Convert AC/DC bike to ALL DC.

[princesirohi]

raghav.glass: parallel charging does not work, it is tried by many and failed.

in the final configuration, you will need only one rr unit and that will be ape rr. so to produce maximum power, you have to rewind the stator with a higher gauge wire (may be 19G) with same number of turns as original. you have to rewind all the poles except ignition coil, you don't have to even touch the ignition coil. rest all poles you have to rewind in CW-ACW-CW-ACW -- fashion. then you have to connect this to ape rr. and the output of ape rr goes to battery.

simple configuration works well.

one more thing, ape rr works properly only when connected to battery, do not try to run it with its output terminals open, do not try to measure its output in open ckt condition. i have blown 7-8 rr units doing this over a period of few years. the ac output of coils will raise with rpm as you said upto 70 volts approx. or even higher, the job of rr unit is to reduce it to 13-15 volts and charge the battery.

[rprathin]

Hi,

Ive modded my pulsar 150 ug3 to have two hella lamps(55w x 2) . total 110w when both are turned on
Ive removed the dome and headlamp.
Ive connected both the hella lamps to the battery with individual relays for each lamp
these relays are actuated by the stock switches i.e., the old headlamp pin.


pic of my bike 534533_490622444295260_1803817759_n | Flickr - Photo Sharing!

ive installed avenger 180 coil and ungrounded the lighting coil end..
but instead of connecting it to the black wire already grounded with it, i put a separate wire and pulled it out of the stator. the other black wire that comes in the harness is still grounded.

Now my problem,

i connected ape rr to the new wire and yellow-with-red-line wire. the output was 11v dc, when i raised the throttle, the voltage dropped, after this, output stopped coming.. i think the rr is gone.

ive removed the stock rr while doing this test.

then i bought a gc1000 rr, now i din raise the throttle much, but the voltage keeps dropping to zero, but when i check the ac voltage output, it increases upto 70v.

i din wanna raise it too much and blow this rr also.

what is happening here?

Pls help

Hey raghav how much would be your total load if it is 110w then you need to do the coil rewinding with 18.5 gauge and keep the bike @3500 rpm or more when using both aux lamp otherwise battery will discharge.

[raghav.glass]

Thanks guys.

I blew one rr by not connecting it to the battery before testing..

Now ive connected the gs1000 rr to the lighting coil and completely removed the stock rr connections.

im getting about 6-7A with avenger coil. il be rewinding like prince said(all poles) and then i suppose il get about 11A.

im also making a circuit with relays for automatic bcu power. right now im using a switch for bcu dc input.

and also, im using 2 separate relays for each lamp. now im trying to make flashing of head lamps for pass! this circuit is here http://www.xbhp.com/talkies/do-yours...st-rs-1-a.html by sajjt.

if anyone has made something for automatic bcu dc input, pls help.

thanks a lot princesirohi and abhijeet

[rajaselvam_1987]

how much the hella lamps costs

[raghav.glass]

The lamps were about 4500. i had to design and make a mount for it.

now to the bcu. i've figured something out.

im using a avenger coil and the charging coil is useless for now. so im gonna connect the stock rr to the the charging coil and get dc output. this dc output im gonna connect to a relay and this relay will close a circuit (battery to bcu yellow wire)
This will automate the bcu switch when i turn on the engine!

[ramki067]

Ruby electricals, Blr will rewind it with a thicker wire and will provide a separate RR for lighting to extract the max from the new coil.
...

Hi Sajjit,
I'm also planning to change my stock Activa headlight bulbs(which are total crap in lighting the road). Is this the ruby auto electricals you are talking about/
ruby auto electricals:#23, Nanje Gowda Street, Krumbigal Road, Lalbagh, Bangalore, Karnataka 560004

Also, will they do the complete job of rewinding the stock coil and replacing the RR unit? what will be the whole cost setup (approximately)?

Thanks,
Ramki

[sajjt]

Hi Ramki,

I don't have Ruby's address or contact no. as I had no chance to deal with them till date, may be our fellow XBHPians can help u for that.

For improving the stock lighting, u can try my method:

I have a 2002 Activa which I use during monsoon seasons and the light output was so pathetic. To rewind the coil or for any tweaks, I need to open the stator cover but its too hard for me to take it out and my mech was TOO busy to take it out the day I asked for. But I need a better lighting output desperately. I closely examined and at last I found a shortcut to make it better or even more.

Without rewinding/RR swap I got a better lighting output with just a simple tweak. Add to some butter, I must say without even spending a penny out of my pocket!!. So this is what I did; from the coil there's two wires (yellow & white) for lighting and battery charging out of that, battery coil is more powerful than the lighting coil. I just swapped the coil out with each other. Bingo!! Now the stock 35W is glowing in its full brightness. Now am happy with the output from the stock coils and my engine is not seemed to be misfiring due to the current dropping and I guess its compensating it from the battery.

One more, I have changed the bulb to P43t which is far better than the stock bulb with less spread. Its possible to install with some simple mods on the reflector bowl.

Hope this helps.

Sajan

[ajcletus500]

can anyone tell me where can i buy the ape rr unit I tried many shops but couldn't find the original one. I live in Mira Road, Mumbai. Any place between Bhyandar and Boriwali is fine for me.

[rprathin]

can anyone tell me where can i buy the ape rr unit I tried many shops but couldn't find the original one. I live in Mira Road, Mumbai. Any place between Bhyandar and Boriwali is fine for me.

got to this url for authorized piaggio service/spare part shop
Piaggio : Our Network

[ajcletus500]

Ok i got the rr but its made by greaves and has 6 wires. Can the extra two wires just be left as it is??

[sajjt]

Guys, my PC's got some serious issue, its acting weird at times, I may have to reinstall the OS. I was not able to see any PMs for the past few weeks. Today I just happened to see a lot of PMs requesting help and most of them are long pending which is useless to reply as they must've pissed off just bcz of non replying. So I hereby apologize to u all for not replying and extending any help for ur issues especially guys like karthik_k, tssyreddy, raghav.glass,ajcletus500,somnath Pal, abhinavsri01, intruderofall etc.

[ajcletus500]

Im sorry for using this pic of someone else, but my phone has stopped working somehow and i need to know asap because I have already started on the work and need my bike ready soon. Im not sure which bikes stator is this but the Hero impulse has a similar stator and a similar coil like that.

[ajcletus500]

also i have re winded the stator with 19 gauge wire. will that b a problem because i had purchased the wire before opening the coil thinking that it would be 8 poles like all other hero bikes but it turned out to be 12 poles to my surprise. I had read that for 12 poles 18 gauge is better, but i doubt that with 18 gauge wire i would manage close to 40 turns per pole which was pretty difficult with 19 gauge wire

[ajcletus500]

i did everything and when i started my bike it was on for a few seconds and then it suddenly became off. The battery was very hot and there was smoke from some of the wires. Aslo the bike does not start at all, even with the kick start. I checked all the fuses, they are all in good condition. Can any one tell me where could i have gone wrong?? Please, its urgent..

[milesh]

Hi Expertz,

i have some query regarding the same, i am having a cbz star, so i am posting some pictures from the same threads in previous pages. I like to achieve all dc without going for ape rr. ( I don't want mess much with electrics also heard somewhere in the thread that for cbz classic/star there is no need to rewind the coil if going for 35watts hid, currently i like to stick with stock 35w bulb)

In the second image two solder points can be seen which are white and yellow (white is charging and yellow is lighting)and green connected to ground. What should i exactly do with these 3 points ?


In first image the pulse generator has green wire , from my reading i believe the green wire should be desolder and solder to the body/ground Corrent me if i am wrong

I am not good at mechanical/electrics ,but started learning