Convert AC/DC bike to ALL DC.

[rprathin]

Hi,

Ive modded my pulsar 150 ug3 to have two hella lamps(55w x 2) . total 110w when both are turned on
Ive removed the dome and headlamp.
Ive connected both the hella lamps to the battery with individual relays for each lamp
these relays are actuated by the stock switches i.e., the old headlamp pin.


pic of my bike 534533_490622444295260_1803817759_n | Flickr - Photo Sharing!

ive installed avenger 180 coil and ungrounded the lighting coil end..
but instead of connecting it to the black wire already grounded with it, i put a separate wire and pulled it out of the stator. the other black wire that comes in the harness is still grounded.

Now my problem,

i connected ape rr to the new wire and yellow-with-red-line wire. the output was 11v dc, when i raised the throttle, the voltage dropped, after this, output stopped coming.. i think the rr is gone.

ive removed the stock rr while doing this test.

then i bought a gc1000 rr, now i din raise the throttle much, but the voltage keeps dropping to zero, but when i check the ac voltage output, it increases upto 70v.

i din wanna raise it too much and blow this rr also.

what is happening here?

Pls help

Hey raghav how much would be your total load if it is 110w then you need to do the coil rewinding with 18.5 gauge and keep the bike @3500 rpm or more when using both aux lamp otherwise battery will discharge.

[princesirohi]

raghav.glass: parallel charging does not work, it is tried by many and failed.

in the final configuration, you will need only one rr unit and that will be ape rr. so to produce maximum power, you have to rewind the stator with a higher gauge wire (may be 19G) with same number of turns as original. you have to rewind all the poles except ignition coil, you don't have to even touch the ignition coil. rest all poles you have to rewind in CW-ACW-CW-ACW -- fashion. then you have to connect this to ape rr. and the output of ape rr goes to battery.

simple configuration works well.

one more thing, ape rr works properly only when connected to battery, do not try to run it with its output terminals open, do not try to measure its output in open ckt condition. i have blown 7-8 rr units doing this over a period of few years. the ac output of coils will raise with rpm as you said upto 70 volts approx. or even higher, the job of rr unit is to reduce it to 13-15 volts and charge the battery.

[rprathin]

Hello Guys..

A special thanx to thread starter "Shreeni" and also i want to convey my thanx to Abhijeet, sajit, Nano, Prince, Psr, Drvmtm, rprathin, shoeb, sandeepcf, , discover vinu and all of you guys here who are helping out others... Kudos to you people

I own a Pulsar DTS-I 2005 model. I wanted to upgrade my bikes headlight to 60/55w. So installed AVY stator coil and finally it resulted in damage of my stock rr and i had purchased another RR.

So now i had removed AVY stator and my bike is running stock with 60/55w Bosch headlight.

So guys after reading this thread, now i want to convert my bike to full dc by Coil rewinding+APE RR+ DC mod

Please help me. I want to make my bike full dc by myself (DIY) with help of you guys.

Plaese comment on following:

Items to be bought:
Copperwire
varnish
Soldering iron (How many watts..??)
lead, flux
APE RR
Wire (I have Finolex house guard 2.5 sq mm 1100v wire. is it ok..??) (Or suggest me one)
Headlight relay

First i want to finish off the rewinding job and APE RR part. so that i can go for later part discussion, that is DC conversion part

COil rewinding section:

Guys can i rewind it on my AVY stator..??? Or my stock coil.? I prefer AVY stator for the job. Please guide me...



I had gone to a motor rewinding copper wire seller. There i said give me 19 guage wire. He said we have 19swg. He added if you want 19awg, we can convert it to awg. I am totally confused
He said for 350gm wire it will cost around 230RS.
please suggest me the best one(grade) for AVY stator and how much quantity.....


AVY stator coil doubts:

[ATTACH=CONFIG]86977[/ATTACH]


Please comment on write up on attached pic of my AVY stator. What is the black gum like thing..?? Is it an insulating paste..??



The second wire(with yellow insulating sleeve) from Ignition coil is going up and down on remaining copper turning poles. Upon removal of copper wire and rewinding, how it should be positioned.?? straight way. am i right..?? (Do any one got pics of rewinded AVY stator..??? Please share them)



After removing (de soldering) the wires from upper one(besides 1st wire of ignition coil) and from points 1, 2, 3 and 4 we should pull out wires. Am i right..??



APE RR doubts:
In earlier years, most of the bikers used old APE RR with four wires. It proved to be durable..!! Some are saying that older ones are durable during some conversations. Now new one with 6 wires is available in market. Which one i have to chose..???

Should i give a order of older one..?? I think it may not be available. Please comment on this new RR durability

I went to some big auto spares shops. There they offered a local made one for 300RS. They said it is good. but i declined and asked for original one. Some of them even said that APE stopped producing original Regulators.

I will visit APE showroom.

Guys.. I am waiting for your replies. Thanx in advance.

Ask for 19swg copper insulated wire

In new ape rr you should only use the wire which are yellow, black and two gray wires. Leave other two wires.

And avy coil if you are going to rewind it then remove every wire just dont touch the pole which is covered with some material and its wires. If the wire is going from the other poles than remove it and then put it back after rewinding..

Iam posting this from my mobile because my computer is gorn for repair so i cannot explain you with the images.
May be tommorow i will get it.

[raghav.glass]

Hi,

Ive modded my pulsar 150 ug3 to have two hella lamps(55w x 2) . total 110w when both are turned on
Ive removed the dome and headlamp.
Ive connected both the hella lamps to the battery with individual relays for each lamp
these relays are actuated by the stock switches i.e., the old headlamp pin.


pic of my bike 534533_490622444295260_1803817759_n | Flickr - Photo Sharing!

ive installed avenger 180 coil and ungrounded the lighting coil end..
but instead of connecting it to the black wire already grounded with it, i put a separate wire and pulled it out of the stator. the other black wire that comes in the harness is still grounded.

Now my problem,

i connected ape rr to the new wire and yellow-with-red-line wire. the output was 11v dc, when i raised the throttle, the voltage dropped, after this, output stopped coming.. i think the rr is gone.

ive removed the stock rr while doing this test.

then i bought a gc1000 rr, now i din raise the throttle much, but the voltage keeps dropping to zero, but when i check the ac voltage output, it increases upto 70v.

i din wanna raise it too much and blow this rr also.

what is happening here?

Pls help

[raghav.glass]

I've disconnected the charging coil. Now when I connect the ape RR to the lighting coil, the voltage drops at high rpm. 2000 - 10v, at 4000- 0v. I dont know what's happening.

[raghav.glass]

hey,

i blew one rr unit yesterday. i have left the black wire inside the stator connected to the ground and only removed the end of the lighting coil.

ive decided to rewind. how do i? all 7 poles in series? acw or cw? 19g wire?

please reply... it will be very helpful

[ajcletus500]

I was gonna wind my stator but now i am confused. Do i have to use awg or swg wire??

[Srinivas sr143sr]

@Srinivas
You can notice that the four poles on the left side are already wound with a heavier gauge wire when compared to those on right side.That is the difference between pulsar's coil and Avy's coil.
How much current are you expecting from this coil ? What will be your load demand ? I recommend you to just un-ground this coil and use APE RR still if you want more then re-wind it.

Hi Shoeb Thanx for your reply.

My load demand: Stock UG2 Pulsar bulbs+ 60/55w(replacing 35w). So I think rewinding is necessary as Drvmtm has same bike, for which he has done this mod.

Can you please answer my above remaining queries

both are same.

Hi bro. I have asked whether that extra 2 wires would make any difference from older APE RR's. Thank for the clarification.

Also, Can you please answer my above remaining queries about wire gauges and other things

[rprathin]

Hello Guys..

APE RR doubts:
In earlier years, most of the bikers used old APE RR with four wires. It proved to be durable..!! Some are saying that older ones are durable during some conversations. Now new one with 6 wires is available in market. Which one i have to chose..???

Should i give a order of older one..?? I think it may not be available. Please comment on this new RR durability

I went to some big auto spares shops. There they offered a local made one for 300RS. They said it is good. but i declined and asked for original one. Some of them even said that APE stopped producing original Regulators.

I will visit APE showroom.

Guys.. I am waiting for your replies. Thanx in advance.

both are same.

[shoeb2015]

@Srinivas
You can notice that the four poles on the left side are already wound with a heavier gauge wire when compared to those on right side.That is the difference between pulsar's coil and Avy's coil.
How much current are you expecting from this coil ? What will be your load demand ? I recommend you to just un-ground this coil and use APE RR still if you want more then re-wind it.

@Above_All
I forgot to tell you that if you re-wind all the three coils then the total output will be less or same of that original coil. The reason is that the pole on right side if re-wound will interfere with the ignition coil and you will notice problem in idling.
The solution to this problem is to leave the battery coil as it is and re-wind the headlight coils and attach the battery coil's end to the re-winded headlight coil's start. For this you will need to get a new coil because your scavenged bare stator will be of no use as it does not have the original battery coil winding.

[Srinivas sr143sr]

Hello Guys..

A special thanx to thread starter "Shreeni" and also i want to convey my thanx to Abhijeet, sajit, Nano, Prince, Psr, Drvmtm, rprathin, shoeb, sandeepcf, , discover vinu and all of you guys here who are helping out others... Kudos to you people

I own a Pulsar DTS-I 2005 model. I wanted to upgrade my bikes headlight to 60/55w. So installed AVY stator coil and finally it resulted in damage of my stock rr and i had purchased another RR.

So now i had removed AVY stator and my bike is running stock with 60/55w Bosch headlight.

So guys after reading this thread, now i want to convert my bike to full dc by Coil rewinding+APE RR+ DC mod

Please help me. I want to make my bike full dc by myself (DIY) with help of you guys.

Plaese comment on following:

Items to be bought:
Copperwire
varnish
Soldering iron (How many watts..??)
lead, flux
APE RR
Wire (I have Finolex house guard 2.5 sq mm 1100v wire. is it ok..??) (Or suggest me one)
Headlight relay

First i want to finish off the rewinding job and APE RR part. so that i can go for later part discussion, that is DC conversion part

COil rewinding section:

Guys can i rewind it on my AVY stator..??? Or my stock coil.? I prefer AVY stator for the job. Please guide me...



I had gone to a motor rewinding copper wire seller. There i said give me 19 guage wire. He said we have 19swg. He added if you want 19awg, we can convert it to awg. I am totally confused
He said for 350gm wire it will cost around 230RS.
please suggest me the best one(grade) for AVY stator and how much quantity.....


AVY stator coil doubts:




Please comment on write up on attached pic of my AVY stator. What is the black gum like thing..?? Is it an insulating paste..??



The second wire(with yellow insulating sleeve) from Ignition coil is going up and down on remaining copper turning poles. Upon removal of copper wire and rewinding, how it should be positioned.?? straight way. am i right..?? (Do any one got pics of rewinded AVY stator..??? Please share them)



After removing (de soldering) the wires from upper one(besides 1st wire of ignition coil) and from points 1, 2, 3 and 4 we should pull out wires. Am i right..??



APE RR doubts:
In earlier years, most of the bikers used old APE RR with four wires. It proved to be durable..!! Some are saying that older ones are durable during some conversations. Now new one with 6 wires is available in market. Which one i have to chose..???

Should i give a order of older one..?? I think it may not be available. Please comment on this new RR durability

I went to some big auto spares shops. There they offered a local made one for 300RS. They said it is good. but i declined and asked for original one. Some of them even said that APE stopped producing original Regulators.

I will visit APE showroom.

Guys.. I am waiting for your replies. Thanx in advance.

[Above_All]

New stator coil costs Rs.188.
Try to apply a layer of varnish to the coil winding area before winding for better insulation.
I used 20 gauge wire. 200 gms will be more than enough, in-fact you can wind two such coils with 200gm wire.

Thanks, i got it from my friends garage , will be saving my stock coil & using this after rewinding so need to buy new one .
Will try to get it done with alternator/starters mechanics .

[UnHappy]

Hey you all guys, anyone tried all this stuff on BAJAJ CT100
If yes then please post pictures and wiring diagram to understand and mod my bike

[shoeb2015]

Finally got Passion Coil Poles . Time to rewind it .
Which guage wire would be good for rewinding ? 18G or 19 G or any-other . How much turns needed per pole ? How much gram required ?
And any other thing to check ? Will be using Pulsar UG4 RR with it /
Also as it doesn't have any surrounding covers , got broken pieces of it . So should i add some covers to avoid current leakage ?
If so will get rewinding done form expert .

New stator coil costs Rs.188.
Try to apply a layer of varnish to the coil winding area before winding for better insulation.
I used 20 gauge wire. 200 gms will be more than enough, in-fact you can wind two such coils with 200gm wire.

[Above_All]

Finally got Passion Coil Poles . Time to rewind it .
Which guage wire would be good for rewinding ? 18G or 19 G or any-other . How much turns needed per pole ? How much gram required ?
And any other thing to check ? Will be using Pulsar UG4 RR with it /
Also as it doesn't have any surrounding covers , got broken pieces of it . So should i add some covers to avoid current leakage ?
If so will get rewinding done form expert .