Convert AC/DC bike to ALL DC.

[sunilyo]

sorry for the late reply.....

you had to rewind the poles which are circled with white color
image below:

[ATTACH]58795[/ATTACH]

don't touch the black colored poles & its wire which are soldered to the stator coil those are for ignition.....
you should only de-solder the wire which are circled with white color...
re-wind with 19swg wire

Thank you rprathin for your reply. I had to put the coil back as i need my bike to go to office. Will be going leave for one month now. I shall do this once i return and post the images.

I also need to tackle the stuck bolts issue when i return

[rprathin]

after a little struggle was successful in taking out the coil. Here is the rearend of the coil.

sorry for the late reply.....

you had to rewind the poles which are circled with white color
image below:



don't touch the black colored poles & its wire which are soldered to the stator coil those are for ignition.....
you should only de-solder the wire which are circled with white color...
re-wind with 19swg wire

[sunilyo]

after a little struggle was successful in taking out the coil. Here is the rearend of the coil.

[sunilyo]

CBZ Star - Coil

So here is the CBZ Star coil. It has 12 poles. out of which 3 are covered in some kind of cloth tape (what are those).

The yellow thing at the bottom left corner should be the pulse generator. Right?

what about the ignition coil?

Which all wires do i need to de-solder?

Which poles should i rewind?

[sunilyo]

Hi,

Last time when i serviced the bike two bolts on magneto cover broke. I guess too much torque caused this. Now i cannot open the case to take the coil out. What should i do?

Is there any alternative. I already have HID installed on my CBZ*. At the moment i do not do much night riding, but day before yesterday i went for a wedding and within 30 minutes the light went off along with the horns and i had to manage with the punny angel eyes. Thanks to the street lights i could see.

What options do i have now. I already have bought the 9Ah battery and APE RR. Will replacing the stock RR and upgrading the battery do any help?

Otherwise my options would be to get the engine open again just to remove that stuck bolt.

Re-edit:: I was able to open the coil cover. Though the screws are still jammed in the crankcase cover. will post the picture of that too in another thread that i have started for this.

I also saw a few videos on youtube on extracting stuck bolts by drill and using some kind of extractors. Any chances of getting the bolt removed like this?

Edit: also any idea where in delhi i can get the heat shrinking sleeves and spade terminal connectors??

[crownpiyush]

don't know about coil wires

[sunilyo]

Sorry forgot to attach the rest of the images in the last post. Here they are

[sunilyo]

Hi

So went today and bought the following:

APE RR unit (OEM) - Rs.1111
19G copper wire (500 gms) - Rs.280
Insulating varnish (1 bottle) - Rs.30
wiring sleeves (2) - Rs.6
9aH exide battery - Rs.1500

Now in order to proceed with the conversion. I wanted to know the following:

a. Which is the ignition coil/circuit?
b. which is the stock RR

I am attaching the images related to the above queries for better clarity.

Looking forward to replies.

[crownpiyush]

can anyone please tell me which is the best bulbs for pilot lamp and for meter ( speedo,rpm and fuel meter).i want white for pilot lamp and blue for meter.
i have purchased some white and blue led bulbs but the quality is very poor and brightness is also very low so anyone please tell me which one to buy?

[crownpiyush]

congrats buddy. So which RR did you finally use?

Also I hunted for the coil winding wire yesterday at many electrical shops in gurgaon but none of them had it. Will try my luck tomorrow at Mehrauli. Hope to find it there.

Any idea apart from the electrical shops where i can find this wire?

Also checked for the 9ah battery both exide and amaron cost Rs.1500 (without exchange). One shop keeper said that Amaron maintenance free battery is not worth and has many complaints. Any comments on this? any one?

thanks buddy
i just converted my bike to full dc but using stock rr with avenger coil as i din't find ape rr here in meerut and you will find the copper wire on the shops who do winding job and i think 500/- is more for 400 gms wire bcoz i got my 350gms 19g wire for 200/- with 4 sleeves.and i m using amaron pro battery for the last 1.5 years and din't face any problem with it.

[sunilyo]

This morning while going to the office i stopped at a local motor winding / repair shop he had this wire with him and said for 400 gms it will cost me Rs.500. It is of 20 gauge so this means if i use this wire then i will have to put in more turns per pole till the brim correct ?

[sunilyo]

converted my bike to full dc and using hid 35w- 6000k.
thanks alot for your help buddy ( rprathin ) .

congrats buddy. So which RR did you finally use?

Also I hunted for the coil winding wire yesterday at many electrical shops in gurgaon but none of them had it. Will try my luck tomorrow at Mehrauli. Hope to find it there.

Any idea apart from the electrical shops where i can find this wire?

Also checked for the 9ah battery both exide and amaron cost Rs.1500 (without exchange). One shop keeper said that Amaron maintenance free battery is not worth and has many complaints. Any comments on this? any one?

[crownpiyush]

converted my bike to full dc and using hid 35w- 6000k.
thanks alot for your help buddy ( rprathin ) .

[crownpiyush]

bro. i have to go to delhi for ape rr and i m thinking to buy the local one and will use the same for sometime, the time i got the original ape rr i will change it to the original.wat do you say?

and after connecting ape rr what else i have to do ?

[rprathin]

ok. what if we run one HID with angel eye, one LED parking light, all 4 indicators, 2 horns, taillight, lights on the speedo/tacho meters.

Then will the stock fuse work?

no then it would not run, if the fuse rating is lower than load than fuse will blow....