Convert AC/DC bike to ALL DC.

[Shreeni0403]

i dont want things to be complicated, and i dont need anybody to console me. i just dont want to do coil rewinding, so i am searching for alternative means, and there's no harm in doing so. i dont follow others blindly, i do my own research before settling on anything. i want to get the job done in minimum changes, as the more you change the stock setup---believe it or not you are compromising the reliability of bike. so thats the whole idea of trying out everything before a final configuration is finalized.

and it was me who for the first time raised this issue of battery overcharging, i only suggested to use a switch for additional charging only when lights are ON. anyway......i m happy with my research.....hopefully i will find a solution.

I donno what to say, but yes even I am kind of not interested/willing to do coil rewinding but luckily my Coil supports the charging issue without rewind, else I had to rewind. But that doesn't mean you should be so sharp in your words. We are obviously taking help of each other, noone is getting paid. So better hold your horses before speaking out like that in open forums.
Chill out.. Happy Experimenting..

EDIT - Oops submitted late by that time Prince had posted

[lakhanironak]

Just bought the APE RR unit for Rs. 1140.

http://picasaweb.google.com/lh/photo/QGUdOZljlcxmAXFANsTS7w?feat=directlink

[princesirohi]

Just bought the APE RR unit for Rs. 1140.

Picasa Web Albums - Ronak

hey buddy, did you purchased it from service center. even i want to purchase one so i called the paggio service center, the guy there asked me whether i want RR unit of 3 wheeler APE or 4 wheeler APE and in 3 wheeler also there are two models. which one did you purchased?

[sajjt]

what do u mean by complement each other ? how do check that on the winding ... Ill need some assistance regarding this.

Coz im really not used to opening the stator cover and working on it .. its really heavy and the sight of it kind of freaks me out at times... even though im almost gonna become a electronics engineer in 4 months ...

Compliment means just to trace both the coils can be clubbed if its in a series pattern like one of the coil ends with CW and other starts with ACW thats all. Its better to take it to an electrician to get it identified as he can guide u more in this. Stator cover is not supposed to open very frequently as water can go inside once any packing or the faces of the cover got damaged, I've seen mechs using screwdrivers to pull out the cover which should not be allowed, instead tap on the tabs provided for. Check for the packings every time u close the cover else, oil leak, water/dust can go side.

Good to hear that u went for an OEM RR, surely give u a trouble free time once u install it properly. Once more update, we can also use the Bajaj GC1000 RR which is having a voltage monitor which will take care of the over charging issue if any.

[princesirohi]

@ sajjt: what is bajaj GC1000 RR... is it an auto rickshaw?

i have found a company website which manufactures electrical & electronic parts of automobiles

here is the site address...

Welcome to Zenwin Motor Parts (P) Ltd.

on this website we can see hero honda ambition RR also has only 4 wires....i.e. only DC output...

[sajjt]

@ sajjt: what is bajaj GC1000 RR... is it an auto rickshaw?

i have found a company website which manufactures electrical & electronic parts of automobiles

here is the site address...

Welcome to Zenwin Motor Parts (P) Ltd.

on this website we can see hero honda ambition RR also has only 4 wires....i.e. only DC output...

Its an auto and above pic posted by me from that site only

[lakhanironak]

hey buddy, did you purchased it from service center. even i want to purchase one so i called the paggio service center, the guy there asked me whether i want RR unit of 3 wheeler APE or 4 wheeler APE and in 3 wheeler also there are two models. which one did you purchased?

Compliment means just to trace both the coils can be clubbed if its in a series pattern like one of the coil ends with CW and other starts with ACW thats all. Its better to take it to an electrician to get it identified as he can guide u more in this. Stator cover is not supposed to open very frequently as water can go inside once any packing or the faces of the cover got damaged, I've seen mechs using screwdrivers to pull out the cover which should not be allowed, instead tap on the tabs provided for. Check for the packings every time u close the cover else, oil leak, water/dust can go side.

Good to hear that u went for an OEM RR, surely give u a trouble free time once u install it properly. Once more update, we can also use the Bajaj GC1000 RR which is having a voltage monitor which will take care of the over charging issue if any.

Yup I bought the RR from the Service Center. But Now I feel I should waited for some more time. Could have bought the GC1000 RR Unit which has voltage monitor. The GC 1000 is a Bajaj Three Wheeler.

The Zenwin Motors Page is good. U can see the GC 1000 RR there, It has a extra wire along with the two wires which are meant for stator coil. The extra wire is for voltage (EDIT : THIS POINT IS WRONG, Sorry)
monitor.

About APE RR, Go for Three Wheeler One. Yeah there are two models, but it doesnt make a difference for us, as they have a difference in the socket for connecting stator wires. Thats All. So U can go for either of them. You can personally inspect both the RRs at the SC before you buy one of them.

About Stator Cover. This was my main concern. Because im really not experienced at opening the cover bymyself everytime and checking the windings. The more no. of times I open it, things will get ruined faster. Such as dust, water, etc getting into the stator.

Ive understood the complement each other funda.

One more thing, Should should I unsolder the center tap from the solder tab, and isolate it for making the wiring FULL WAVE. and then connecting the ground end to the yellow wire ?

[princesirohi]

in GC 1000 RR, the voltage monitor wire is to be connected to where...??? we need a voltmeter?

[gajah_gendut]

in GC 1000 RR, the voltage monitor wire is to be connected to where...??? we need a voltmeter?

to ignition key (+) as i usually posted before. or you can connect wire to any wire that has 12V (+) when ignition key on, like to brake light wire.

so, when ignition key off, there's no current goes to RR. actually you can connect directly to battery (+), although this circuit consume very small current, but if you left your bike for several days, battery will emptied slowly.
that's why i suggest you to connect battery monitor to ignition key, not directly to battery.

yesterday i modded one more P180 to dc light. using two RRs. one stock RR and honda tiger ones. as usual, lighting coils go to honda tiger RR. with ignition key off, battery voltage 12.8V. when key on but engine off, i got 12.6V.

from RR stock i got this results :
RPM V A
1200 13.5V ~0.7A
2000 13.7V 2.3~2,5A
4000 13.9V ~4.2A
>5000 14.1 ~4A

from honda RR (stock RR uninstalled )
RPM V A
1200 13.8V 1.5A
2000 14.2V 2.5~2.8A
4000 14.7V ~3.9A
>5000 14.9V ~4A

i couldn't measure amperage above 5000 rpm, because my digital multimeter has only 5A maximum ability. it was only cheap tools i can buy .

when joint two RR operating together, i got ~13.7V when idle, with lighting on i got 13.2V, when hi rev and lighting on got 14.3V

i was very happy with the result. but also worried about BCU. is bcu able to get ~15VDC input?

[princesirohi]

@gajah:

yes BCU can take 15.0 volts as stock RR upper voltage limit is 15.0 Volts. its given in training manual.

u didn't measured the current output of the two RR's combined?

[gajah_gendut]

@prince


my digital multimeter doesn't have capability to measure above 5A DC
in it's manual book said, when measuring between 4.5-5A must be done quickly about 2 seconds. more time will burn the multimeter...

so, i don't want to try measure two combined amperage RR output

[princesirohi]

@prince


my digital multimeter doesn't have capability to measure above 5A DC
in it's manual book said, when measuring between 4.5-5A must be done quickly about 2 seconds. more time will burn the multimeter...

so, i don't want to try measure two combined amperage RR output

OK.....

but remember combined output or two RR will be little less than their algebraic sum.

[Rossi_Fan]

If GC 1000 RR is having a battery monitor, then its better than the APE RR. Sajjt what do u say?

To be honest, its not that live as the other threads when we were discussing.

[princesirohi]

yesterday i tried to source for a Hero Honda Ambition's RR unit. but its not available in pune. guess i have to go for APE RR unit.

[lakhanironak]

THE OEM APE RR ROCKS. No Other Words !!

I have Successfully Converted my bike's Electricals From AC to DC.

I have followed whatever gajah_gendut and sajjt told me. Also inputs from Shreeni0403 n princesirohi helped me a lot.

I thankyou'll for all the guidance.

4th Feb 2010.

Finished Reading this Thread Back to Back at 4 pm. Thought of finishing the mod by the same night. But I thought if I get the work on the stator done, then I wont be able to ride in darkness backhome, Coz I had planned to do all the wiring for the RR, Headlight by myself. So I thought of buying the RR first. I just made it in time to the PIAGGIO SC at 6.30 pm. It closes at 6.45 pm.

5th Feb 2010.

2 pm :Ungrounded the grounded end of the Light Coil. And joined that end to the Yellow Wire. Thats it. No REWINDING. This Process was done by a auto electrician. The whole idea was explained to him first. Be sure to carry the APE RR with you, it helps a lot. He used Coil wire to extend the wire from the grounded end of light coil to the yellow. Then he insulated the soldered points with epoxy not with heat shink. Tell Him to disconnect the Two wires Yellow and White from the Socket thats supposed to be connected to wiring harness. Also Insulate those wires. He also checked the connectivity between those two wires, and he confirmed that the whole coil has become one now and that meant that it was FULL WAVE. This costed me Rs. 50.

Next I had to replace the Packing, Lots of Oil Leak. This was because of my inexperienced hands at opening the stator cover. Since I have a Yamaha, parts arent available everywhere. I had no Option, had to rush with a dying battery to the SC. It was already 4 pm. I dint want to ride in the dark so I had to pester the guys at Yamaha to speed up the work.

6.30 pm : Now the Easier Part. Installing the OEM RR. Keep in mind, I havent replaced the stock RR, I just added a new one. I Had to locate a place where I could install it. I placed it next to the Battery, which made conections easier.In the process I had to sacrifice my first aid kit.Since my battery is on the left side, the wiring was really simple. Just connected the two wires coming from stator ( yellow and white) to the grey wires of APE RR. I used Higher Gauge Wire for this. Next Connected the Yellow wire of the RR to the battery positive, and Black Wire to the negative.

For instantly checking if things were working. I started the Bike, Turned the HID ON ( The HID was connected with a extra switch), and it turned on. Left the bike on for 5 minutes, and after switching of the bike, the selfstarter was also working.

7.00 pm:This part took me 2 hrs, even though its the easiest. Now to connect all the lights to the Battery routing it through the ignition, This was confusing as well as head cracking as I had to troubleshoot it a lot, Coz the wiring in my bike is really messed up. Loose connections etc. Not much of a problem, but its like a puzzle. And the conections for the HID are through a relay. Should I connect the Halogen also with a Relay ? Will be discussing this up in my next post. Will post stats of current etc and Photos.

Costs Involved :
APE RR OEM - Rs 1140
Stator Mod - Rs 50

@princesirohi : Y dont you try the GC 1000 RR. It adds an extra funtionality to the RR unit which is battery monitor. I wish I could but the discussion abt GC1000 started l8r. Also it sounds cooler than "Piaggio APE" . There was this senior of mine from Oman (Even im from there) who once visited a auto expo in Bhopal. And there was this Leaflet about the GC1000, for a moment he mistook it as some SuperBike by Bajaj , It was a big joke here, he later ended up buying the Pulsar 150 but still dreamt abt GC1000. No offense to any Bajaj Owners Here !!

It also depends on the cost. Im not sure how much more it costs. Moreover U can have a ALL BAJAJ bike with the GC1000 RR

Right Now, Just gonna go for a short ride with a fully functional HID.
Till Then Cheers ALL.