Convert AC/DC bike to ALL DC.

[sandeepcf]

Re: Convert AC/DC bike to ALL DC.

Thanks brother rprathin . but i just worried about the ignition coils , what i will do with them ? Do you have any idea about CBZ Star coils ? where these Ignition coils goes ? in cbz rr unit or directly in cdi or in engine ? what i will have to do with them ? maybe tomorrow i will open my stator coil or maybe after 2 days , first i will have to buy 19swg wire and varnish and and fibre glass sleaves only after that i will proceed ahead for removing old wires from stator and then rewind with new wire . Do you have any idea how much current and voltage i will get with this 19swg wire and ape rr ?

Before rewinding, try DC conversion with original winding only. You can do that by floating the ground and connecting it to the RR.
Check the current with Ammeter and if you are not satisfied then go for rewinding.
If your usage is with in the city with lower RPM's Do not rewind.

Forget about Ignition Coil. Its got nothing to do with DC conversion.

And since you purchased the APE RR I am not giving the details of Pulsar 200NS RR now(I have to open the panels).

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Thanks brother rprathin . but i just worried about the ignition coils , what i will do with them ? Do you have any idea about CBZ Star coils ? where these Ignition coils goes ? in cbz rr unit or directly in cdi or in engine ? what i will have to do with them ? maybe tomorrow i will open my stator coil or maybe after 2 days , first i will have to buy 19swg wire and varnish and and fibre glass sleaves only after that i will proceed ahead for removing old wires from stator and then rewind with new wire . Do you have any idea how much current and voltage i will get with this 19swg wire and ape rr ?

you dont have to touch the ignition coil and its wires only the poles which are for charging and lighting.
Try ungrounding first as sandeepcf said.

[Yogesh__Sj]

Re: Convert AC/DC bike to ALL DC.

Before rewinding, try DC conversion with original winding only. You can do that by floating the ground and connecting it to the RR.
Check the current with Ammeter and if you are not satisfied then go for rewinding.
If your usage is with in the city with lower RPM's Do not rewind.

Forget about Ignition Coil. Its got nothing to do with DC conversion.

And since you purchased the APE RR I am not giving the details of Pulsar 200NS RR now(I have to open the panels).

i have CBZ Star kick start bike with 2.5AH battery , so 2 years ago i had upgrade its battery to 7ah ups battery and at that time a electrician have done something in my stator to increase the output for my HID , and at that time he had installed old Bullet rr in my bike , this rr have 2 units connects to each other , it was working properly till few months back , but now i am feeling that its output again goes low , thats why I was thinking to rewind stator with 19swg wire . i feel this because when my headlights was on my horns blows low noise and my hid blinks and sometimes goes off . and 3-4 years ago a another electrician had done something my bikes headlight , so after that i can switch on my headlight without starting my bikes engine .
brothers can you tell me if i will rewind its stator with 19sgw wire , i will still need to ungrounding it ? i think at this time i will only got 2 wires after rewinding , 1 is starting point and 2nd is Ending point . and what i will have to do with the wires of pulse generator and nutral switch wires ?
sorry for asking soo many questions , but i need to collect all information before opening the stator coil , because i will have to finish it within 1 day after opening it , because i need my bike everyday . so sorry again for all these questions .

[Yogesh__Sj]

Re: Convert AC/DC bike to ALL DC.

Today i bought 400gms good quality 19swg wire for Rs.240 and 250ml Insulation varnish for Rs.50 and 2 fiberglass sleaves for Rs.10 and i already have good quality high capacity 1.5sqmm and 2sqmm wires coper wires , now brothers can you tell me can i apply varnish on stator before rewinding new wire on it and after finishing rewinding also ? or only after finishing rewinding new wire ?
what i will have to do with the both ends of new wire , i should took these ends out of engine or i should sholder other wire with these ends and bring that other wires out of engine cover ?

[sandeepcf]

Re: Convert AC/DC bike to ALL DC.

can you tell me can i apply varnish on stator before rewinding new wire on it and after finishing rewinding also ? or only after finishing rewinding new wire ?what i will have to do with the both ends of new wire , i should took these ends out of engine or i should solder other wire with these ends and bring that other wires out of engine cover----Recommended

Instead of varnish Use Fevitite Instant(Red Color). Works great and sets in less than 10 minutes.

[Yogesh__Sj]

Re: Convert AC/DC bike to ALL DC.

My bike have 12 poles stator , and i have count that it have 40 turns per pole , so i think i can manage to do 45-50 turns with 19swg wire . so will it gives me benefits of doing more turns per pole than oem ? or it will be a wastage of wires ?
i have checked that my bikes battery voltage is 13.04v with engine off
and it drops when i start engine at
1 RPM -- 12.90v
2 RPM -- 14.45v
and with engine start and 35w headlight on it gives
1 RPM -- 12.50v
3 RPM -- 13.85v
5 RPM -- 14.26v
after rewinding i will use 55/60w philips bulb i bought it many years ago near about Rs.1100-1200 for 2 bulbs for my car . and in future i am thinking to use 55w HID kit .
so i am sure with 55/60w bulb these rating will surely goes more down . and in city driving it will goes worst in city traffic . and with 55w HID it will goes more worst ,
so i think my coil rewinding will not goes waste with these 19swg wires and ape rr .
so friends tell me how much current i could got after rewinding with 19swg wire + Ape rr ?

----consecutive posts auto-merged-----

Instead of varnish Use Fevitite Instant(Red Color). Works great and sets in less than 10 minutes.

Thanks for info brother , but i have already bought Insulation varnish , and i have never seen this Fevitite Instant at any hardware stores around my area . so insulation varnish will not work on these coils ?
by the way i had tested this 19swg wire quality its very good , i have tried to burn this on gas burner for 5-6 sec. , but it didn`t burn even a little bit , so i think it will not gonna burn easily in stator coil case also

[hhsplendor]

Re: Convert AC/DC bike to ALL DC.

Is there anybody using yamaha Fazer RR unit for full dc conversion , I know bobisbacktorock is using it with stock coil ungrouding process ..
But after rewinding with thicker gauge with this RR ??
Is there any other cheaper oem RR available (p220 is 3 pole, can't use , so any other bikes) which can take this load except APE RR ?
What about Pulsar 200ns RR , is that also 3pole? it cost 798rs appx (ape rr is too costly around 1400rs) @sandeepcf
As per yamaha fz16 manual it has capacity of 20amps , but have anybody checked it with higher amps ? like 10+ amps ..

I found honda stunner faced power loss (facing load on engine in lower rpm) after rewinding with 18 gague wire, so for rewinding should I use 19gauge or 20 gauge ?..
Appx how much power I can expect for a 7 pole stator with 20 gauge & and 19 gauge wires ?? bike Bajaj platina 125..

[abhishek.1]

Re: Convert AC/DC bike to ALL DC.

FZ rectifier can be used. It's single phase and has a rated capacity of about 20 Amps. Easy on the pocket as well.

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

Help needed...I have installed the HID lamps in my Yamaha Enticer(kick Start) & obiously am facing battery drain problem..I changed the RR unit to APE RR..Before going for coil rewinding I wanted to do try something else so as to retain the stock windings so after consulting with an electrician he said to first try joining both lighting & charging coil & give that as input to RR unit..so he did some sodering work in the stator coil & said to try that first & if it doesnt work then go for coil rewinding..after installing the modified stator coil i did the voltage check using multimeter.

The AC voltage readings ranges from 12VAC to upto 100VAC(full RPM) so then i gave the AC input to the grey wires of APE RR(without connecting the RR to battery) & checked the DC voltage readings..the DC output from APE RR went upto 14.6V..but the problem is that when i connect the APE RR to the battery, the voltage doesnt go beyong 12.6 volts. The battery voltage when engine off is 12.3 volts. Im bit confused. The AC output from stator is fine. The DC output from RR is fine but the voltage is not enough when connected to battery.

I connected the RR, multimeter & battery in series to measure the charging amps but the reading were very low. 0amps at idle & 0.5 amps at max RPM. What might be the problem?? Will the coil rewinding solve the problem??

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Help needed...I have installed the HID lamps in my Yamaha Enticer(kick Start) & obiously am facing battery drain problem..I changed the RR unit to APE RR..Before going for coil rewinding I wanted to do try something else so as to retain the stock windings so after consulting with an electrician he said to first try joining both lighting & charging coil & give that as input to RR unit..so he did some sodering work in the stator coil & said to try that first & if it doesnt work then go for coil rewinding..after installing the modified stator coil i did the voltage check using multimeter.

The AC voltage readings ranges from 12VAC to upto 100VAC(full RPM) so then i gave the AC input to the grey wires of APE RR(without connecting the RR to battery) & checked the DC voltage readings..the DC output from APE RR went upto 14.6V..but the problem is that when i connect the APE RR to the battery, the voltage doesnt go beyong 12.6 volts. The battery voltage when engine off is 12.3 volts. Im bit confused. The AC output from stator is fine. The DC output from RR is fine but the voltage is not enough when connected to battery.

I connected the RR, multimeter & battery in series to measure the charging amps but the reading were very low. 0amps at idle & 0.5 amps at max RPM. What might be the problem?? Will the coil rewinding solve the problem??

How much old is your battery?
Switch on the hid and start the engine then with mm check the voltage if it is going down or is it stable or going up.
You can also check the amps by connecting mm with battery while engine is on and then check if it is taking juice from battery or not. If not then everyrhing is fine.

[sandeepcf]

Re: Convert AC/DC bike to ALL DC.

the DC output from APE RR went upto 14.6V..but the problem is that when i connect the APE RR to the battery, the voltage doesnt go beyong 12.6 volts. The battery voltage when engine off is 12.3 volts. Im bit confused.

That is the property/characteristic of APE RR. The DC output even goes to 19V if not connected to the battery. If your battery is in good condition the voltage goes to a maximum of 13~13.8v max. This is the same situation with my APE RR in Unicorn.

I connected the RR, multimeter & battery in series to measure the charging amps but the reading were very low. 0amps at idle & 0.5 amps at max RPM. What might be the problem?? Will the coil rewinding solve the problem??

How will you get AMP reading if there is no load? In your case the battery is the only load and if the battery is full it can't take any current from RR output. So you are getting such low readings. Also please check the battery health.

[abiral.shrestha]

Re: Convert AC/DC bike to ALL DC.

That is the property/characteristic of APE RR. The DC output even goes to 19V if not connected to the battery. If your battery is in good condition the voltage goes to a maximum of 13~13.8v max. This is the same situation with my APE RR in Unicorn.

Battery seems to be fine..Its 2 years old but not a problem till now..I will upgdare to a high amp battery once this setup is properly working..Currently its a 4ah battery.

How will you get AMP reading if there is no load? In your case the battery is the only load and if the battery is full it can't take any current from RR output. So you are getting such low readings. Also please check the battery health.

Will measure the amp again with HID turned on

----consecutive posts auto-merged-----

The battery is 2yrs 4ah battery..Will upgrade to higher AH battery once this setup starts working properly

[Sashi Kant]

Re: Convert AC/DC bike to ALL DC.

i converted my honda stunner to dc, used 18 awg cooper wire to wind the coil and removed the stock rr replaced it with yahama szr\'s RR unit i can now run 130/100w for hours, i am using it from 1 month went for long night drive of about 2.5 hours 115km one way trip and even in stop and go traffic didn\'t give any problem, about battery i upgraded exide xpack vrla xpt7z.

[jammbuster]

Re: Convert AC/DC bike to ALL DC.

i converted my honda stunner to dc, used 18 awg cooper wire to wind the coil and removed the stock rr replaced it with yahama szr\'s RR unit i can now run 130/100w for hours, i am using it from 1 month went for long night drive of about 2.5 hours 115km one way trip and even in stop and go traffic didn\'t give any problem, about battery i upgraded exide xpack vrla xpt7z.

Bro... i also want to covert my bike honda stunner to dc.. can u pls let me know step by step procedures and accessories that you used... i m staying in delhi.

[Sashi Kant]

Re: Convert AC/DC bike to ALL DC.

Bro... i also want to covert my bike honda stunner to dc.. can u pls let me know step by step procedures and accessories that you used... i m staying in delhi.

Bro... i also want to covert my bike honda stunner to dc.. can u pls let me know step by step procedures and accessories that you used... i m staying in delhi.

hi bro
first of all that discontinuation is not a big deal as we have ignitor in market.

remove the left cover of the engine, i.e. to remove the stator cover get \"8 mm\" and \"10mm\" bolt with a T handle bar.
step 1: purchase a new oem stator(coil assembly) from honda original parts dealer to protect the warranty, and stator cover gasket. don\'t go your self to buy send someone else.
step 2: remove the sprocket cover using \"10mm\" bolt and \"T\" bar then remove all the 8mm nut attached with engine its not a big deal.
step 3: as you can see the coil, unfasten it using allen key i think its \"6mm allen key\" unfasten all the component attached.
step 4: desolder the one end of the coil unwind the existing cooper wire get 400 gm of 18 awg varnished wire from shop wind it on the coil assembly as much turn as possible.
step 5: rewinding should go like 1st pole clockwise 2nd anti-clock 3rd pole clock 4th anti-clock and so on.
after all the above things done don\'t ground one end of the coil rather connect it to existing green wire and make it floating, and the other side with white wire. Other side of green wire must be attached to the white plastic socket cut that and now you will be left with two wire white and green wire that solely connect only to the copper coil inside.
rest of the idea i think you have how to proceed, if you still find problem reply me i will revert back with pictures.