Convert AC/DC bike to ALL DC.

[aumer98]

Re: Convert AC/DC bike to ALL DC.

Can you elaborate how many turns per pole.

Also the voltage you mentioned was it above 3k RPM?

If the 3 pole stator isn't putting out enough current you voltage will drop.
Better move to LED headlamps. Main reason is a 55/60w halos will consume a reasonable 4.6A at 13.5V DC.
LED on other hand will consume somewhere around 3A DC
As of we can't modify the stator and rotor arrangements in a motorcycle without major modification.

100-112 turns per pole
Total 3 poles
and at max RPM total AC current is 52v with 19g wire
And output dc volts is 13v at max RPM
My amp meter is not working to get the Amp reading.

[Manoj Sivaraman]

Re: Convert AC/DC bike to ALL DC.

100-112 turns per pole
Total 3 poles
and at max RPM total AC current is 52v with 19g wire
And output dc volts is 13v at max RPM
My amp meter is not working to get the Amp reading.

Can I know the Battery voltage at no load above 3k RPM

[aumer98]

Re: Convert AC/DC bike to ALL DC.

Can I know the Battery voltage at no load above 3k RPM

at max rpm with no load the dc voltage of battery is 12.80-13v

[Manoj Sivaraman]

Re: Convert AC/DC bike to ALL DC.

at max rpm with no load the dc voltage of battery is 12.80-13v

I guess something is wrong. At no load voltage must be 14.1 least.
Take a closer inspection on the windings and wiring.

[jawahar1886]

Re: Convert AC/DC bike to ALL DC.

Hai to all members, iam new to this site

i have one Caliner 115 bike,

i want to change my bike wiring(Headlight, Taillight, Meter Lights, Signal-lights) full setup AC to DC,

Please give some suggestions to change or increase Lighting of my caliber

thankyou

[aumer98]

Re: Convert AC/DC bike to ALL DC.

I guess something is wrong. At no load voltage must be 14.1 least.
Take a closer inspection on the windings and wiring.

Hey,
First sorry for the delay as for this corona virus pendamic.
Ok so going back to the topic
Tried winding with 19.5g wire and the output was 14.4v dc at max RPM
But the bike was taking load as if i their are two persons on it even when i am alone riding it.
So switched back to 19g wire
(I was having extra coil plate the OE one with 19g wire)
And the output was same 14.4v DC at max RPM
And at ideal its around 12.80.
Turned on the light output is 12.60 at max rpm.
Also battery is not draining now
I used pulsar ug3 rr
Headlight is - philips xtreme vision 60w/55w (turned out that its melting the reflector now need to change)
Here are some photos of the 19.5g winding
Sorry as i was not able to upload the 19g winding pic.



As i am an mechanic
I was thinking of converting the kick start bajaj platina to self start by making some changes in bike
But by attaching the self on kick shaft and not magnet [emoji848] anyone know who can help or guide with any alternative work or idea

[Khemchand Sure]

Re: Convert AC/DC bike to ALL DC.

Hello guys,

Im frustrated with my pathetic headlight , so planning to switch to LED headlight.
While doing some research on how it can be done came across this thread. And I was going through some you tube videos as well

As I don't even know abcd of electricals , was trying to understand things. (Anyways I am not going to take risk and do it myself). Came across a yoy yube video, the guy suggest a different way.
Just want experts in this group to tell , is it safe to it or even if it is correct, as suggested by this video.

This is link to the video

https://youtu.be/l-4Snr1sia8

[Maxsteel]

Re: Convert AC/DC bike to ALL DC.

Hello guys,

Im frustrated with my pathetic headlight , so planning to switch to LED headlight.
While doing some research on how it can be done came across this thread. And I was going through some you tube videos as well

As I don't even know abcd of electricals , was trying to understand things. (Anyways I am not going to take risk and do it myself). Came across a yoy yube video, the guy suggest a different way.
Just want experts in this group to tell , is it safe to it or even if it is correct, as suggested by this video.

This is link to the video

https://youtu.be/l-4Snr1sia8

Which bike do you own or want to change light

[Khemchand Sure]

Re: Convert AC/DC bike to ALL DC.

Honda hornet 160 first gen 2016 model.
Headlight is pathetic, im about to complete 5 yrs, so no warranty issue. planning to change it.

Which bike do you own or want to change light

[aumer98]

Re: Convert AC/DC bike to ALL DC.

Honda hornet 160 first gen 2016 model.
Headlight is pathetic, im about to complete 5 yrs, so no warranty issue. planning to change it.

mandatory- good Battery for LED (or else LED will shot with over voltage if its not a good type)
for LED conversion you dont need any modification of coil or rr unit. axcept the AC output of headlight to be disconnected and to LED you need DC output
find the Yellow wire that goes to the right hand switch or to the headlight switch/button - disconnect the yellow wire inbetween
now you have 2 yellow wire
1- goin to light bulb switch
2- comming from petrol tank side - leave with a tape at the end.

joint the 1. yellow wire to front brake light black wire (right side front brake)
tap it well and then you can connect the LED and use it
their will not be much discharge of battery as LED dont consume much power.

dont use AC power on LED as it will get shot in seconds

[Toshar Deven]

No one here since 2020! Damn these all bikes comes with DC setup as stock.

[Mortis]

Hello, I need a bit of help with this. I have an Activa 110 and have converted the headlight to DC by connecting one wire from the headlight switch wire to the Ignition. I have also swapped to LED and so far this has worked flawlessly for the last 3 years. As such I dont go for long rides and even less so at night but on those rare occasions that I do, I have noticed that around the 1.5hr mark the battery gets quite low (horn sounds weak, etc) but so far hasnt drained completely yet.
Iam going to have longer evening commutes soon and I suspect I might encounter a drained battery sooner or later as my day/night riding will be more 50-50 vs the 90-10 it is currently.
I have been looking for someone to rewind the coil for a long time now and all the mechanics simply dismiss it. I finally found a coil repair guy who was ready to do it if I get him the wire size, no of turns and other details.
So can someone help me with the "recipe" for this ? Full details as much as possible would be appreciated as I am unfamiliar with this and need to supervise asd explain to another person who I guess is also unfamiliar with this.
I also wanted to confirm if rewinding the coil in my current setup will help charge my battery faster ?

[aumer98]

i am a mechanic myself from Aurangabad Maharashtar, if anyone want help regarding RRunit and 50/60w halogen bulb in old bikes that have the 3 poles in alternator can help you with it
can contact on telegram - @umair_0fficial
successfully done in
Activa 110 - no winding require
bajaj platina 100 ks - winding require
hero splendor - winding require
honda unicorn 150 - no winding require

[Manoj Sivaraman]

No one here since 2020! Damn these all bikes comes with DC setup as stock.

I still remember reading from page 1 till 80 or something. When I converted my 2013 RTR160 to full DC with 18AWG coil and APE RR. Some remarkable members like Devraj etc. kept this thread alive back then. Its been nearly 9 years and motorcycles have come a long way since. Since the rules of BS4 and AHOs most manufacturers moved quickly to LEDs which used to be a wow factor back in 2013 or 15. Now with BS6 to meet the requirements of ECUs and other loads even basic motorcycles started implementing full DC systems.
Reading this thread feels NOSTALGIC for sure..

[rprathin]

I still remember reading from page 1 till 80 or something. When I converted my 2013 RTR160 to full DC with 18AWG coil and APE RR. Some remarkable members like Devraj etc. kept this thread alive back then. Its been nearly 7 years and motorcycles have come a long way since. Since the rules of BS4 and AHOs most manufacturers moved quickly to LEDs which used to be a wow factor back in 2013 or 15. Now with BS6 to meet the requirements of ECUs and other loads even basic motorcycles started implementing full DC systems.
Reading this thread feels NOSTALGIC for sure..

I used ape RR to convert my Sccoty Pep+ and Pulsar 180 UG3 to all-DC almost 10 years ago, when I was still in school. Now that I'm employed (good old days).