Convert AC/DC bike to ALL DC.

[jammbuster]

Re: Convert AC/DC bike to ALL DC.

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.

Thanks for the reply bro.. will visit to mechanic for the same.... let me know how much cost u paid for all this... also my bike is almost two year old so Warranty is not an issue

Its better for my knowledge if u placed pics of the parts tht u used

[Sashi Kant]

Re: Convert AC/DC bike to ALL DC.

Thanks for the reply bro.. will visit to mechanic for the same.... let me know how much cost u paid for all this... also my bike is almost two year old so Warranty is not an issue

Its better for my knowledge if u placed pics of the parts tht u used

400 gm cooper 18 awg costed i think it was about rs. 273, be sure to get stator cover gasket may below rs. 100, warranty not an issue then don\'t buy extra coil assembly.
ok by today 10 am i will post pics how to re-wire and and use yamaha szr\'s RR unit its will cost rs. 375 original from yamaha showroom

[shbz]

Re: Convert AC/DC bike to ALL DC.

Hello everyone.. i m new here.. i just wanted to know 1 thing that i m facing with my Cbz Xtreme(2010).. i replaced parking stock bulbs with 5smd led bulbs 2 3 times but they get blown off..
please can any1 help me with this?
please please..

[powerShift]

Re: Convert AC/DC bike to ALL DC.

hi guys,
i am really very bad in terms of auto electricals. i want the same setup for my Hunk.
which gauge copper wire is to select for rewinding? how much turns on each coil.?
any one from Mumbai or around has done it in their hunk?
i want to do everything on my own but under supervision of experienced person.

[New guy]

Re: Convert AC/DC bike to ALL DC.

hi guys,
i am really very bad in terms of auto electricals. i want the same setup for my Hunk.
which gauge copper wire is to select for rewinding? how much turns on each coil.?
any one from Mumbai or around has done it in their hunk?
i want to do everything on my own but under supervision of experienced person.

I got coil rewinding for my RTR from a mech in andheri east.
His name is Prashant - 08828338338, 9004203167

[powerShift]

Re: Convert AC/DC bike to ALL DC.

thanks New guy for the pointer. just now i got an auto electrician in my neighborhood. can you please help me with wire gauge and number of turn if you can get this detail from youe electrician?

[powerShift]

Re: Convert AC/DC bike to ALL DC.

also how much did rewinding job cost you

[New guy]

Re: Convert AC/DC bike to ALL DC.

also how much did rewinding job cost you

Sorry it was long back. I only remember i used ape three wheelers RR. Winding and installation was done by the mech.
Search this thread for xbhp handle nanotechnology.
He should be able to advise you.

Also take a look here : http://www.xbhp.com/talkies/universa...g-hid-etc.html

[usdhindsa]

Re: Convert AC/DC bike to ALL DC.

Hi All!

I am planning to covert my GS150R to full DC using Pulsar UG4 RR. Pulsar UG4 RR is a full DC bike and its RR should do the job as I plan to use 35W headlamp. I am posting a pic of the RR. Could anyone please let me know which two wires go to the +ve and -ve terminal of the batter and which two to the ignition coil. There are four wires: 1. Blue-white 2. Blue-white 3. Black-yellow 4. White.

I will deeply appreciate the help/assistance.

[sandeepcf]

Re: Convert AC/DC bike to ALL DC.

Hi All!

There are four wires: 1. Blue-white 2. Blue-white 3. Black-yellow 4. White.

Blue wires ------------- alternator/stator.
Black ---------------------Ground
White -----------------------Battery

[usdhindsa]

Re: Convert AC/DC bike to ALL DC.

Thank you so much!!!

[art]

Re: Convert AC/DC bike to ALL DC.

Couple of days ago my pulsar's (150ug3) RR went bad...i was left with no lights, speedo, horns etc....RR was shorting the battery current so i diconnected it by unplugging its socket. I am using Exide chloride 7AH UPS battery....I took the battery out and charged it using my 4AMP external charger, meanwhile I was going through these threads carefully and was also analyzing ug3 circuit closely. Finally I convinced myself to experiment DC conversion on my bike. So once again connected the charged battery. As RR was unplugged so i connected a high gauzewire from +ve terminal of the battery to yellow wire of the socket going to headlight. Every thing lit again and my bike was in DC mode but with no charging. The "EUREKA" moment was when i cranked the bike using self, engine came to life in one attempt. NO BCU BYPASS WAS DONE...VOILA....restarted using kick this time again the engine roared...went for 58kms long trip at night without any problem except battery got discharged after running 20-25 mins....the battery is around 3 yrs old so its ok. daily i charge the battery at night using external charger and plug it back in the morning....searching for APE RR in scrap shops..as i love to do JUGGAD

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An idea is oozing out of my mind...How about using both charging and lighting coils to charge the battery but using this circuit? I dont know whether the regulator part of RR will work with DC at its input, as i dont have any proper RR circuit to analyze...if RR supports DC then this circuit can boost charging in stock condition...and can also be converted to full wave after ungrounding the coils in the stator...so electronic gurus kindly throw some light

[art]

Re: Convert AC/DC bike to ALL DC.

found the above circuit had already been suggested by gajah_gendut (http://www.xbhp.com/talkies/universa...-all-dc-5.html.... This circuit will provide additional charging current to the battery in stock stator condition , if the RR supports DC input.

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

found the above circuit had already been suggested by gajah_gendut (http://www.xbhp.com/talkies/universa...-all-dc-5.html.... This circuit will provide additional charging current to the battery in stock stator condition , if the RR supports DC input.

hello Art,

many such methods were tried and many of them failed. please go through all pages. Pavanchirmade's bikes was set on fire due to parallel charging (As far as i remember). I kindly advise you not to attempt such methods and waste your time and money.


i am also not sure how much time will your AC BCU will handle the DC current. BCU is the most prone part for failure in the whole vehicle. Slightest voltage/anything change will leads to fail. Be prepared for surprises...!!!!

There a lot of stories in that thread.. dozens of rr's and BCU failure stories...!! Please go through each and every page before trying anything...!!!!

Never try parallel charging..!!!!!!!!!!!!!! Either you go for complete DC or leave it as it is...!!! Either go for APE RR or UG4 RR if you are going for DC..!!!

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

found the above circuit had already been suggested by gajah_gendut (http://www.xbhp.com/talkies/universa...-all-dc-5.html.... This circuit will provide additional charging current to the battery in stock stator condition , if the RR supports DC input.

hello Art,

many such methods were tried and many of them failed. please go through all pages. Pavanchirmade's bikes was set on fire due to parallel charging (As far as i remember). I kindly advise you not to attempt such methods and waste your time and money.


i am also not sure how much time will your AC BCU will handle the DC current. BCU is the most prone part for failure in the whole vehicle. Slightest voltage/anything change will leads to fail. Be prepared for surprises...!!!!

There a lot of stories in that thread.. dozens of rr's and BCU failure stories...!! Please go through each and every page before trying anything...!!!!

Never try parallel charging..!!!!!!!!!!!!!! Either you go for complete DC or leave it as it is...!!! Either go for APE RR or UG4 RR if you are going for DC..!!!

[art]

Re: Convert AC/DC bike to ALL DC.

[QUOTE=Srinivas sr143sr;1148264]hello Art,

many such methods were tried and many of them failed. please go through all pages. Pavanchirmade's bikes was set on fire due to parallel charging (As far as i remember). I kindly advise you not to attempt such methods and waste your time and money.


i am also not sure how much time will your AC BCU will handle the DC current. BCU is the most prone part for failure in the whole vehicle. Slightest voltage/anything change will leads to fail. Be prepared for surprises...!!!!

There a lot of stories in that thread.. dozens of rr's and BCU failure stories...!! Please go through each and every page before trying anything...!!!!

Never try parallel charging..!!!!!!!!!!!!!! Either you go for complete DC or leave it as it is...!!! Either go for APE RR or UG4 RR if you are going for DC..!!!

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buddy I was just the suggesting the circuit.....my bike's BCU is already in suspect zone....randomly the horns keep honking continuously...nowadays when I turn handle right the digi-console keeps restarting and trips reset to zero. The RR shows no charging current but the head light are lighting...Earlier the headlight was not lighting so i just connected a wire to the yellow wire of RR to start the lights....nothing more than that....electricals awaits checking at SVC....As of now battery is charged externally.