Convert AC/DC bike to ALL DC.

[JACK3935]

Re: Convert AC/DC bike to ALL DC.

I have converted my Honda Dazzler by cutting Yellow wire and shorted with Red wire at Regulator/Rectifier unit and installed 6AM batteryReplace headlight with LED 35W/35W, Break/tail 2W/2W LED , turn signal with duke LED turn signal, Number Plate 1W LED running since last 4 Month without no issue

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I have converted my Honda Dazzler by cutting Yellow wire and shorted with Red wire at Regulator/Rectifier unit or yellow ot black at headlight and installed 6AM battery


Replace headlight with LED 35W/35W, Break/tail 2W/2W LED , turn signal with duke LED turn signal, Number Plate 1W LED running since last 4 Month without no issue

[Toshar Deven]

Re: Need to install HID for discover 125

Factor of safety is more precisely and heavily used in mechanical designing. A bike's on paper max load is 150kg (means 2 person) but it can easily sustain even 5-6 times (600kg or more.) Big machines have even more Fos of 10-15 times.
But this is not the case with electrical systems. You can't load 20A in a 5A system. It will be very un-economical and impractical. That's why a weak point 'fuse' is given. There is no fuse in mechanical systems so they have to give fos.

Rewinding is best solution for using 60w bulb. Main problem is there are no mechanic here with good knowledge of electrical stuffs.

Thank You for the information. I guess it was my good luck that my Discover 135s took all the load and pain for 60w bulb in stock condition.
As for the rewinding, I know there are no mechanics that can do that for ease so I tried it myself. Just like you, I too got confused with few first pages but kept on reading each and every post of these thread. Contacted few persons from the thread who helped me during the process. Few trial and error for full 1 year I successfully rewinded my coil with 17 swg wire eventually giving me 15A of current or even more.

Rewinding is not difficult, it asks for patience.

[SkpMech]

Re: Need to install HID for discover 125

Sir, there is a thing called "Factor Of Safety" which indirectly means that there are safety margins upto which you can extend something without bottle necking it. If you somehow take your bike upto 160 kmph then it won't harm your tyres because they are design to work efficiently upto speeds of 260 kmph and has nothing to do with speedo readings written on your speedometer.
Similarly if your stock HL came with 35w bulb, replacing it with 60W will not cause catastrophic failures to the electrical system. I am in no ways taking responsibility for it but advising this with my own experience that I have already done that with my bike and surprisingly it worked. It was my advice to simply replace bulb before going for coil rewinding as later has many chances of failures in long run.

If one uses 60w bulb on stock system and turns on their indicator or horn and nothing will burn as wiring harnesses are designed to sustain load upto 240 Watts for short burst of time after which there is FUSE which will knonk off indicating that something is wrong eventually saving WH.
A 35w struggles at low RPM has complete different reasons which I dont think you are familiar off.

LED headlights from good reputed brands which are made with respect to correct dimensions of H4 bulb are more or equally good then halogen bulbs. There are hundreds of Chinese LED bulbs whose focus go everywhere instead of road causing this blinding factor. Go with Morimoto MLED, Hella Bi-led System and Bosch for proper LED HL, they will cost more but are way better in terms of output.

Any modification to vehicles that are not registered with its RC are considered as illegal modifications in eye of transport laws. Bypassing them has their own advantages.
H4 55w/60w bulbs are very much legal and 99% used by Inidan automotive. RE, TVS, BAjaj Pulsar range all uses 60w bulbs as stock.

Factor of safety is more precisely and heavily used in mechanical designing. A bike's on paper max load is 150kg (means 2 person) but it can easily sustain even 5-6 times (600kg or more.) Big machines have even more Fos of 10-15 times.
But this is not the case with electrical systems. You can't load 20A in a 5A system. It will be very un-economical and impractical. That's why a weak point 'fuse' is given. There is no fuse in mechanical systems so they have to give fos.

60w will definitely work but definitely the alternator will not be able to supply enough wattage so bulbs will glow dimmer at low speed. But at higher rpm more voltage will be produced as rate of magnetic flux cut by stator will increase so bulbs will glow properly.

But main problem is wiring harness will have to handle high currents so continuous usage at high current will cause overheating at eventually burn.

Using 60w bulb instead of 35w means 25w extra load. 25w means nearly 2A more current will be drawn.

Heat is directly proportional to sqaure of current. So 2A more current will cause 4 times more heating then 35w bulb. That's a lot of heating man.

2. Even branded LED don't work properly until they come with projector. Reflector is designed for halogen bulb only. This reflector is not designed to work with LED so it doesn't throw Led light properly and blinda trafic. Bikes which comes with LED have specially designed reflector so they work perfectly. Also LED don't work in rainy night because cooler color temperature.

Rewinding is best solution for using 60w bulb. Main problem is there are no mechanic here with good knowledge of electrical stuffs.

[babybiker125]

Re: Convert AC/DC bike to ALL DC.

LED bulb spread is bad.....

[Toshar Deven]

Re: Need to install HID for discover 125

What if 60W bulb is used along with turn indicator , horn etc. Wiring harness may burn. Even 35w AC light struggles at low rpm. How 60w will survive? Switching between high/low beam will also take more time which is dangerous.
I think using 60w bulb without increasing power output is not a good idea.

I don't like Led headlights. They are so irritating. I get blinded many times when incoming vehicle is fitted with white LED lights. It's very dangerous and I don't want others to suffer so I don't want to use it. Also such modification is illegal.

Sir, there is a thing called "Factor Of Safety" which indirectly means that there are safety margins upto which you can extend something without bottle necking it. If you somehow take your bike upto 160 kmph then it won't harm your tyres because they are design to work efficiently upto speeds of 260 kmph and has nothing to do with speedo readings written on your speedometer.
Similarly if your stock HL came with 35w bulb, replacing it with 60W will not cause catastrophic failures to the electrical system. I am in no ways taking responsibility for it but advising this with my own experience that I have already done that with my bike and surprisingly it worked. It was my advice to simply replace bulb before going for coil rewinding as later has many chances of failures in long run.

If one uses 60w bulb on stock system and turns on their indicator or horn and nothing will burn as wiring harnesses are designed to sustain load upto 240 Watts for short burst of time after which there is FUSE which will knonk off indicating that something is wrong eventually saving WH.
A 35w struggles at low RPM has complete different reasons which I dont think you are familiar off.

LED headlights from good reputed brands which are made with respect to correct dimensions of H4 bulb are more or equally good then halogen bulbs. There are hundreds of Chinese LED bulbs whose focus go everywhere instead of road causing this blinding factor. Go with Morimoto MLED, Hella Bi-led System and Bosch for proper LED HL, they will cost more but are way better in terms of output.

Any modification to vehicles that are not registered with its RC are considered as illegal modifications in eye of transport laws. Bypassing them has their own advantages.
H4 55w/60w bulbs are very much legal and 99% used by Inidan automotive. RE, TVS, BAjaj Pulsar range all uses 60w bulbs as stock.

[SkpMech]

Re: Need to install HID for discover 125

Coil Rewinding

Coil rewinding is a process in which bike stator coil (the copper wire coiled thing) is removed completely out of the bike and stock copper wire is replaced with thicker wire expecting that it will generate comparatively greater amount of current.
TBH, Coil rewinding is easy AF if the person has basic concepts cleared or belongs to technical baground. One should stay away if not familier with electrical concepts because its a DIY consist many post rewinding work which actually does require knowledge. If Still want to continue then there are few known people throughout india which can do the rewinding job for you. Most of the local mechanic won;t even touch your coil as fo them, a stator coil is unservicable part. It can only be replaced.

It took me almost 1 year and around 10k for this DIY but now I run one of the brightest HL in my bike I guess.
Good quality AUX lights on handle bar or crash guard may do the work for you.

FYI - Start reading after Pg 101 for some usefull information about coil rewinding.

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A 55/60W H4 Halonix bulb willl cost you below 100 rupees. Replace old 35w stock bulb with 60W bulb. Thats it.
I did the same in my bike and kept it as it is for good 5 years. Feel if this much of light is enough for you! If not, then look for other alternatives like coil rewinding.
As far as using 60w H4 bulb, you are just bottle necking the electrical setup, nothing much. What max could go wrong, a weaken battery?

Stay away from Aliexpress HIDs. You can get good HID with warranty in India itself. Look for Uglare on fb or Amazon.

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Why you want to rewind? If you need more light in front of you then good quality LED may do the work.
I re-winded my bike's coil because I do long solo highway rides in night time only. LED would also work for me but stock electrical setup can only work good for half hour max whereas I needed light for atleast 5 hours.
start reading the thread after Pg 101. You will get to know about rewinding .

What if 60W bulb is used along with turn indicator , horn etc. Wiring harness may burn. Even 35w AC light struggles at low rpm. How 60w will survive? Switching between high/low beam will also take more time which is dangerous.
I think using 60w bulb without increasing power output is not a good idea.

I don't like Led headlights. They are so irritating. I get blinded many times when incoming vehicle is fitted with white LED lights. It's very dangerous and I don't want others to suffer so I don't want to use it. Also such modification is illegal.

[Toshar Deven]

Re: Need to install HID for discover 125

Coil Rewinding

Coil rewinding is a process in which bike stator coil (the copper wire coiled thing) is removed completely out of the bike and stock copper wire is replaced with thicker wire expecting that it will generate comparatively greater amount of current.
TBH, Coil rewinding is easy AF if the person has basic concepts cleared or belongs to technical baground. One should stay away if not familier with electrical concepts because its a DIY consist many post rewinding work which actually does require knowledge. If Still want to continue then there are few known people throughout india which can do the rewinding job for you. Most of the local mechanic won;t even touch your coil as fo them, a stator coil is unservicable part. It can only be replaced.

It took me almost 1 year and around 10k for this DIY but now I run one of the brightest HL in my bike I guess.
Good quality AUX lights on handle bar or crash guard may do the work for you.

FYI - Start reading after Pg 101 for some usefull information about coil rewinding.

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

I have heard that rewinding does increase current output from stator, but I have not tried it myself. I myself also want to do rewinding and install 55/60w halogen bulb. If anyone can help me I really need brighter headlights.

A 55/60W H4 Halonix bulb willl cost you below 100 rupees. Replace old 35w stock bulb with 60W bulb. Thats it.
I did the same in my bike and kept it as it is for good 5 years. Feel if this much of light is enough for you! If not, then look for other alternatives like coil rewinding.
As far as using 60w H4 bulb, you are just bottle necking the electrical setup, nothing much. What max could go wrong, a weaken battery?

Stay away from Aliexpress HIDs. You can get good HID with warranty in India itself. Look for Uglare on fb or Amazon.

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

What is the purpose of rewinding? Does it increases current output so that higher wattage bulb can be installed? I also want to do that in my CT100 and Discover 100 but I didn't understand how to do the rewinding. The instructions given in starting of this thread isn't comprehensible. It will be very good if some expert person guide us by providing detailed theory of rewinding the magneto coil.

Why you want to rewind? If you need more light in front of you then good quality LED may do the work.
I re-winded my bike's coil because I do long solo highway rides in night time only. LED would also work for me but stock electrical setup can only work good for half hour max whereas I needed light for atleast 5 hours.
start reading the thread after Pg 101. You will get to know about rewinding .

[SkpMech]

Re: Convert AC/DC bike to ALL DC.

My CT100 is giving 5 to 8v max DC output. So battery is not charging and horn not working. Even after changing RR unit, voltage output is same. AC output from stator coil is in the range of 8v to 60v. What could be the problem?

[babybiker125]

Re: Need to install HID for discover 125

What is the purpose of rewinding? Does it increases current output so that higher wattage bulb can be installed? I also want to do that in my CT100 and Discover 100 but I didn't understand how to do the rewinding. The instructions given in starting of this thread isn't comprehensible. It will be very good if some expert person guide us by providing detailed theory of rewinding the magneto coil.

I have heard that rewinding does increase current output from stator, but I have not tried it myself. I myself also want to do rewinding and install 55/60w halogen bulb. If anyone can help me I really need brighter headlights.

[SkpMech]

Re: Need to install HID for discover 125

Come'on guys no reply even after 5 days? Please help me I really need bright headlight for my Discover 125. Can I just rewind the coil and install a 55/60w halo bulb? Will that work without RR change? Is ape RR really needed? Can I use the HID kits sold on aliexpress? Do I need to upgrade my battery to 7ah or higher? Currently it has the stock 5ah one. And what is the difference between H4 single bulb and H4 hi lo? I'm confused Please help me.

What is the purpose of rewinding? Does it increases current output so that higher wattage bulb can be installed? I also want to do that in my CT100 and Discover 100 but I didn't understand how to do the rewinding. The instructions given in starting of this thread isn't comprehensible. It will be very good if some expert person guide us by providing detailed theory of rewinding the magneto coil.

[babybiker125]

Re: Need to install HID for discover 125

Intensity too low or the pattern/throw isn't good?

Intensity is ok, but throw is bad.

[yashasvi]

Re: Need to install HID for discover 125

I am using this fog light.

Intensity too low or the pattern/throw isn't good?

[babybiker125]

Re: Need to install HID for discover 125

Sorry akash but i don't have any knowledge about what you need, i hope someone with experience answers you

I am using this fog light.

[yashasvi]

Re: Need to install HID for discover 125

Yash Sir, I already have one of those LED lights on the crash guards, they are not the round one that you have shown but rectangular ones with 6 leds. They are not very good. I want to know more about coil winding and hids. Please give me some suggestions.

Thanks,
Akash.

Sorry akash but i don't have any knowledge about what you need, i hope someone with experience answers you

[babybiker125]

Re: Need to install HID for discover 125

Just get the led lights which are installed on the leg guards, they are cheap, offer good visibility and no modifications would be required. Get the ones which have aluminium fins at the back to radiate heat. I got this for 300rs, got two of them and the visibility is excellent.

Yash Sir, I already have one of those LED lights on the crash guards, they are not the round one that you have shown but rectangular ones with 6 leds. They are not very good. I want to know more about coil winding and hids. Please give me some suggestions.

Thanks,
Akash.