Convert AC/DC bike to ALL DC.

[ashwinprakas]

Re: Convert AC/DC bike to ALL DC.

Hi Guys,

Hoping someone who'd done the mod would be able to confirm/correct my understanding and also answer my queries so that I can go ahead with the modification with full confidence.

My understanding/concerns are;


1. There should be NO continuity between the ground and coils.


2. The two wires that go back to the stator should be connected to either ends of the coil without any possibility of grounding.


3. How is the Pulsar Coil wired, in some instances I see that the Pulsar coil needs to be independently grounded, how do I determine if it needs to be done as such in my motorcycle and if it needs to be done would just grounding it to the case do? Asking because on some bikes I've seen that the Pulsar coil comes with independent wiring in which case I presume that I am supposed to leave it alone.


4. In some specific posts I see that while working with the stator it is advised to not touch the "Ignition Coil", this is something I don't understand, is the reference to the primary ignition coil i.e the one circled in below?





If so, how is the same wired? Is it connected to the coils or does it have independent wiring that leads to the CDI?


As for the RR unit I'm familiar with the wiring(P220) so I'd just get myself a Pulsar's RR unit and rewire the pins.

[Sean Mc'Ken]

Re: Convert AC/DC bike to ALL DC.

Hi guys I need some help... I have found a stock pulsar 180 UG4 CDI... It's DC and I have pulsar 200 dtsi old and it has AC CDI please help me to change my bikes CDI to DC CDI of pulsar 180.... Some wiring help I need

[Soundsgreat]

Re: Convert AC/DC bike to ALL DC.

Hi,

Guys I want to get my Aviator converted to full,have most of the thing here but have a doubt, Unlike others Aviator (2009) has 2 set coils ( 3each) one set of charging (with little thicker gauge) and one set for lighting (thinner Gauge), My question is can I remove the entire winding and start rewinding as one coil using all 6 poles ?? if yes 18 or 19 Gauge wire is recommended ??

I tried to connect the coils in series ( joining 3+3) and was getting 21V output from both and when fed to the APE RR the voltage wouldn't go beyond 12.6-7V and a Max Current of 2.6A on either the Headlight (using a 60/55W Bulb) and same goes for charging. Is this OK shouldn't it be 14.4-8V or so ? With this voltage will battery charging be a problem ??

Please do let me whether Am going wrong somewhere ? Worst case I want to either take a new stator coil from Ruby Electricals or a stock one and see...

Regards.

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

Are you using stock coil or rewounded coil?

Rewounded 19 guage wire on 6 poles

[grv15]

Re: Convert AC/DC bike to ALL DC.

I'm too using 200 NS's rectifier in my setup with 50/60w bulb + 20w*2 led fog lamps+dual horn & other stock indicator bulbs. It's output is adequate for my setup.

Are you using stock coil or rewounded coil?

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

Hello guys,
I'd like to share my experience of converting my 2008 Pulsar 200 dtsi to full dc setup.

I desoldered the ground's end of the lighting coil and bring it out of the stator cover through the black wire which is not grounded to the frame of the bike anywhere.
I followed the instructions given at the start of this thread religiously.

Then, I fed the ac output of the lighting coil through the stock Yellow and Black wires to the newely purchased Pulsar 200ns RR.
I connected yellow & black wires to two blue wires coming out of the P200ns RR.
Red wire coming out of 200ns RR to positive side of battery 🔋.
Black wire from 200ns RR is grounded to the body of the bike.

I already have all the electricals of my bike on dc (🔋) through the key on/off switch.
And I modified the stock self starter switch to contact type with separate wires to the starter relay. I had to do this coz of the BCU. You already know that it doesn't allow to start the bike on dc system.

Now, I am using 55/60W halogen bulb in stock reflector without any problem. However, its still not glowing to its full intensity due to stock wires of higher gauge. I am going to install a relay system with low gauge wires soon.

Now, the voltage its generating is: (when all the lights are off)
Idle: 12.5v to 13v, approx. 1amp.

2k rpm: 13.5 to 13.8v, approx. 2 to 2.8 amp.

Above 2k rpm: stablise at13.8v, approx. 3amp.

These are my observations so far.
With headlight at On position, voltage at battery drops gradually when idling. It stablize around 2k rpm and starts increasing with the throttle above 2k rpm.

So, in my view, output of P200ns RR is sufficient for a 55/60w halogen bulb with the lighting coil only. And with the rewinded coil with 19swg wire, it can supply more amperage to support more current hungry lighting setups.
But keep in mind, its still early days to come to any rock solid conclusion.

I bought Pulsar 200ns RR part no. REGR- PLSR-JL01 from authorised bajaj spare parts shop for Rs.715 only. See attached pics for details.

I'm too using 200 NS's rectifier in my setup with 50/60w bulb + 20w*2 led fog lamps+dual horn & other stock indicator bulbs. It's output is adequate for my setup.

[grv15]

Re: Convert AC/DC bike to ALL DC.

Hello guys,
I'd like to share my experience of converting my 2008 Pulsar 200 dtsi to full dc setup.

I desoldered the ground's end of the lighting coil and bring it out of the stator cover through the black wire which is not grounded to the frame of the bike anywhere.
I followed the instructions given at the start of this thread religiously.

Then, I fed the ac output of the lighting coil through the stock Yellow and Black wires to the newely purchased Pulsar 200ns RR.
I connected yellow & black wires to two blue wires coming out of the P200ns RR.
Red wire coming out of 200ns RR to positive side of battery 🔋.
Black wire from 200ns RR is grounded to the body of the bike.

I already have all the electricals of my bike on dc (🔋) through the key on/off switch.
And I modified the stock self starter switch to contact type with separate wires to the starter relay. I had to do this coz of the BCU. You already know that it doesn't allow to start the bike on dc system.

Now, I am using 55/60W halogen bulb in stock reflector without any problem. However, its still not glowing to its full intensity due to stock wires of higher gauge. I am going to install a relay system with low gauge wires soon.

Now, the voltage its generating is: (when all the lights are off)
Idle: 13v to 13.8v, approx. 1amp.

2k rpm: 13.8 to 14.3v, approx. 2 to 2.8 amp.

Above 2k rpm: stablise at14.5v, approx. 3amp.

These are my observations so far.
With headlight at On position, voltage at battery drops gradually when idling. It stablize around 2k rpm and starts increasing with the throttle above 2k rpm.

So, in my view, output of P200ns RR is sufficient for a 55/60w halogen bulb with the lighting coil only. And with the rewinded coil with 19swg wire, it can supply more amperage to support more current hungry lighting setups.
But keep in mind, its still early days to come to any rock solid conclusion.

I bought Pulsar 200ns RR part no. REGR- PLSR-JL01 from authorised bajaj spare parts shop for Rs.715 only. See attached pics for details.

[ntchrist]

Re: Convert AC/DC bike to ALL DC.

Fz & R15's RR is pin type which directly connects to the wiring harness, unlike the Ape RR which has wires coming out of the RR so it's difficult to know which pin is for what

Yes buddy I am aware of the pin connectors...What I meant was that I have read that people have used it as a replacement of Ape RR. I hope one of the experienced XBHPian will answer your query

[grv15]

Re: Convert AC/DC bike to ALL DC.

My above post got deleted, I don't know how?

I want to confirm whether this Ape RR is original or not. Price quoted by dealer is Rs.1540


Pls share your views also.

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

I am not too good with the electricals though...but FZ and R15 are DC bikes and I am not sure how to connect AC input to these. These are similar to Ape RR where two wires are connected to the coils coming out of the stator and one for positive and one negative terminals of the battery.

Fz & R15's RR is pin type which directly connects to the wiring harness, unlike the Ape RR which has wires coming out of the RR so it's difficult to know which pin is for what

[ntchrist]

Re: Convert AC/DC bike to ALL DC.

Can you guide me on which pin is for AC input & which one is for DC output on Fz RR??

I am not too good with the electricals though...but FZ and R15 are DC bikes and I am not sure how to connect AC input to these. These are similar to Ape RR where two wires are connected to the coils coming out of the stator and one for positive and one negative terminals of the battery.

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

You can try R15 or Yamaha fz RR which is a 4 pin connector.. Will cost you about INR 800, The RR can take about 100 watts easily... Not idea about Pulsar 200 RR

Can you guide me on which pin is for AC input & which one is for DC output on Fz RR??

[ntchrist]

Re: Convert AC/DC bike to ALL DC.

Guys plz suggest me a high output RR other than Ape RR.. I have been using coil rewinding & Ape RR setup since 1.5 years, till now I hadn't faced any issue( Ape RR wasn't OEM, got it for Rs 400 from auto parts store bt looks exactly like OEM Ape RR) recently I have encountered a weird problem, the output from the RR doesn't go beyond 9.5 volts at any RPM.. Also to be noted that all the led lights on the bike(DRL & tail lamp) are flickering as if RR is giving pulses of DC voltage instead of steady flow of current. Checked the output from stator, it's absolutely fine. I cannot get an Ape RR since I'm from Nepal & we don't have Ape 3 wheeler here, thinking of getting Pulsar 200 NS RR bt confused whether it's 4 wires (single phase) RR or not. If anybody can post the image of their 200 NS's RR, it would a great help, also is there any difference between previous 200 NS's RR & current generation BS IV with AHO model??

You can try R15 or Yamaha fz RR which is a 4 pin connector.. Will cost you about INR 800, The RR can take about 100 watts easily... Not idea about Pulsar 200 RR

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

Guys plz suggest me a high output RR other than Ape RR.. I have been using coil rewinding & Ape RR setup since 1.5 years, till now I hadn't faced any issue( Ape RR wasn't OEM, got it for Rs 400 from auto parts store bt looks exactly like OEM Ape RR) recently I have encountered a weird problem, the output from the RR doesn't go beyond 9.5 volts at any RPM.. Also to be noted that all the led lights on the bike(DRL & tail lamp) are flickering as if RR is giving pulses of DC voltage instead of steady flow of current. Checked the output from stator, it's absolutely fine. I cannot get an Ape RR since I'm from Nepal & we don't have Ape 3 wheeler here, thinking of getting Pulsar 200 NS RR bt confused whether it's 4 wires (single phase) RR or not. If anybody can post the image of their 200 NS's RR, it would a great help, also is there any difference between previous 200 NS's RR & current generation BS IV with AHO model??

[rsk11584]

Re: Convert AC/DC bike to ALL DC.

Hi Guys,

I am planning to make the Pilot + Group (Pilot, Speedo, Rear, Number Plate) Lights on battery in my 2016 Model TVS Jupiter. I saw some tutorials on youtube wherein people had modified it to full headlight on battery, but i want to keep headlight on AC current only.
My question is as below:

There are two connectors going to the headlight switch a total of 4 wires, which makes me think the switch connects two inputs to two outputs as below:

When the swithc moved to PIlot lamp mode it connects first AC source to Pilot + Group lights
when the switch is further moved to headlight position, it connects the second AC source to headlight


I want to input battery connection to the first connector as Input and terminate the AC source therein. So will it make my Pilot + Group Lights on Battery and leave the Headlight to AC only?


If the switch doesnt fully seperate the two input and two outputs then shall i use a totally new switch and install it for supplying power from battery to Pilot + Group Lights.


I am attaching photos of two connectors connected to switch and the switch itself. Can anyone clarify please.