Convert AC/DC bike to ALL DC.

[ramki067]

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

Hi Sajan,

Thanks. I found time today to go to Ruby electricals. Its the same address that i mentioned. Nowadays, they are just doing coil rewinding and magnet recharging. They said they cannot upgrade/increase the guage of the coil, so they do just rewinding with a new guage wire of stock size!!! They charge Rs.450/- for rewinding and magnet charging.
Ruby on Google Map :

https://plus.google.com/103417086909460460113/about?hl=en

So, now what do i do? Please help.

Thanks,
Ramki

[MG13]

Hello xbhpians!
This is my first post. So if any mistakes happen from my end please correct me.

I own Hero Honda Glamour 2012, self start but without disc brake.
I am very much interested in Converting my bike to full DC. I have read most of the technical discussions related to it. Even I have found a discussion related to Glamour modding to full DC, but unfortunately I think it is not complete so I was not able to gain full confidence reading it. So, I am again putting up my queries here. I am sorry if any repetitions occur.

Anyone please guide me for step-wise DC conversion for this particular bike model (would be very helpful if it is along with pictures).

Thanks & Regards.

[MG13]

HH Glamour (Self) 2012 DC Conversion

Hello xbhpians!
This is my first post. So if any mistakes happen from my end please correct me.

I own Hero Honda Glamour 2012, self start but without disc brake.
I am very much interested in Converting my bike to full DC. I have read most of the technical discussions related to it. Even I have found a discussion related to Glamour modding to full DC, but unfortunately I think it is not complete so I was not able to gain full confidence reading it. So, I am again putting up my queries here. I am sorry if any repetitions occur.

Anyone please guide me for step-wise DC conversion for this particular bike model (would be very helpful if it is along with pictures).

Thanks & Regards.

No Replies......!!

Can anyone please post pics of HH Glamour 2012 model (with self start) stator coil along with markings for ungrounding????? Please!!!!!!!
I will be rewinding it too.
19swg or even lower diameter of wire?????? which one should I prefer??????
I have already collected RR unit.

Waiting for your replies!!!!!!!!!!!!!!!!!!!

[sandeepcf]

No Replies......!!

Can anyone please post pics of HH Glamour 2012 model (with self start) stator coil along with markings for ungrounding????? Please!!!!!!!
I will be rewinding it too.
19swg or even lower diameter of wire?????? which one should I prefer??????
I have already collected RR unit.

Waiting for your replies!!!!!!!!!!!!!!!!!!!

Do post your stator coil's pictures so that members here can assist you.

[joshdsy]

Re: Convert AC/DC bike to ALL DC.

So I had this little mishap ... my cable came lose from my rr and my 55/60 watt was glowing like awasome till it fused out along with half the bulbs in my bike... my bike is a 2001 cbz with AC DC setup.. as in stock.. I'm just curious that the stock coil is actually capable of buring a 55watt bulb. Is there anyway to tap into that? I mean without converting to DC.

Sent from my GT-I9003 using Tapatalk 2

[MG13]

Full DC Conversion for HH Glamour Self 2012 model.

Do post your stator coil's pictures so that members here can assist you.

Taken from mobile....so quality is poor...please help regarding my queries.......

Since I am a Newbie.... I am requesting little detailed instructions for this Hero Honda Glamour (with Self only) 2012 model stator coil assembly.

1. Which connections need to be ungrounded?
2. Which pole should not be touched (i.e. Ignition) ?
3. Does it require Rewinding for more than 150-200W load??? [N.B. - Battery is 12V 4Ah]
4. If it requires rewinding, which wire should I select - 19swg or even lower wire diameter or higher one??????
5. RR has 4 wires. - 2 grey, 1 black, 1 yellow. How should the connections be made finally?????
6. Should the other electrical wires be changed? If yes, which ones???
7. If any other instructions are necessary...please remind me.

Thanks & Regards.

[sandeepcf]

Taken from mobile....so quality is poor...please help regarding my queries.......

Since I am a Newbie.... I am requesting little detailed instructions for this Hero Honda Glamour (with Self only) 2012 model stator coil assembly.

1. Which connections need to be ungrounded?
Green wire on the stator.
2. Which pole should not be touched (i.e. Ignition) ?
No ignition coil is present.
3. Does it require Rewinding for more than 150-200W load??? [N.B. - Battery is 12V 4Ah]

4. If it requires rewinding, which wire should I select - 19swg or even lower wire diameter or higher one??????
19 would suffice.
5. RR has 4 wires. - 2 grey, 1 black, 1 yellow. How should the connections be made finally?????
if you are refering to Ape RR 2 grey wires to 2 ends of newly wounded coil; black always goes to ground; yellow goes to battery(red on your current RR)
6. Should the other electrical wires be changed? If yes, which ones???
Please refer to the wiring diagram of you bike; Mostly you need to change the wires(not exactly change but tweak) your headlight wires.
7. If any other instructions are necessary...please remind me.

Thanks & Regards.

Image 1:
Blue - pulse generator
white - coil
greens - grounding for both pulse generator and coil respectively.


Forget about the connector for now. after rewinding we wont be needing the white wire and definitely not the green wire from the coil. Though white wire can be used it will lack uniformity.


Process:


The process is exactly the same as with the Unicorn: please refer to it.


As you have already removed the stator coil, next thing to do is unwind the present wire as fast as you can. Be careful because the varnish may cut you skin in the process.


Get 350gms(safeside) of 19G wire and wind in clock wise & anti-clockwise...donot solder anything until the winding is complete.
(OR)
why don't you leave the current wire untouched and complete the rest of the process using new RR? If you still need more current then you can always rewind later


The rest of the process I believe you have done your homework.

[MG13]

Image 1:
Blue - pulse generator
white - coil
greens - grounding for both pulse generator and coil respectively.


Forget about the connector for now. after rewinding we wont be needing the white wire and definitely not the green wire from the coil. Though white wire can be used it will lack uniformity.


Process:


The process is exactly the same as with the Unicorn: please refer to it.


As you have already removed the stator coil, next thing to do is unwind the present wire as fast as you can. Be careful because the varnish may cut you skin in the process.


Get 350gms(safeside) of 19G wire and wind in clock wise & anti-clockwise...donot solder anything until the winding is complete.
(OR)
why don't you leave the current wire untouched and complete the rest of the process using new RR? If you still need more current then you can always rewind later


The rest of the process I believe you have done your homework.

Thanks a lot. I'll be posting after getting the job done.
Thanks again.

[MG13]

I have started the DC conversion process on my HH Glamour bike but after completion now I am facing few big issues.......

The biggest one is battery charging issue......

I have not rewinded the stator coil.....but now it seems to me that the RR is not being able to charge my bike's 12V 4Ah battery at all.....

If anyone has anything better justification please be kind to post it for my help............

Things performed:
1. Disconnected Original RR and attached new RR.
2. Connected the output wires from coil to the Grey wires of new RR, yellow to Red(i.e. to battery) and black to ground. [N.B.: the connections coming to the earlier RR had 4 wires...yellow for light, red to battery, 2 more wires to ground.]
3. Opened the headlight visor, and disconnected the yellow wires for light and connected the yellow wire coming from light switch to off wire coming from key.
4. Everything is working fine....except speed dial light(not glowing, might be different case)

Are there any mistakes??????

Help required!!!!!!!!!!!

Thanks & Regards.

[sandeepcf]

I have started the DC conversion process on my HH Glamour bike but after completion now I am facing few big issues.......

The biggest one is battery charging issue......

I have not rewinded the stator coil.....but now it seems to me that the RR is not being able to charge my bike's 12V 4Ah battery at all.....

If anyone has anything better justification please be kind to post it for my help............

Things performed:
1. Disconnected Original RR and attached new RR.
2. Connected the output wires from coil to the Grey wires of new RR, yellow to Red(i.e. to battery) and black to ground. [N.B.: the connections coming to the earlier RR had 4 wires...yellow for light, red to battery, 2 more wires to ground.]
3. Opened the headlight visor, and disconnected the yellow wires for light and connected the yellow wire coming from light switch to off wire coming from key.
4. Everything is working fine....except speed dial light(not glowing, might be different case)

Are there any mistakes??????

Help required!!!!!!!!!!!


Thanks & Regards.

1. First get a Multimeter.
2. Describe your output wires from the coil. What wires did you use as "output wires"? New wires or existing ones? Did you properly un-ground the coil? A multimeter short circuit test can determine this.
3. Check the AC voltage from the coil.
4. Check the DC voltage from the RR Out.
5. You should connect the wire from ignition key to the source wire for all lighting(Old RR yellow wire--not sure of the color).

[discoverVinu]

Good News APE RR capacity increased...

Guys guess what,due to increased demand for APE RR from XBHP users, the RR making company has increased the capacity of the RR from 20A to 27A ( you can see the capacity which is punched by the company on RR)( lately I had to buy new APE RR from showroom near lalbagh road Bengaluru).may be they thought increasing the capacity would reduce field failure, but in practical it is Us the xbhp users who have created the scarcity.and the RR company have been thinking many of the RR are failing in field( Just my wild Guess).

[vineeshvv]

Guys I am using CBZ Xtreme 2007 Model i want to plug z OSRAM NIGHT BREAKER PLUS 60/55w in my CBZ so what are the setup i should be followed

is it important to convert my bike electricals to FULL DC SETUP

or other any options i just want plug OSRAM NIGHT BREAKER PLUS 60/55w nothing more

[raghav.glass]

Guys I am using CBZ Xtreme 2007 Model i want to plug z OSRAM NIGHT BREAKER PLUS 60/55w in my CBZ so what are the setup i should be followed

is it important to convert my bike electricals to FULL DC SETUP

or other any options i just want plug OSRAM NIGHT BREAKER PLUS 60/55w nothing more

If you want to just change the bulb to 60/55, just go for coil rewinding. Full dc might be necessary only if you require nill flickering.
even if you convert to full dc, coil winding is the first task. im not sure how much your rr can handle. but rewind and try.

[sandeepcf]

If you want to just change the bulb to 60/55, just go for coil rewinding. Full dc might be necessary only if you require nill flickering.
even if you convert to full dc, coil winding is the first task. im not sure how much your rr can handle. but rewind and try.

RR is the problem here, not coil winding. Converting to Full DC doesnot necessarily requires coil winding. His RR outputs only 40watts to the lights.

[MG13]

1. First get a Multimeter.
2. Describe your output wires from the coil. What wires did you use as "output wires"? New wires or existing ones? Did you properly un-ground the coil? A multimeter short circuit test can determine this.
3. Check the AC voltage from the coil.
4. Check the DC voltage from the RR Out.
5. You should connect the wire from ignition key to the source wire for all lighting(Old RR yellow wire--not sure of the color).

Here's the full report:
1. Ungrounded as required.
2. Made connections as required.
3. Stock winding(21g) giving 9.5 to 10 V only.
4. Rewinded (19g) gave 6.5 to 7 V only.
5. Again rewinded with 21g giving more turns.......now giving 13.5V
6. Everything else was performed as required.

Now issues are:
Discharge rate is faster than charging rate.
How to rectify it?????????????????

The CDI is running from battery(12V 4Ah). therefore, whenever the battery is near to getting empty, the bike does not run as it normally does.....it kind of runs when fuel is empty.....stops ..goes...stops...goes....!!!!!

Now I having to recharge the battery at a garage.....after little long trips.....load is somewhat 120-130W.....

Please help.....how to increase charging rate??????????