Convert AC/DC bike to ALL DC.

[l_gbabuin]

xenon hid

hey friends,
i am going to upgrade to xenon hid, in my yamaha crux, will the existing stock reflector(plastic) withstand the heat produced by xenon?or do i have to change to a metal relector?

[sajjt]

I think you don't need APE RR if you are not opting for HID. You can just rewind the coil and get custom RR (donno where u can source in Chennai but in Bangalore Ruby does rewind and changes RR too). For a 55/60w you can use stock headlight unit + holder. AC/DC setup will cost you less as well when compared to converting to all DC.

Shree, I know it will support a HID after rewinding with an average rpms, but will it support city drives especially b2b?

Ruby is giving a custom RR for AC+DC system for 400-500/ right? Pulsar AC+DC RR will cost only 350/ approx which is proved to be a rugged one and the socket difference will be the only glitch.

Honda Activa is not using P43t socket AFAIK, Generally all good halogen falls under P43t base so if u want to use any of these, u need to do some conversion on the existing holder.

[sajjt]

hey friends,
i am going to upgrade to xenon hid, in my yamaha crux, will the existing stock reflector(plastic) withstand the heat produced by xenon?or do i have to change to a metal relector?

Hi Ganesh, HID wont heat as halogens, they only heatsup at the time of initialization after gaining its full brightness, it will be cooler than a normal halogen. So there wont be any issues if u r using a good quality HID. But there r instances blackening of reflectors after using some brands of HID. Expert says it can be the UV radiation but all HID manufactures are claim that UV shield is there with the kits. Who knows its there?

Prepare ur mind to receive the on comers wild comments once u start using HID on the stock reflectors.

Have u sorted out ur DC conversion issues? No postings on that.

[Shreeni0403]

Shree, I know it will support a HID after rewinding with an average rpms, but will it support city drives especially b2b?

Ruby is giving a custom RR for AC+DC system for 400-500/ right? Pulsar AC+DC RR will cost only 350/ approx which is proved to be a rugged one and the socket difference will be the only glitch.

Honda Activa is not using P43t socket AFAIK, Generally all good halogen falls under P43t base so if u want to use any of these, u need to do some conversion on the existing holder.

Again missed reading properly.

I said, if NOT opting HID then AC/DC setup would be fine for a 55/60w Halogen. Yes Ruby is expensive but where else can you get custom RR for Honda's to run on AC/DC ?? Atleast I am not aware where to procure it.

[sajjt]

Again missed reading properly.

I said, if NOT opting HID then AC/DC setup would be fine for a 55/60w Halogen. Yes Ruby is expensive but where else can you get custom RR for Honda's to run on AC/DC ?? Atleast I am not aware where to procure it.

Appreciate ur proof reading skills

U can run a Honda after rewinding (Out of 8 poles u can utilize 5 poles for lighting and 3 for charging with 19G wire) to a AC+DC setup and swap with a AC+DC RR (Pulsar 150 UG1) Its the most economical way I can suggest.

[chennaiautoking]

Team,
Any Idea about the rewinding location (pulsar 150 & Honda Activa coil rewinding shop) in chennai?
I have tried some shops near pudhupet but they said they won't do it. any help on this would be appreicated.

[aargee]

Update
I found a reliable & knowledgeable (not sure how much, have to see in forth coming days) guy through sources who could get the winding done. The first thing the guy said was that the stock magnet of Activa cannot support more than 40W output to the maximum of winding on the stock stator; this was news to me, atleast. We spoke over this for over half hour, keeping it short, he said coil winding directly depends upon the power of magnet & simply winding up the coil would only yield 10-15% more watts only. We also touch based upon Rx for which he said, Rx's magnet could support upto 90/100.

So he asked me to power up the magnet on stock magnet as no other vehicle's magnet will suit Activa directly.

He would remove the stock winding completely & HAND WIND the new coil from scratch & he also mentioned that his winding would be clockwise & anticlockwise which is not the stock norms. I couldn't question him too much as it appeared to touch base his trade secrets . So any input on this greatly appreciated.

Question - Has anyone done a coil winding on Activa & powered to 60/55? Is the info supplied by this guy a correct one?

@Sajjt - What's your take on this?

@Chennaiautoking - If you're willing to wait for sometime, or atleast till my work is over, see my output & then you can decide to get the work done if you're interested.

[abhijeet080808]

Magnet power is also factor in coil o/p. But more than 40W seems easy enough. Also, clockwise + anticlockwise is followed even by manufacturers - nothing top secret there!

[chennaiautoking]

I would like to do the coil winding for Activa and my pulsar 150

As soon as I get the info it would be very help full for me.

I will wait for your update on this.

Thanks

[aargee]

But more than 40W seems easy enough.

I'm not sure, I understood this well; are you saying, 40W from additional coil winding for Activa is less or fair enough?

Also, clockwise + anticlockwise is followed even by manufacturers - nothing top secret there!

Is it? Appreciate if you can educate me on this pls. Tks.
PS - So are you saying, that guy was trying to show off to me ?

[l_gbabuin]

Yes friends,
the magnetic strength of the magnet and the core area(size of the core over which coil is winded) also plays a major role in power output.if the magnet is not big or powerful you will end in low power output that the stock coil after rewinding.this is from my personal experience,i did the coil winding in my yamaha crux,but the power reduced by nearly 20 %.so again bought a new oem stator coil,ungrounded the coil and used.first in my original oem stator coil,i ungrounded the stator coil,connected a ape rr,and converted full dc,the coil could not support more than 40watts,so i rewounded the stator,i wound with 19g wire,same number of turns as oem coil but oem has 20-21g.now the output dropped below 30watts(approximate).so again reverted back to oem coil with stator coil ungrounding with full dc,now with new oem coil and full dc my coil supplies nearly 60watts at more than 40km/hr speed.but for local driving iam happy with 35/35 philips hs1 with h4 autopal dome.i will be converting to xenon hid within a few months as i have already ordered.

[l_gbabuin]

dear all finally i had time to take and post pictures,
i have made my own led brake/tail lamp bulb with led's for my bike,and posted the pictures and circuit diagrams,


the amps meter.


the led light with parking on


the led light with parking and brake light on


the circuit diagram







the led bulb







above abhi's rr on board fixed on a heatsink of defective ape's defective delhi rr.
the led light consumes 5watts for brake light and 1watts for park light,but its brightness exceeds the oem bulb21watts/5watts.actually the oem bulb was broken,and the metal part of bulb was used to fix the led board.

all console lights are led.

[sajjt]

I'm not sure, I understood this well; are you saying, 40W from additional coil winding for Activa is less or fair enough?


Is it? Appreciate if you can educate me on this pls. Tks.
PS - So are you saying, that guy was trying to show off to me ?

I dont think so, new generation alternators are capable of driving a min of 60W at stock condition to support HL+other console lights. Its got a DC ign system I guess right? So definitely it should support a 55/60W after rewinding with a APE RR. U cant drive a 100/90W on stock dome evenif it supports, so forget the idea of plonking it on this.


Yes, ur mech is just bluffing. For rewinding the stator coils u need to follow CW, ACW or vise versa and its the rule of thumb in this.

Power of magnet plays a vital role here. I still remember once I brought one of my friend's bull for rewinding,to the electrician, he changed the magnet as well along with the coils to support the extra coils.

Ganesh, its sad to hear that ur mod didnt worked out well, is there any chance to check with a new magnet assy for the improvement in op? Can u post the pumping rates what u r getting now? For HID, u need to have a min charging rate of 3.5A @ avg rpms with a 9AH batt else, u'll face batt issues on low rpm drives.

[aargee]

Thanks @Sajjt

I dont think so, new generation...support a 55/60W after rewinding with a APE RR.

Ok, so how about, I get the winding done from him & then use it along with the stock magnet? If there isn't sufficient power, what's the maximum damage that can happen? Any ideas?

U cant drive a 100/90W...plonking it on this.

Done

Yes, ur mech is just bluffing. For rewinding the stator coils u need to follow CW, ACW or vise versa and its the rule of thumb in this.

Thanks. I got it now.

he changed the magnet as well along with the coils to support the extra coils.

See, in your case, he'd to wind additional coil. But in this case, I'm only asking to wind 4+3 coils that's all. Are you saying that's also not sufficient?

Now this provokes another question. When the lighting coil is wound, wouldn't the charging coil also be affected due to this? Does this mean that the 5A battery for Activa will also start receiving more than the stock voltage? I don't want to disturb that part; or should I not touch the charging coil & wind only the lighting coil?

[l_gbabuin]

I dont think so, new generation alternators are capable of driving a min of 60W at stock condition to support HL+other console lights. Its got a DC ign system I guess right? So definitely it should support a 55/60W after rewinding with a APE RR. U cant drive a 100/90W on stock dome evenif it supports, so forget the idea of plonking it on this.


Yes, ur mech is just bluffing. For rewinding the stator coils u need to follow CW, ACW or vise versa and its the rule of thumb in this.

Power of magnet plays a vital role here. I still remember once I brought one of my friend's bull for rewinding,to the electrician, he changed the magnet as well along with the coils to support the extra coils.

Ganesh, its sad to hear that ur mod didnt worked out well, is there any chance to check with a new magnet assy for the improvement in op? Can u post the pumping rates what u r getting now? For HID, u need to have a min charging rate of 3.5A @ avg rpms with a 9AH batt else, u'll face batt issues on low rpm drives.

Dear Sajit,
i thing it is 5 amps,because my amps meter needle deflects upto 5amps while in the morning when i start and race my bike for 1 minute,after that it comes to zero.i have ordered for xenon hid,i will check with that when it arrives.and about that magnet i dont have any idea.