Convert AC/DC bike to ALL DC.

[Toshar Deven]

3 Pole

Thanks
I tried some dmm testing before fit it into bike

Firstly check it's continuity dmm one red wire to first pole wire and black wire to last pole wire .. and found continuity

Secound checked grounding with dmm
Red wire connect to first pole wire and black to Stator no sound
Then red wire connect to last pole wire and black to Stator .. no sound

Its a good news then. :-) Post a high res. pic of the stator so that we can see if the winding is done tightly or not. There should be a very tight winding and high number of turn on all three poles to get maximum output because there are only 3 poles generating ucrrent instead of tested 7 or 12 poles. Are you sure he used a 19g wire to rewind?

Troubleshooting :-
- Fix the rewinded stator back into casing, tighten the nuts back, connect ignition coil wire only. Check the 'Unregulated AC' output directly from the coil two extended wires using DMM on AC 200/750v mode. Raw output should be more then 9v at idle to 90v at 70% engine rpm. Move to next step if get these desired units.

- Connect both AC wires to RR unit, RR white (DC out?) wire to DMM red wire (attach red wire to Amp socket on DMM), comm. black wire from DMM to positive of battery terminal and RR black wire to negative terminal of battery (not on body frame for now). set the dmm dial to 10amp mode. Dmm should be in series between RR white and battery +ve.

- Turn on your phone camera video mode and make a video of DMM readings. Slowly increase the engine RPM to see the current drawn by the battrey from RR unit. It should be well above minimum 3 amps at 40% engine rpm.

- Post results. (Note- Coil grounding with the stator core is not acceptable at any point. You can even check continuity between coil ends and ends with ground when the stator is fixed inside its casing. Just use two AC output wire to check continuity readings)

[rprathin]

Re: Bajaj Discover, UG3, 8 Pole stator DIY

Yeah :-) I have seen the method on google and gave a try to this. I am facing exact problems from which you gone through earlier. I have seen your post (pg. 70-80) about self rewinding of Pep+ stator. You are also very good at DIY stuff. :-) I am thinking to remove the stator and rewind it with proper technician before Leh ride. What do you say?
Did you converted your other to DC also?

There wont be any issues if the soldering is done properly which you did.
Due to the circumstances after buying Jupiter i am so busy that i can't do the conversion. I Might do that in future.

[sidharthk]

Re: 3 Pole

Its a good news then. :-) Post a high res. pic of the stator so that we can see if the winding is done tightly or not. There should be a very tight winding and high number of turn on all three poles to get maximum output because there are only 3 poles generating ucrrent instead of tested 7 or 12 poles. Are you sure he used a 19g wire to rewind?

Troubleshooting :-
- Fix the rewinded stator back into casing, tighten the nuts back, connect ignition coil wire only. Check the 'Unregulated AC' output directly from the coil two extended wires using DMM on AC 200/750v mode. Raw output should be more then 9v at idle to 90v at 70% engine rpm. Move to next step if get these desired units.

- Connect both AC wires to RR unit, RR white (DC out?) wire to DMM red wire (attach red wire to Amp socket on DMM), comm. black wire from DMM to positive of battery terminal and RR black wire to negative terminal of battery (not on body frame for now). set the dmm dial to 10amp mode. Dmm should be in series between RR white and battery +ve.

- Turn on your phone camera video mode and make a video of DMM readings. Slowly increase the engine RPM to see the current drawn by the battrey from RR unit. It should be well above minimum 3 amps at 40% engine rpm.

- Post results. (Note- Coil grounding with the stator core is not acceptable at any point. You can even check continuity between coil ends and ends with ground when the stator is fixed inside its casing. Just use two AC output wire to check continuity readings)

Actually I don't have any pic of stator
Sorry for that because it done very fast

But when I again open my stator then I will click pics and send I want to open as soon as possible but it the only bike in my house so bike needed to my father all day or any time [emoji26]
So when next time his out of time I will open the stator and click pics and if there any possible I rewind it

I will try in the morning how much ac volt it gives
If it less then 9v at idl or less then 90v at 70% rpm ?
What should I do ?
If apr rr is good then I can try to buy it it's very difficult for me but I can try if it improve dc or amp 😢
I will measure the amp in the morning
I forget to ask you why my bike get load after this stator coil or rr connected ?
Bike feel extra heavy [emoji29] I feel it in its sound
What about hids lights
And why all signal try on after blub changed to led ?
I try a temporary solution Remove signal blub for speedo metter all signal work fine after that [emoji4] [emoji5]

[Toshar Deven]

Re: 3 Pole

Actually I don't have any pic of stator
Sorry for that because it done very fast

But when I again open my stator then I will click pics and send I want to open as soon as possible but it the only bike in my house so bike needed to my father all day or any time [emoji26]
So when next time his out of time I will open the stator and click pics and if there any possible I rewind it

I will try in the morning how much ac volt it gives
If it less then 9v at idl or less then 90v at 70% rpm ?
What should I do ?
If apr rr is good then I can try to buy it it's very difficult for me but I can try if it improve dc or amp 😢
I will measure the amp in the morning
I forget to ask you why my bike get load after this stator coil or rr connected ?
Bike feel extra heavy [emoji29] I feel it in its sound
What about hids lights
And why all signal try on after blub changed to led ?

I try a temporary solution Remove signal blub for speedo metter all signal work fine after that [emoji4] [emoji5]

Dear
I can understand the feeling of modifying a bike which is the only mode of main transport in a family. Same story here, but i tickle with my bike only on weekends (fri night, sat day, sat night, sun day) so that i can rectify things before monday. Please have a look at the family need first, then only proceed with the time.

-- Buy two or three stator cover "packing seals" from automotive shops in advance. They cost 10-15 rupees each and use them to seal you stator cover.
-- No need to open stator cover tomorrow morning, you can post the photos later also and I will make replies to you then on time. Just be sure the photos are not blurred.

-- You have Old single pole stator? right? You can fix it back for some time for proper functioning of bike and rewind current 3 pole stator taking extra time if necessary. Check with old single pole stator if it also affecting engine performance. Swapping stator is very easy and you know it.

-- The re-winded stator should give you around 50v of current at 50% engine RPM? Voltage should increase gradually with increasing RPM. My rewinded stator gave me 10v at idle and 109v at 7k rpm.

-- No need of buying a Ape RR. That will do no good with a weak stator. UG4 RR is well capable. You should first use this RR for atleast a month or two and then only move to APE RR if you want little more.

-- You can Check check continuity between the rewinded coil ends, coil and ground, AC voltage output with stator only inside the engine and engine running. Check and post these exact values before opening the stator. There will be no need of stator photos for now if you get right amount of voltage.

-- Be attentive in measuring Amp output from RR. A wrong twist in DMM dial will make things in fire.
DMM red wire on Amp socket (top most i guess in chines multimeters), red wire connected and taped temp. to RR white wire, DMM black comm. wire to battery +ve terminal. RR black wire to battery -ve term. Dial to AMP mode, write down the reading on a paper with approx engine rpm.

-- Rewinded coil also generate magnetic fields when working. More number of turn in wiring will give more current output but also resistant to magnetic waves of rotor magnet. This resistant should be not much. Check with OEM original single coil stator. Check if coil wires do not touch with rotor magnet.

-- HID will work only on DC. Let you convert your bike to DC first then use the mod without hid for a couple of week. Then install HID.
Note- HID without projector is illegal and will cause a lot of glare on oncoming traffic. Where do you live?

[sidharthk]

Re: 3 Pole

Dear
I can understand the feeling of modifying a bike which is the only mode of main transport in a family. Same story here, but i tickle with my bike only on weekends (fri night, sat day, sat night, sun day) so that i can rectify things before monday. Please have a look at the family need first, then only proceed with the time.

-- Buy two or three stator cover "packing seals" from automotive shops in advance. They cost 10-15 rupees each and use them to seal you stator cover.
-- No need to open stator cover tomorrow morning, you can post the photos later also and I will make replies to you then on time. Just be sure the photos are not blurred.

-- You have Old single pole stator? right? You can fix it back for some time for proper functioning of bike and rewind current 3 pole stator taking extra time if necessary. Check with old single pole stator if it also affecting engine performance. Swapping stator is very easy and you know it.

-- The re-winded stator should give you around 50v of current at 50% engine RPM? Voltage should increase gradually with increasing RPM. My rewinded stator gave me 10v at idle and 109v at 7k rpm.

-- No need of buying a Ape RR. That will do no good with a weak stator. UG4 RR is well capable. You should first use this RR for atleast a month or two and then only move to APE RR if you want little more.

-- You can Check check continuity between the rewinded coil ends, coil and ground, AC voltage output with stator only inside the engine and engine running. Check and post these exact values before opening the stator. There will be no need of stator photos for now if you get right amount of voltage.

-- Be attentive in measuring Amp output from RR. A wrong twist in DMM dial will make things in fire.
DMM red wire on Amp socket (top most i guess in chines multimeters), red wire connected and taped temp. to RR white wire, DMM black comm. wire to battery +ve terminal. RR black wire to battery -ve term. Dial to AMP mode, write down the reading on a paper with approx engine rpm.

-- Rewinded coil also generate magnetic fields when working. More number of turn in wiring will give more current output but also resistant to magnetic waves of rotor magnet. This resistant should be not much. Check with OEM original single coil stator. Check if coil wires do not touch with rotor magnet.

-- HID will work only on DC. Let you convert your bike to DC first then use the mod without hid for a couple of week. Then install HID.
Note- HID without projector is illegal and will cause a lot of glare on oncoming traffic. Where do you live?

I live in rajasthan district hanumangarh

[sidharthk]

Re: 3 Pole

Dear
I can understand the feeling of modifying a bike which is the only mode of main transport in a family. Same story here, but i tickle with my bike only on weekends (fri night, sat day, sat night, sun day) so that i can rectify things before monday. Please have a look at the family need first, then only proceed with the time.

-- Buy two or three stator cover "packing seals" from automotive shops in advance. They cost 10-15 rupees each and use them to seal you stator cover.
-- No need to open stator cover tomorrow morning, you can post the photos later also and I will make replies to you then on time. Just be sure the photos are not blurred.

-- You have Old single pole stator? right? You can fix it back for some time for proper functioning of bike and rewind current 3 pole stator taking extra time if necessary. Check with old single pole stator if it also affecting engine performance. Swapping stator is very easy and you know it.

-- The re-winded stator should give you around 50v of current at 50% engine RPM? Voltage should increase gradually with increasing RPM. My rewinded stator gave me 10v at idle and 109v at 7k rpm.

-- No need of buying a Ape RR. That will do no good with a weak stator. UG4 RR is well capable. You should first use this RR for atleast a month or two and then only move to APE RR if you want little more.

-- You can Check check continuity between the rewinded coil ends, coil and ground, AC voltage output with stator only inside the engine and engine running. Check and post these exact values before opening the stator. There will be no need of stator photos for now if you get right amount of voltage.

-- Be attentive in measuring Amp output from RR. A wrong twist in DMM dial will make things in fire.
DMM red wire on Amp socket (top most i guess in chines multimeters), red wire connected and taped temp. to RR white wire, DMM black comm. wire to battery +ve terminal. RR black wire to battery -ve term. Dial to AMP mode, write down the reading on a paper with approx engine rpm.

-- Rewinded coil also generate magnetic fields when working. More number of turn in wiring will give more current output but also resistant to magnetic waves of rotor magnet. This resistant should be not much. Check with OEM original single coil stator. Check if coil wires do not touch with rotor magnet.

-- HID will work only on DC. Let you convert your bike to DC first then use the mod without hid for a couple of week. Then install HID.
Note- HID without projector is illegal and will cause a lot of glare on oncoming traffic. Where do you live?

Today I checked unregulated ac volt at idle 15 to 20
And high rpm 80+
And Amp it show .80 to 1.50 high or low Rpm same

[Mortis]

Re: Convert AC/DC bike to ALL DC.

Is it possible to convert the Honda Navi to full DC electricals ? Has anyone done it or is there a guide for it ? Im planning to pick one up and would prefer the Headlight at the least to be on DC, cant stand the flickering.
Ideally I would prefer it if someone could point me to a good mechanic in Mumbai who can make the necessary changes for me, preferably in the western suburbs Andheri to Bandra area. I usually prefer to leave electrical modifications to the experts as it isnt my strong suite.
I have briefly gone through this thread but most of the terms and parts have gone over my head and Im unsure as to what all I might need.

[sidharthk]

Re: Convert AC/DC bike to ALL DC.

Is there any one who can reply ?
Because I'm waiting for reply from long period.. please reply
I'm in middle of Ac/DC to full DC...

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

Is it possible to convert the Honda Navi to full DC electricals ? Has anyone done it or is there a guide for it ? Im planning to pick one up and would prefer the Headlight at the least to be on DC, cant stand the flickering.
Ideally I would prefer it if someone could point me to a good mechanic in Mumbai who can make the necessary changes for me, preferably in the western suburbs Andheri to Bandra area. I usually prefer to leave electrical modifications to the experts as it isnt my strong suite.
I have briefly gone through this thread but most of the terms and parts have gone over my head and Im unsure as to what all I might need.

Honda Navi is not so fast two-wheeler and riders usually do not stretch it much if the roads are bad. Navi's 110cc engine is not that torque and alternation to its coil will affect its top end. If you are really concerned about flicker free output, you can purchase LED flood lights/pencil beams which goes farther and ran on battery and can fitted them on anywhere in front. These lights are low wattage, comparatively brighter and will do the purpose. Battery will get charge all day and can be used 3-4 hour continuously with normal AC headlight together. A solo cree LED bulb will make worse the HL focus. Whats your opt?

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

Is there any one who can reply ?
Because I'm waiting for reply from long period.. please reply
I'm in middle of Ac/DC to full DC...

[sidharthk]

Re: Convert AC/DC bike to ALL DC.

Actually my father don't know about it.
As he only know the im change headlight bulb or charging RR. 😊
When he out of station then my experiment go on

Can you tell me it worth to upgrade old bike like my ?

I will arrange some tool for my bike stator opener and magnet puller it will take some time bcoz I don't want to go shop and request him to open and close stator 😐
Today I checked some thing when bike not started I touch ac white wire to battery +ve it spark only on white wire spark not yellow wire
its normal ?

[sidharthk]

Re: Convert AC/DC bike to ALL DC.

According to me
There are total 6 wire stator
2 (white and yellow ) for Ac
1 green for earth (ground)
1 neutral gear indicator
1 black for ignition
1 for plus or CDI

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

Actually my father don't know about it.
As he only know the im change headlight bulb or charging RR. 😊
When he out of station then my experiment go on

Can you tell me it worth to upgrade old bike like my ?

I will arrange some tool for my bike stator opener and magnet puller it will take some time bcoz I don't want to go shop and request him to open and close stator 😐
Today I checked some thing when bike not started I touch ac white wire to battery +ve it spark only on white wire spark not yellow wire
its normal ?

[Sean Mc'Ken]

Re: Convert AC/DC bike to ALL DC.

please somebody help me here.. i got pulsar 200 dtsi and its charging is nt working, replaced RR stock but no voltage frm stator coil.. everthng else works fine.. only battery nt getting charged.. right now my financial condition is very very bad.. i cnt afford a new coil.. plz suggest something.. i dnt use yellow wire for headlamps buz those are directly DC powereb by battery.. so yellow wire is cut and kept aside and totally idle.. so is there anyway i cn use it for charging purpose??? please help. i dnt have any other vehicle right now except this

[Srinivas sr143sr]

Re: Convert AC/DC bike to ALL DC.

please somebody help me here.. i got pulsar 200 dtsi and its charging is nt working, replaced RR stock but no voltage frm stator coil.. everthng else works fine.. only battery nt getting charged.. right now my financial condition is very very bad.. i cnt afford a new coil.. plz suggest something.. i dnt use yellow wire for headlamps buz those are directly DC powereb by battery.. so yellow wire is cut and kept aside and totally idle.. so is there anyway i cn use it for charging purpose??? please help. i dnt have any other vehicle right now except this

Yellow wire carries already regulated current. Leave it aside.

Yellow-Red wire and Body of your bike (ground) can be used to connect to Regulator (in place of 2 blue-white wires from stator). This will give the AC current to stator and stator gives DC output for battery charging via White wire(+ve) and Black-Yellow(-ve) wire.

If you want to do, then :

1) Cut two blue-white wires, Yellow-Red wire at socket side (Not regulator ones)
2) Attach the Yellow-Red wire to a blue-white wire
3) Attach a wire to body of bike at any place or screw and connect it to another blue-white wire
4) leave Yellow, Black-Yellow, White wires as it is. No problem even if yellow wire was cut. but White and Black-yellow should be in their own places.
4)Testing: now just take a new wire and connect or push at the White wire of the regulator and start the bike. now try to touch and remove the other end of wire to the body of bike. if it sparks then you are getting DC and your battery is getting charged.


BUT as you are using the battery for Lighting and all the things... VERY SOON YOUR REGULATOR WILL FAIL AS IT IS NOT DESIGNED TO SUPPORT THEM..!!! THATS FOR SURE...!!! BE READY FOR IT...!!!!

You do one thing. Remove the stator (ask any mechanic) and have a look at the blue-white wires that are soldered to coil winding. if there is a cut in the wire you can easily replace the wire and solder it. If there is not cut in the wires, check for continuity(Using multimeter) between the ends of both the blue-white wires. You will be able to trace the culprit wire and you can replace it..!!
The cost will be not more than 50-60RS or max 100Rs.

P200 heavily relies on battery as it has no Kickstarter, also it draws way more power than UG4 for starting the bike.

If you want to use bulb/LED through DC, you have to compulsorily rewind the coil and use a better Regulator. Many people are misguided to use the LED/DC lamps with their existing AC-DC setup. Its a big no.