited by Shreeni0403; 01-20-2010 at 06:13 PM.
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    Topic Moved and Approved.
    ...in search of that perfect world - My Travel Blog :)

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    This will help out guys who are hungry for power & knowlegde.
    Yamaha FZ16 - 2009 to 2011
    Pulsar 220F Black - 2011.......

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    I am ashamed of my useless post in this thread, but this is a very good initiative! Will benefit a lot of us (even the RTR guys who are still stuck in AC)
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    Well done Shree, its very comprehensive for all with easy step by step procedures

    And thanks for the courtseys too.

    Well, for Pulsar DC conversion is almost the same even the ground isolation procedure except with the pulse coil as its connected seperate. In Pulsar, just isolate the coil from the stator core and connect the black wire to the coil only not to the body. DOne.. Next is re routing of wires are explained as simple as every one can follow. Only thing is u need to cut some of the stock wires in Pulsar to do this job.

    Nice try Shree. Hats off to u man. Lets make this thread as a dedicated Universal DIY Elcetrical Mods
    Do it Yourself, what so ever, if Possible
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    Rusted road_ripper's Avatar
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    Quote Originally Posted by sajjt View Post
    Well done Shree, its very comprehensive for all with easy step by step procedures

    And thanks for the courtseys too.

    Well, for Pulsar DC conversion is almost the same even the ground isolation procedure except with the pulse coil as its connected seperate. In Pulsar, just isolate the coil from the stator core and connect the black wire to the coil only not to the body. DOne.. Next is re routing of wires are explained as simple as every one can follow. Only thing is u need to cut some of the stock wires in Pulsar to do this job.
    Buddy, I am bit confused with the wires, A pic would be of great help as explained in this thread and do we have to use the APE RR unit in a pulsar ug3 or a Avenger RR unit would be ok to use?

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    I didn't go for rewind or the RR swap. I installed an avenger coil and used rahuldevnath's ckt which had a rectifier to convert the AC meant for headlight to DC and charge the battery using it and connecting the headlight wiring directly to the battery via a relay. It is able to run a 35watt HID flawlessly. I was earlier running a Philips 55/65watt halogen. that too was nice bright and flicker free.
    I don't trust my own ckts thats why i have stuck to OEM parts and all. sajan, shreeni and abhijeet080808 are daredevils who push all the mods a step ahead. kudos to you people

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    Rusted road_ripper's Avatar
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    Quote Originally Posted by pavanchirmade View Post
    I didn't go for rewind or the RR swap. I installed an avenger coil and used rahuldevnath's ckt which had a rectifier to convert the AC meant for headlight to DC and charge the battery using it and connecting the headlight wiring directly to the battery via a relay. It is able to run a 35watt HID flawlessly. I was earlier running a Philips 55/65watt halogen. that too was nice bright and flicker free.
    I don't trust my own ckts thats why i have stuck to OEM parts and all. sajan, shreeni and abhijeet080808 are daredevils who push all the mods a step ahead. kudos to you people
    Basically even i want to run the headlight alone in DC and dont want the entire bike to be converted into DC, Only the headlight i.e An hid preferabbly but am afraid of charging issues, After I connect the headlight to DC, Which circuit are you referring to if i want to increase my charging rate?? A pic of the diagram and the circuit will be very much helpful.

    Thanks
    Pradeep

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    Rusted Shreeni0403's Avatar
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    Quote Originally Posted by pavanchirmade View Post
    I didn't go for rewind or the RR swap. I installed an avenger coil and used rahuldevnath's ckt which had a rectifier to convert the AC meant for headlight to DC and charge the battery using it and connecting the headlight wiring directly to the battery via a relay. It is able to run a 35watt HID flawlessly. I was earlier running a Philips 55/65watt halogen. that too was nice bright and flicker free.
    I don't trust my own ckts thats why i have stuck to OEM parts and all. sajan, shreeni and abhijeet080808 are daredevils who push all the mods a step ahead. kudos to you people
    Even i tried using RahulDevnath's ckt, i donno why.. Probably it wont support Unicorn wiring very much, I was getting negative charge. To be precise the battery was discharging more. But what he did is exactly what we are doing here but instead of using custom made RR, we are relying on tried and tested RR of APE.

    My Delhi made APE RR blew off and started giving 18-20v which fried my Amaron battery, Osram NB, couple of other bulbs. So i ve clearly mentioned not to use Delhi made RR's.

    Quote Originally Posted by road_ripper View Post
    Basically even i want to run the headlight alone in DC and dont want the entire bike to be converted into DC, Only the headlight i.e An hid preferabbly but am afraid of charging issues, After I connect the headlight to DC, Which circuit are you referring to if i want to increase my charging rate?? A pic of the diagram and the circuit will be very much helpful.

    Thanks
    Pradeep
    Apart from headlight what else is running on AC ??

    The main intention behind all this experiment is to ensure right charging rate with powerful headlights running on battery.
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    @ All
    This setup which shreeni has mentioned is awesome. But the halogen bulbs of higher wattage say upwards of 65watt tend to fry the reflector of the stock headlamps due to the excessive heat they emit. To extract the most out of this ckt, get a round headlamp with Autopal Ambassador headlight lens and reflector ie: sealbeam. It can withstand the tremendous amount of heat emitted by even a 130 watt bulb and the beam throw is the best when it comes to round headlight.

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