Convert AC/DC bike to ALL DC.

[sandeepcf]

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??????????

Original stator of CBZ Xtreme has nearly 60~66 turns per pole.
I used 18.5g wire and managed 48 turns per pole with my friends Xtreme and still got required voltage at 1300RPM. Same is the case with my Unicorn (18g and 44 turns).
Please check your winding method.


1. How did you check the ground was floated?


2. What wires did you use to connect the coil to the new RR?


3. What were the AC voltages from the Coil (should range from 8V(Idle) to 80+V(max RPM)?


Most problems with the rewinding process can be diagnozed from the above answers.


what is your 130 watt load??

[vineeshvv]

finally i have converted my electricals to full dc set up and now using osram night breaker plus , will change to philips diamond vision very soon

[on2wheels]

am so lucky i got right thread at right time. thanks guys.

i want to improve headlight of HH Hunk, with 35/35 bulb.
i have following queries.


1. if system kept as it is, ie, AC, will 55/60 bulb with rewinding coil + Custom RR help?
2. if yes, which wire(thickness) and how many turns on coils are needed to support above setup?

3. if complete DC is the only solution, which wire(thickness) and how many turns on coils are needed? so as to follow the procedure mentioned in begining of this thread.


The only reason i am keeping DC as second option is, if battery got completely discharged or any issue with battery occurs in night, headlight wont be working, right?

[rprathin]

am so lucky i got right thread at right time. thanks guys.

i want to improve headlight of HH Hunk, with 35/35 bulb.
i have following queries.


1. if system kept as it is, ie, AC, will 55/60 bulb with rewinding coil + Custom RR help?
2. if yes, which wire(thickness) and how many turns on coils are needed to support above setup?

3. if complete DC is the only solution, which wire(thickness) and how many turns on coils are needed? so as to follow the procedure mentioned in begining of this thread.


The only reason i am keeping DC as second option is, if battery got completely discharged or any issue with battery occurs in night, headlight wont be working, right?

if want dc then 18 gauge wire as many turns possible with ape rr check this thread you will find enough information for converting to dc

[on2wheels]

if want dc then 18 gauge wire as many turns possible with ape rr check this thread you will find enough information for converting to dc

I am keeping DC as last option, now i am trying for 55/60 bulb on stock AC setup with 9 ah battery. i guess charging rate should be increased. please find below attached image of Hunk coil i got from this thread only. which all poles should be rewinded with which wire(thickness) to provide more current to hedlight and battery. please note, i am not going for DC as of now.

[rprathin]

I am keeping DC as last option, now i am trying for 55/60 bulb on stock AC setup with 9 ah battery. i guess charging rate should be increased. please find below attached image of Hunk coil i got from this thread only. which all poles should be rewinded with which wire(thickness) to provide more current to hedlight and battery. please note, i am not going for DC as of now.

the poles that would need winding are only lighting poles you need to check yourself which are those poles as i don't see the difference in the poles wire gauge and i also don't know the wire color for your ride generally the lighting poles are winded with thicker gauge wire but here all poles looks similar (like already dc) so you need to check which poles are for lighting you can check the same by following the wire from stator coil to rr then check which wire is for lighting and battery charging.

[rajaselvam_1987]

I am keeping DC as last option, now i am trying for 55/60 bulb on stock AC setup with 9 ah battery. i guess charging rate should be increased. please find below attached image of Hunk coil i got from this thread only. which all poles should be rewinded with which wire(thickness) to provide more current to hedlight and battery. please note, i am not going for DC as of now.

the poles that would need winding are only lighting poles you need to check yourself which are those poles as i don't see the difference in the poles wire gauge and i also don't know the wire color for your ride generally the lighting poles are winded with thicker gauge wire but here all poles looks similar (like already dc) so you need to check which poles are for lighting you can check the same by following the wire from stator coil to rr then check which wire is for lighting and battery charging.

Bro this is the same coil which is present in my twister, So i hope same type of RR used in both the bikes. So simply rewind the coil will not help here and also there is no separate pole for the lighting. It's a single wire which is wounded to all the 12poles. The RR only change the output of the coil to AC & DC that too up-to certain limits. So even if you wind a coil with thick wire the RR is not capable to produce more output.
So best option is, make it full DC with coil winding & RR swap.

[rprathin]

Bro this is the same coil which is present in my twister, So i hope same type of RR used in both the bikes. So simply rewind the coil will not help here and also there is no separate pole for the lighting. It's a single wire which is wounded to all the 12poles. The RR only change the output of the coil to AC & DC that too up-to certain limits. So even if you wind a coil with thick wire the RR is not capable to produce more output.
So best option is, make it full DC with coil winding & RR swap.

to me before it also looked like that single wire is used to wind all 12 poles now you cleared it.

[jimmy79]

Greetings,

Bumping this thread but i need help

My name is Ozgur and i'm sending you this message from Turkey. I'm going to convert my Kymco Agility 125 scooter to full DC setup but i have one problem: i do NOT have the 'very praised' OEM Piaggio Ape rectifier unit. Could someone please give me a link where i can buy the said piece? I'm going to pay via Paypal. I REALLY need help with this.

A little bit of background to what i'm trying to achieve: I've installed a 35 watt bi-xenon kit to my scooter and upgraded the scooter's 12V 7A battery to 12V 10A to give better buffer. I use the HID only during night time. With this setup, HID seems to hold just fine for 2 hours under heavy city traffic but then i begin to have battery issues as you all know. I was looking into 3 phase 11 pole stator with 7 cables rectifier combo but unfortunately that kind of a stator doesn't fit into my scooter. So converting to DC seems to be my only solution.
My scooter with Bi-xenon:


Again; i need to buy 1 OEM Piaggio Ape rectifier, but i don't know from where. Your help is much appreciated

Regards.

P.S: I'll post the results once(and IF) i can finish with this project. I'll do everything myself, even wiring (if it's required). By the looks of it, the conversion seems pretty easy tho'.

I hope i don't disturb anyone with this 'first' message of mine. I really need to solve this issue in 2-3 weeks time so i'm kinda in a hurry :/

[lakhanironak]

Re: Convert AC/DC bike to ALL DC.

@jimmy79 : Here you go, this is a UK site, you can inquire with them.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

Hi All..

I have decided to make my Pulsar 2005 Alloywheel to make to full DC using Ape RR.

I have a AVY stator and using it for rewinding. I removed old copper wiring, purchased 19swg 400gms.


The follwing is pic from page 98 posted by crownpiyush




in above pic leftside of ignition coil (Yellow coil), only one wire (Black) is soldered. Another wire is desoldered.

My AVY stator coil pic



The highlighted (Red ) one has a wire soldered. What is it..??? Should i desolder it and remove it...??? (As above Piyush picture is showing to remove that wire).

As per piyush pics from 98, 99 pages, there are 3 wires coming out from the coil total winding. One from ignition coil and two from winded copper. Is it correct..??

Please help me in this regard.

Thanks in Advance

Srinivas

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Hi All..

I have decided to make my Pulsar 2005 Alloywheel to make to full DC using Ape RR.

I have a AVY stator and using it for rewinding. I removed old copper wiring, purchased 19swg 400gms.


The follwing is pic from page 98 posted by crownpiyush




in above pic leftside of ignition coil (Yellow coil), only one wire (Black) is soldered. Another wire is desoldered.

My AVY stator coil pic



The highlighted (Red ) one has a wire soldered. What is it..??? Should i desolder it and remove it...??? (As above Piyush picture is showing to remove that wire).

As per piyush pics from 98, 99 pages, there are 3 wires coming out from the coil total winding. One from ignition coil and two from winded copper. Is it correct..??

Please help me in this regard.

Thanks in Advance

Srinivas

yes you should desolder that wire.
don't worry about how many wire are coming just unwind the whole coil without touching the ignition coil and its wires. then rewind it after that you know what to do.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

yes you should desolder that wire.don't worry about how many wire are coming just unwind the whole coil without touching the ignition coil and its wires. then rewind it after that you know what to do.

thanks for the information bro... Ive unwounded the coil and was stuck at that point whether to keep that wire or not because that wire is adjacent to ignition coil wire...One finding is lighting coils wire gauge of Avy is same as that of 19swg..!!The company winding is so compact and good that it take more than a hour to remove whole winding (varnish used made the winding to stick very much)Now i will continue winding with 19swg tightly and will post the pics... one more thing...Recently our xbhp member "discovervinu" in a thread said that the field strength of Ape RR has increased to 27A. Should i specificly ask for that piece in showroom..?

[rprathin]

Re: Convert AC/DC bike to ALL DC.

thanks for the information bro... Ive unwounded the coil and was stuck at that point whether to keep that wire or not because that wire is adjacent to ignition coil wire...One finding is lighting coils wire gauge of Avy is same as that of 19swg..!!The company winding is so compact and good that it take more than a hour to remove whole winding (varnish used made the winding to stick very much)Now i will continue winding with 19swg tightly and will post the pics... one more thing...Recently our xbhp member "discovervinu" in a thread said that the field strength of Ape RR has increased to 27A. Should i specificly ask for that piece in showroom..?

yes you should ask him about the the new ape rr but i think may be you won't get that now. As the stocks would be of old ape rr.
better ask the guy he would tell you better on this.

[DeVille]

Re: Convert AC/DC bike to ALL DC.

Does anyone here know a good mechanic in Mumbai who can help me complete the conversion on my P200dtsi?
Im stuck as the connections of the BCU cant be done to the new rewound coil as the AC output has been removed.


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