Convert AC/DC bike to ALL DC.

[princesirohi]

Prince, it would be fine if u could stick to our universal language for easy communication. I was struggling to pick ur word by word to get that, sorry for my poor proficiency on our national lang.

sorry for that bro......i was trying to tell what that person said.

APE RR out is 1:1 upto 20A man, if u can pump in 20A, it will gracefully give it to the other end. My coil is giving 8A @4.5K beyond that I couldnt test as my puny Rs.90 DMM probe was heatingup like an element due to the laod.

U can choose any model, its having diff sockets, for a Pulsar wire cut is required not like Uni, so anything will chalega yar

can u tell me how many turns are required in each coil & do i need all 7 coils ?

[Shreeni0403]

can u tell me how many turns are required in each coil & do i need all 7 coils ?

I don't know if number of turns are counted either !!! Just a tight winding till the coil fills up is good enough if I am right.!! No need to rewind all coils, only the lighting coil rewinding should be enough. Am I right Sajan/Abhi ?

[princesirohi]

plZ TELL ME THE NUMBER OF TURNS REQUIRED and i have one more idea, suppose i change the connections of existing coil windings, connect the lighting coils and charging coils together and give thier combined output to APE RR. are standard coils also wound in same fashion i.e. clockwise-anticlockwise-clockwise-anticlockwise and so on.

@ shreeni: in the first post of this thread....u said disconnect green wire of pulse generator and ground it. why was that?

[rahuldevnath]

I don't know if number of turns are counted either !!! Just a tight winding till the coil fills up is good enough if I am right.!! No need to rewind all coils, only the lighting coil rewinding should be enough. Am I right Sajan/Abhi ?

Lightning coil or the charging coil?

plZ TELL ME THE NUMBER OF TURNS REQUIRED and i have one more idea, suppose i change the connections of existing coil windings, connect the lighting coils and charging coils together and give thier combined output to APE RR. are standard coils also wound in same fashion i.e. clockwise-anticlockwise-clockwise-anticlockwise and so on.

@ shreeni: in the first post of this thread....u said disconnect green wire of pulse generator and ground it. why was that?

No idea of the number of turns. But generally when we wind up the coil for 55W lighting, it's more of a "turn and check" method.

BTW what's the output of APE RR unit after regulation?

[princesirohi]

@ shreeni: in the first post of this thread....u said disconnect green wire of pulse generator and ground it. why was that?

@ sajjt: turn and check method means?

what if i connect the lighting and charging coils in series without rewinding. willit give the desired result.

[sajjt]

@ shreeni: in the first post of this thread....u said disconnect green wire of pulse generator and ground it. why was that?

@ sajjt: turn and check method means?

what if i connect the lighting and charging coils in series without rewinding. willit give the desired result.

Dude, it may work I've'nt tried it, but all that depends on the winding pattern of the both coils start and ending, like end of the lighting pole was CW then start of the charging coil should be in ACW then only u can put it in series and get the max out of the coils.

For rewinding u dont've to worry about the turns as its very clear for the electrician who does the job, what they will do is, just cut one of the poles winding to get a cross section and count it, and then complete the job with a higher guage wire done

Uni's lighting coil and the pulse coil's earth is common through the green wire. To isolate the grounding from the light coil, at the same time PC needs to be grounded, so PC earth to be gnded to the body. Am I right Shree? Thats nothing to do with a Pulsar, u only need to pull out the black wire grounded together with ign coil, and gnd the ign coil to the body of the core. Cut the black and Yellow wire just before the first socket connecting it to the wiring harness and feed the new RR.

Here's the Pulsar coil and identify the wires

[Shreeni0403]

Uni's lighting coil and the pulse coil's earth is common through the green wire. To isolate the grounding from the light coil, at the same time PC needs to be grounded, so PC earth to be gnded to the body. Am I right Shree?

Yup, Exactly !!

[princesirohi]

ok wish me luck ...i will try coil rewinding on saturday.

some pics...

[gajah_gendut]

Hello. I'm new member here from Indonesia. I apologize before, because I have bad English. So,

I want to share my exeperience converting motorcycle light from AC to DC.

I have converted several bikes here. Bajaj Pulsar 180/200, Honda Supra /Wave (all version), Yamaha Jupiter (Spark), Honda GL Pro/Max, Yamaha Scorpio etc.

Basically, all I've done just "floating" stator ground. Soldering out from stator plate ground, extend with wire, then connect to a full wave RR.

Then I connect stock headlight wire to 12V (+) ignition key. Simple work, but need little time to do with patience

This is basic motorcycle AC lighting.

Orange wire is AC supply for lighting. White for charging battery. Red to battery 12V (+). And black connected to ground/frame/battery (-).

If you want to convert lighting to DC, this what you can do.



You must unsolder stator ground and lighting wire (orange) from stator solder tab. Then orange wire connected to ground wire. solder them together and add heatshrink tube cover exposed solder joint.
Now, white and orange wires become input your new full wave RR.
If you've done. Congratulation. You had all of power from your motorcycle.
Because half wave stock charging (AC lighting) just give you about 60% of power from your stator. Rest of power just shorted to ground.

Now you can have DC lighting by connecting light supply wire to 12V ignition key.

Usually I use Honda Tiger (GL200) RR. Because it is a full wave RR. But sometimes I use my home made RR for better charging (14V++). Stock RR of Honda tiger only give 13.8V max.

May be anyone wants Full wave RR circuit for do DIY, I'll post soon. this RR can be use for both single phase or 3 phase stator.

Or next time I'll post some pictures of some motorcycle stator before and after mods to full wave generator.

Once more, I'm sorry for my terrible English. I hope you all understand what i wrote.

Thank you.

[gajah_gendut]

ok wish me luck ...i will try coil rewinding on saturday.

some pics...

sorry. i dont think you need to re-wind your bajaj stator. you can float your stator lighting ground coil, extend with wire, and use both wires from your stator lighting as input of your 2nd full wave RR.

I did in some Bajaj P180/200 of my friends'. I have convert those bike to DC lighting without problem. even some using hid light. never problem to their battery at all.

I have an idea to make a seri or parallel charging and lighting stator coils , but no chance to do. I have no pulsar here...

maybe that's good idea to do. You can compare the results, which better using seri/parallel both coils as input for full wave RR.

[princesirohi]

@gajah_gendut: even i had this idea, but was not so sure. so now we have two options...

1) charging coil of stator has two wires coming out in stock condition. connect it to an RR (may be stock one) and remove the ground from lighting coil and take the connection out of stator using a wire. now connect one more RR to these two wires. now combine in parallel the output of these two RR's.

2) remove the ground of lighting coil and connect it to one end of charging coil internally in stator. take connections from other end of lighting coil and remaining end of charging coil. connect an RR and check the output.

which one u prefer? and why....remember i need atleast 5 Amps at 4000 RPM.

[sajjt]

Hello. I'm new member here from Indonesia. I apologize before, because I have bad English. So,

I want to share my exeperience converting motorcycle light from AC to DC.

I have converted several bikes here. Bajaj Pulsar 180/200, Honda Supra /Wave (all version), Yamaha Jupiter (Spark), Honda GL Pro/Max, Yamaha Scorpio etc.

Basically, all I've done just "floating" stator ground. Soldering out from stator plate ground, extend with wire, then connect to a full wave RR.

Then I connect stock headlight wire to 12V (+) ignition key. Simple work, but need little time to do with patience

This is basic motorcycle AC lighting.

Orange wire is AC supply for lighting. White for charging battery. Red to battery 12V (+). And black connected to ground/frame/battery (-).

If you want to convert lighting to DC, this what you can do.



You must unsolder stator ground and lighting wire (orange) from stator solder tab. Then orange wire connected to ground wire. solder them together and add heatshrink tube cover exposed solder joint.
Now, white and orange wires become input your new full wave RR.
If you've done. Congratulation. You had all of power from your motorcycle.
Because half wave stock charging (AC lighting) just give you about 60% of power from your stator. Rest of power just shorted to ground.

Now you can have DC lighting by connecting light supply wire to 12V ignition key.

Usually I use Honda Tiger (GL200) RR. Because it is a full wave RR. But sometimes I use my home made RR for better charging (14V++). Stock RR of Honda tiger only give 13.8V max.

May be anyone wants Full wave RR circuit for do DIY, I'll post soon. this RR can be use for both single phase or 3 phase stator.

Or next time I'll post some pictures of some motorcycle stator before and after mods to full wave generator.

Once more, I'm sorry for my terrible English. I hope you all understand what i wrote.

Thank you.

Wow, thats very well explained. Pls do posting the diagram as well as pics u were refering.

[lakhanironak]

I did some research on the bike's battery today. I always thought I had a 9ah battery. But I checked the battery today and it turned out to be a 7ah. Hence I removed a friends P150's 9ah battery and fitted it onto my bike. The battery fits in ... but the terminals are wrongly placed as the pulsar has its battery on the right side and my bike has it on the left. So I somehow adjusted the battery and connected the terminals.

After connecting the 9ah battery, these are the differences i observed. The HID started without much effort. After Stablizing, I could operate the rest of the DC electricals i.e, horn, indicators without any problem, No fluctuation in HID nor there was a problem with sound of the horn or dimming of indicators.

So I conclude from this that ill have to change to a new battery. Ill go in for the AMARON ProBikeRider Battery which has a 60 month warranty.

Also I was trying to look around for the RR unit and couldnt find one. AFAIK the RR unit is supposed to be placed before the charger and found the device below :



Is this the RR Unit, coz it doesnt look like one ?

So ill be going to a autoelectrician this Weekend. Do I need to buy the APE RR unit before get the coil winding and rest of the procedure done ? or can I ride for a while even after coil winding ?

Ill be waiting for princesirohi to see how he proceeds.

Ill be going in for the change in battery ASAP. Also will be buying a Charging Kit for charging the battery from the wall point.

I also found a really good document regarding DC conversion from www.trailtech.net
Its about conversion from AC to DC on a KTM street bike by using the TrailTech RR Unit.
Here is the link :

TrailTech.net : KTM AC/DC Conversion

[gajah_gendut]

Wow, thats very well explained. Pls do posting the diagram as well as pics u were refering.

i will do it tommorow. i'm posting from my cellphone. very limitted connection. sorry.

[gajah_gendut]

@princesirohi
this pic is stock wiring of pulsar.


i think we have 3 options to mods pulsar charging.

1. unground lighting coil, exted it with wire, and make connect to 2nd RR.



2. joint both charging and lighting coil in paralel, then use more powerfull RR (i think they will be higher amperage, but still have same voltage)



3. joint both coil in serial connection and using more powerfull RR. (i think they will have high voltage but sama amperage).





usually i used 1st choice, because have no chance to try thoose last options.
thoose last worth to try, i'll find out soon. good news, a friend of mine will send his p180 to me this weekend. he wanted me to make some experiment with his bike.

i have modded his bike to DC two weeks ago, working very nice, but he want to have some accesories in his bike, like additional spot light, some communication radio, phone charger, etc.

i'll report the result ASAP. thanks.