Convert AC/DC bike to ALL DC.

[crownpiyush]

hi guys,

i own a pulsar 150 Dtsi 2005 model alloy wheel one and i want a HID setup and after reading all the posts i understood two things that i have to rewind the coil with 19g wire and i have to use APE RR unit for dc conversion.but the problem is that i got very less knowledge of electricals and now i got confused how to rewind the coil so please help me guys.

i really want to use HID setup without battery drainage problem like you all guys are using.it will be a very great help for me.

waiting for your reply

[rprathin]

hi guys,

i own a pulsar 150 Dtsi 2005 model alloy wheel one and i want a HID setup and after reading all the posts i understood two things that i have to rewind the coil with 19g wire and i have to use APE RR unit for dc conversion.but the problem is that i got very less knowledge of electricals and now i got confused how to rewind the coil so please help me guys.

i really want to use HID setup without battery drainage problem like you all guys are using.it will be a very great help for me.

waiting for your reply

Can someone just post a video or a video link on how to convert to a Full DC setup? As this will be very helpful to many people who have no clue of rewinding and other connections.

these thing will help you in rewinding the stator coil...

(the coil in the pic is of Suzuki gs150RR)


visit his for how to remove old winding

https://picasaweb.google.com/110302058110056835101/RemovingTheWinding?authuser=0&authkey=Gv1sRgCKr7k8HKhb2PRA&feat=directlink#5700376219959914786

visit this url to know about the rewinding

https://picasaweb.google.com/110302058110056835101/WindingTheCoil?authuser=0&authkey=Gv1sRgCOHo6uuQrqbYuAE&feat=directlink#5712048522592072146

after rewinding there will be 2 wire coming out from coil, connect these two to the ape rr grey wire...connect yellow ape rr wire to battery positive and black to battery negative terminal....

[sunilyo]

these thing will help you in rewinding the stator coil...

(the coil in the pic is of Suzuki gs150RR)


visit his for how to remove old winding

https://picasaweb.google.com/110302058110056835101/RemovingTheWinding?authuser=0&authkey=Gv1sRgCKr7k8HKhb2PRA&feat=directlink#5700376219959914786

visit this url to know about the rewinding

https://picasaweb.google.com/110302058110056835101/WindingTheCoil?authuser=0&authkey=Gv1sRgCOHo6uuQrqbYuAE&feat=directlink#5712048522592072146

after rewinding there will be 2 wire coming out from coil, connect these two to the ape rr grey wire...connect yellow ape rr wire to battery positive and black to battery negative terminal....

This is perfect rprathin, now i can do it myself . now i need to learn how to use a multimeter

One more question i do not know how many poles a stock CBZ* stator has. For HID setup is it necessary to have a stator with a higher number of poles or just increasing the wire gauge will do the job.

[crownpiyush]

these thing will help you in rewinding the stator coil...

(the coil in the pic is of Suzuki gs150RR)


visit his for how to remove old winding

https://picasaweb.google.com/110302058110056835101/RemovingTheWinding?authuser=0&authkey=Gv1sRgCKr7k8HKhb2PRA&feat=directlink#5700376219959914786

visit this url to know about the rewinding

https://picasaweb.google.com/110302058110056835101/WindingTheCoil?authuser=0&authkey=Gv1sRgCOHo6uuQrqbYuAE&feat=directlink#5712048522592072146

after rewinding there will be 2 wire coming out from coil, connect these two to the ape rr grey wire...connect yellow ape rr wire to battery positive and black to battery negative terminal....

ok now i m getting something that how to wind the wire but i m still confused about which point to mark as 1 and which point as 2 bcoz pulsar coil looks differ as i have to leave the ignition pole as it is and ya one more thing there are 4 point where wires are soldered in my pulsar coil.

so please me more clear.

thanks alot for such a great help buddy

[rprathin]

ok now i m getting something that how to wind the wire but i m still confused about which point to mark as 1 and which point as 2 bcoz pulsar coil looks differ as i have to leave the ignition pole as it is and ya one more thing there are 4 point where wires are soldered in my pulsar coil.

so please me more clear.

thanks alot for such a great help buddy

see the image
your coil must be like this
forget about point marking just see the image and follow what i had written there. if you had any problem please ask...


after rewinding plz post the images of the coil...

[rprathin]

This is perfect rprathin, now i can do it myself . now i need to learn how to use a multimeter

One more question i do not know how many poles a stock CBZ* stator has. For HID setup is it necessary to have a stator with a higher number of poles or just increasing the wire gauge will do the job.

just increasing the wire to 19gauge it will give the output for 35watt hid and other electrical loads like (meter light, brake light, horns, indicator, etc..)

see the image below to learn how to use multimeter to calculate dc ampere...

[crownpiyush]

Finally i removed the wire from all the poles except ignition coil.


please tell me on which point to solder the wire which i marked as 1 , 2 and 3.

[crownpiyush]

up-down arrows are for winding pattern and than the coil wire is routed through the fibre glass sleeves to the soldering point and one came out from the magneto cover with red wire.

is this the right way of winding ?

[rprathin]

up-down arrows are for winding pattern and than the coil wire is routed through the fibre glass sleeves to the soldering point and one came out from the magneto cover with red wire.

is this the right way of winding ?

.the winding pattern should be like this:
if first pole is winded clockwise then second pole should be winded anti-clockwise... i think the image also represents this only...
after rewinding post the image of the re-winded coil...

try to do the winding as tight as possible leave no gaps...

ok now after rewinding the coil there will be two ends of the copper wire( one from where you had started the winding and one from where you had ended the winding) , you had to solder these two ends to the thicker wire which should be able to carry out 20amps(maximum) solder them perfectly, the point where you r soldering should not be in any contact with the coil body or any thing else..(it should be only connected to the copper ends and to the thick wire) & put fire proof sleeves use varnish also..now take these 2 thick wire out of the magneto assy. and connect to the grey wire of ape rr...

[crownpiyush]

ok buddy i will post the pics after re-winding the coil.

one more thing i would like to ask that the wire which i have to use for rewinding is of pure copper or its copper insulated wire and how much wire is required?

[sunilyo]

^^ for good results and reliability it is always better to for pure copper winding just like we do it for heavy electronics and household wiring especially power points.

regarding length i read somewhere in this forum to use 19 gauge wire with 12 foot per pole.

I have another question. i have been reading about using the bajaj avenger 180 stator coil if someone is not interested to go the rewinding route. My question is can i use this coil on my cbz Star? it is a kick start though. If not then is there any other option other than re-winding? I would be interested in going this route.

[crownpiyush]

ok than i will go for pure copper wire and thanks for d quick reply.

@rprathin - i will post the pics after rewinding but i will not solder anything.

[rprathin]

ok than i will go for pure copper wire and thanks for d quick reply.

@rprathin - i will post the pics after rewinding but i will not solder anything.

you should use this type of wire

[rprathin]

^^ for good results and reliability it is always better to for pure copper winding just like we do it for heavy electronics and household wiring especially power points.

regarding length i read somewhere in this forum to use 19 gauge wire with 12 foot per pole.

I have another question. i have been reading about using the bajaj avenger 180 stator coil if someone is not interested to go the rewinding route. My question is can i use this coil on my cbz Star? it is a kick start though. If not then is there any other option other than re-winding? I would be interested in going this route.

just post the pic of your coil, i will tell what can be done....

[crownpiyush]

you should use this type of wire
[ATTACH]58138[/ATTACH]

ok i will ask for insulated copper wire 19swg. any idea about its cost?