Convert AC/DC bike to ALL DC.

[susheelkumar]

Re: Convert AC/DC bike to ALL DC.

Anybody knows where I can find a reliable mechanic in bangalore who has hands on experience on converting AC/DC to complete DC??
If yes please help me with the address or phone number to contact the person.

[Yogesh__Sj]

Re: Convert AC/DC bike to ALL DC.

Hi friends , i am new here , and this is my first post , i need your help friends ,I have CBZ Star kick start , i want to use 55w HID and dual heavy horns and maybe a little more load later in future , i have already installed led in my meter console , all indicators are my own led made , and tail light also is my own home made with leds and parking light also is led (all lights is LED) , so friends can you tell me what i will have to do ? i have 7.2AH Exide ups battery . but i am feeling that my with HID on my horns sounds bad in low rpm , so i want more load and current in low rpm also . so please help me friends , suggest me best thing for this . Coil rewind is sufficient or i will have to use Ape rr also with it ? 3 years ago a electrician had done something in my wiring near headlight , so after that i can switch on my headlight without starting engine . and near about 2 years ago a electrician have done something in my stator coil and put a rr unit in my bike when i had upgrade my bike battery from 2.5AH to current 7.2AH battery , currently i am using 35W HID with dual horns and other normal lights (all LED) , but i want to upgrade my headlight to 55W HID Projector with dual angle eyes and demon eyes . so please suggest me best solution for this .

[sandeepcf]

Re: Convert AC/DC bike to ALL DC.

Some of my doubts:
I have DMM UNI-T(DT830D).

Now coming the part which i was unable to understand: Checking DC Amps. I had connected the red probe of DMM to RR + and Black probe to Battery + point. Switched DMM to DC Amp mode.
This scenario means the RR+ is disconnected from the battery right?(O'course Ammeter is always connected in series). Have yo tried to check the voltage at the RR+ when the RR is still disconnected from the battery? you will get weird voltages upto 30V. This is the case with APE RR - with no load the voltage varies a lot.
when bike is off reading:0.00

Started the bike: no load, raised throttle max i can see is 3.xx Amps.
This is the maximum current the battery is drawing at that moment. So no change in Ampere reading at various RPMS.

Started the bike: Added the 60/55w halogen bulb to battery + and -ve terminals. Raised the throttle and the Amps reading is fluctuating between 3,4,5,6,7 and all these were not constant with RPM. I doubt whether my DMM is working clearly or not (But works perfectly for checking dc volts and ac volts).
The correct method to calculate wattage is VOLTS * AMPERES. so check the different voltages and the corresponding amperes at different RPMS. This way you can confirm if your DMM is faulty or not.


Since i am not getting any clarity on checking DC Amps, So to test battery discharge, i took my bike today with directly attached 60/55w light to battery poles, riding as slow as possible in 1.5 to 2.5 RPM (Max 3 RPM) along with frequent application of Horns, side indicators with flasher and a buzzer, brake lights and halting at signals. i rode the bike around 25 minutes. stopped bike many times and using self start to check for discharge. Amazingly there is no RPM flicker in my bike and bike getting started normally using self and also Neutral light didnt got dim on using horn. I need your opinion guys...!!!!
I am not aware of this method.


The APE RR is getting somewhat littlebit hot (not unbearable).. is it ok..??
It gets warmer with 55/60 bulb and hotter with 100/90 bulb.

I used to use the same DMM as yours and got headaches. So I ditched that method and bought a Bullet AMP meter. I connect the amp meter and check the charge/discharge rate. At nearly 2100 RPM the amp meter needle balances in my Unicorn with 55/60 headlight+5w Tail lamp. At 5000 RPM the amp meter needle balances with 100/90w+5w Tail lamp. you can check the different RPMs when the needle balances with different loads like 35/35, 55/60, 100/90, 130/90 etc and thus can calculate how much watts you are getting at different RPMS.

Also please help me in connecting the 60/55w bulb using Relay. what relay to be used and the connections to be made...!! Please help me guys..!! Thanks in advance...!!!
I use micro relays. These are simple with 4 pins. search for connections in google images.

----consecutive posts auto-merged-----

Voltage always varies with load. The RR's are linear regulators and not switch mode ones.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

yes you are wright.
That method seemed easy to me also but keeping mm while ridding looks like alien in my city every people looks like if i am alien riding pulsar

Hehe... you are right... even to me it was happened... People look anxiously towards me when i am testing the bike at my home..!!!!
I will test my bike as you said and will let you know about the dc volts buddy.....

A year back bike electrician made my bike full dc by just adding a relay (i think its maruti car relay ). at that time my 35w bulb glowed by full dc... He said there will be no battery discharge...!!! But he is wrong...!!! the battery got discharged right from the start.. (My RPM needle began to flicker).... whatever RPM i had maintained, there is discharge in my bike..!!! so i stopped using headlight..!!! after that the wiring harness got many cuts and i had to change to new harness..!!!

Now what is the relay i have to use for 60/55w bulb..??

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Ohh... the volts method is seeming to be somewhat easy...!!! that means my bike should stay in between say 13.5-14.xx volts dc with all loads while driving.... am i right..??? please clarify....

yes you are wright.
That method seemed easy to me also but keeping mm while ridding looks like alien in my city every people looks like if i am alien riding pulsar

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

it is connected correctly. The wires will get hot it happens on my mm also but the reading don't get wrong the mm must not me good as told by other
members.
O
ther way to find the battery discharge and charge is to use the volt function of the mm and connect it to the battery then ride the bike normaly like you always ride with lights and other loads see the volts, does it goes down or stays like that

simple is if you can buy new mm.

Ohh... the volts method is seeming to be somewhat easy...!!! that means my bike should stay in between say 13.5-14.xx volts dc with all loads while driving.... am i right..??? please clarify....

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Hello dude...

below is the pic of my multimeter which was set in 10A (DC Amps mode) and leads were connected. As said above red probe connects to +ve of APE RR and black probe connects to +terminal of battery. I came to know this from the pic of yours in previous pages. Is it correct...?? also the wires are getting hotter while checking DC amps... Some people in previous pages said that my model DMM (UNI-T D830D) shows weird DC Amp readings and its not a quality product. Please suggest me regarding this...

it is connected correctly. The wires will get hot it happens on my mm also but the reading don't get wrong the mm must not me good as told by other
members.
O
ther way to find the battery discharge and charge is to use the volt function of the mm and connect it to the battery then ride the bike normaly like you always ride with lights and other loads see the volts, does it goes down or stays like that

simple is if you can buy new mm.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

first, tell me is your meter something like this if yes then i will draw the wiring using paint software through which you would be able to get idea on how to connect the mm for checking amps.
After getting the battery charge and discharge rate everything would be cleared.

Hello dude...

below is the pic of my multimeter which was set in 10A (DC Amps mode) and leads were connected. As said above red probe connects to +ve of APE RR and black probe connects to +terminal of battery. I came to know this from the pic of yours in previous pages. Is it correct...?? also the wires are getting hotter while checking DC amps... Some people in previous pages said that my model DMM (UNI-T D830D) shows weird DC Amp readings and its not a quality product. Please suggest me regarding this...

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Hello Guys,


Now coming the part which i was unable to understand: Checking DC Amps. I had connected the red probe of DMM to RR + and Black probe to Battery + point. Switched DMM to DC Amp mode.
when bike is off reading:0.00
Started the bike: no load, raised throttle max i can see is 3.xx Amps. (Fluctuting rapidly and not constant with RPM)
Started the bike: Added the 60/55w halogen bulb to battery + and -ve terminals. Raised the throttle and the Amps reading is fluctuating between 3,4,5,6,7 and all these were not constant with RPM. I doubt whether my DMM is working clearly or not (But works perfectly for checking dc volts and ac volts). Guys...Please clarify regarding above one.


Also please help me in connecting the 60/55w bulb using Relay. what relay to be used and the connections to be made...!! Please help me guys..!! Thanks in advance...!!!

first, tell me is your meter something like this if yes then i will draw the wiring using paint software through which you would be able to get idea on how to connect the mm for checking amps.
After getting the battery charge and discharge rate everything would be cleared.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

Hello Guys,

been away from xbhp many days..... uuffff...!!!!! Apologies for being away many days and coming back for help..!!! My bike is P150 UGII 2005 alloy wheel model and i want to convert my bike to full DC..!! i have rewinded avy stator and ape RR (Please Refer to pages 116 and 117)

recently i have changed my bikes wiring harness to UGIII (SWISS company) and also i had changed my switches to P135 backlit switches (Special thanks to rprathin who had given me the idea). The reason for going to UGIII wiring is i want to install P180 digital meter to my bike after sometime. Bike electrician did all the work i.e; wiring and connecting the swithes without BCU..!!!

Yesterday i went to my bike mechanic and installed my rewinded 19swg AVY coil and routed the AC out wires to APE RR and fitted it to the bike..!!! Headlight wiring job is not done. Now i want to know how to add relay for switches for installing 60/55w halogen bulb.

Some of my doubts:
i have DMM UNI-T(DT830D).
Checked current from AC out (from stator): Reading is from 30-above 100 v when throttle raised. i felt it as good.
DC voltage at battery when ignition off: around 13.5 volts.
DC voltage at battery when bike started: Amazingly it is 14.6-14.7 volts starting from 0.9RPM to full throttle. even at 0.9RPM RR is pumping 14.7 volts :O

Now coming the part which i was unable to understand: Checking DC Amps. I had connected the red probe of DMM to RR + and Black probe to Battery + point. Switched DMM to DC Amp mode.
when bike is off reading:0.00
Started the bike: no load, raised throttle max i can see is 3.xx Amps. (Fluctuting rapidly and not constant with RPM)
Started the bike: Added the 60/55w halogen bulb to battery + and -ve terminals. Raised the throttle and the Amps reading is fluctuating between 3,4,5,6,7 and all these were not constant with RPM. I doubt whether my DMM is working clearly or not (But works perfectly for checking dc volts and ac volts). Guys...Please clarify regarding above one.

A robust, non technical, layman method, i know to estimate the battery discharge for P150 UG2 bikes is as follows. The same method has been useful for me when my OEM RR konked off. After riding the bike a few 100's of meters the RPM needle should not flicker when we Press Horn/Indicator/Buzzer/Even brake light.
whenever there is battery discharge, the RPM needle flickers even with application of normal brake and also Neutral light gets dim on using horn.

Since i am not getting any clarity on checking DC Amps, So to test battery discharge, i took my bike today with directly attached 60/55w light to battery poles, riding as slow as possible in 1.5 to 2.5 RPM (Max 3 RPM) along with frequent application of Horns, side indicators with flasher and a buzzer, brake lights and halting at signals. i rode the bike around 25 minutes. stopped bike many times and using self start to check for discharge. Amazingly there is no RPM flicker in my bike and bike getting started normally using self and also Neutral light didnt got dim on using horn. I need your opinion guys...!!!!


The APE RR is getting somewhat littlebit hot (not unbearable).. is it ok..??



Also please help me in connecting the 60/55w bulb using Relay. what relay to be used and the connections to be made...!! Please help me guys..!! Thanks in advance...!!!

[Yogesh__Sj]

Re: Convert AC/DC bike to ALL DC.

Hi friends , i am new here , and this is my first post , i need your help friends ,I have CBZ Star kick start , i want to use 55w HID and dual heavy horns and maybe a little more load later in future , i have already installed led in my meter console , all indicators are my own led made , and tail light also is my own home made with leds and parking light also is led (all lights is LED) , so friends can you tell me what i will have to do ? i have 7.2AH Exide ups battery . but i am feeling that my with HID on my horns sounds bad in low rpm , so i want more load and current in low rpm also . so please help me friends , suggest me best thing for this . Coil rewind is sufficient or i will have to use Ape rr also with it ? 3 years ago a electrician had done something in my wiring near headlight , so after that i can switch on my headlight without starting engine . and near about 2 years ago a electrician have done something in my stator coil and put a rr unit in my bike when i had upgrade my bike battery from 2.5AH to current 7.2AH battery , currently i am using 35W HID with dual horns and other normal lights (all LED) , but i want to upgrade my headlight to 55W HID Projector with dual angle eyes and demon eyes . so please suggest me best solution for this .

[sri19022003]

Re: Convert AC/DC bike to ALL DC.

Hello ,
even I can proudly claim that the I did the a RTR 160Fi with 18gauge wire -1st time in india , before that no one tried 18gauge in RTR Fi . I can guarantee my rewinded coil pulls 100/130W halogen bulb with out battery drain if the the average RPM of the bike remains 4K rpm or above

Hi Devraj,

Do you have any good option for HHSplendor 2003 model (3 pole coil) to fit 55/60W on the headlamp and what are the specifications of it.

Regards,
Sri

[Devraj]

Re: Convert AC/DC bike to ALL DC.

someone please help guys.

Hello ,
RTR 160 needs coil rewinding if you planing to run 3x35W HID or 55W halo in headlight + two 30W LEDs .RTR 160 & 180 both have the same coil , recommendation is 18gauge wire instead of 19gauge .
& the RRunit must be changed to ape's . I used to own R&D motovil so I know those facts . a new RTR160'c coil cost approx 800/- , Hand rewinding with low quality wires cost 400~500 max . & hand winding with high quality dual later wires cost 600~700 max. There is triple layer wire too which can withstands 600*F . those are little costly . If I am not wrong R&D motovil does the winding job with hand only . I offer machine winding + triple layer wire winding job in 1550/- . I am attaching some pics here of what I have to offer . . even I can proudly claim that the I did the a RTR 160Fi with 18gauge wire -1st time in india , before that no one tried 18gauge in RTR Fi . I can guarantee my rewinded coil pulls 100/130W halogen bulb with out battery drain if the the average RPM of the bike remains 4K rpm or above

[smanna94]

Re: Convert AC/DC bike to ALL DC.

Hi ,
can anyone tell me what will be pros. or cons. of rewinding the coil with 19 gauge wire with maximum number of turns ,like stock+15 turns extra on every pole of stator while having a ape rr unit? please can anyone guide me?

someone please help guys.

[sri19022003]

Re: Convert AC/DC bike to ALL DC.

Hi,

BTW one of my friend is running on 55/60 W Headlamp directly from the battery using the Cars 90/100 Relay & Wiring Kit on his Suzuki Access.
He runs atleast 3.5 hrs during the day & 30 mins night driving. (Never we got a chance to test for 3-6 hrs of night driving), So no complaints till now regarding the battery draining.

Regards,
Sri