Convert AC/DC bike to ALL DC.

[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.

[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)

[sidharthk]

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?

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



Hello

- I don't know much about Pulsar UG4s RR unit. You can read more about it on the same thread after page 65 or so. You will get much more information about this alternate RR. Please go through that page by page.

-There is no need to rewind 3 pole stator from the auto electrician. Most electrician will do the work as they want, not the way you instruct them. Please post a high resolution photo of your 3 pole stator. What is length of one pole? Connect one DMM probe to one end of coil, touch another end of other probe to stator core/iron part on continuity function. It shouldn't show any grounding of coil with core. If found something wrong, then you can rewind your stator with 19g wire yourself in a CW and ACW neat fashion. This process wont cost you much but you will be more sure that coil re-winded by you is better then the work done by your electrician. Check other forums to see if three poles are enough to produce required amount of current. All the best

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

[Toshar Deven]

Re: Bajaj Discover, UG3, 8 Pole stator DIY

You did the correct way. Normally tin soldering wire which we use have melting point of 188 degree Celsius so it would be fine, the area around coil is way below that temperature for it to become even brittle. If soldering is done perfectly then i bet it would be stronger than the wire itself.

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?

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

I have 12 35w hid with blaster I don't know how to connect it when I connect it to battery it glow only for 1 min after that It only fliker and off. I want to install this light into my headlight or any other high power 45 w headlight. So I need to upgrade my battery to 5 A to higher ? Or there is any other solution ?

Hello

- I don't know much about Pulsar UG4s RR unit. You can read more about it on the same thread after page 65 or so. You will get much more information about this alternate RR. Please go through that page by page.

-There is no need to rewind 3 pole stator from the auto electrician. Most electrician will do the work as they want, not the way you instruct them. Please post a high resolution photo of your 3 pole stator. What is length of one pole? Connect one DMM probe to one end of coil, touch another end of other probe to stator core/iron part on continuity function. It shouldn't show any grounding of coil with core. If found something wrong, then you can rewind your stator with 19g wire yourself in a CW and ACW neat fashion. This process wont cost you much but you will be more sure that coil re-winded by you is better then the work done by your electrician. Check other forums to see if three poles are enough to produce required amount of current. All the best

[sidharthk]

Re: Convert AC/DC bike to ALL DC.

I have 12 35w hid with blaster I don't know how to connect it when I connect it to battery it glow only for 1 min after that It only fliker and off. I want to install this light into my headlight or any other high power 45 w headlight. So I need to upgrade my battery to 5 A to higher ? Or there is any other solution ?

[sidharthk]

Re: Convert AC/DC bike to ALL DC.

Hello friends
I try to do my Hero Honda cd 100 (1995 or 1988) full dc
Firstly i tell you about my bike it's in good condition not like factor but much better then same model
I have 12 v 25w/25w headlight bulb/ halogen blub
12v 2.5A battery
Single coli stator (only one coli for lighting and charging) one ignition coli and a plus
But I changed the battery 12v 5A
And changed the charger to ug4 and connect headlight to ignition switch now my headlight switch on without starting bike. but battery not charging at low or high rpm battery show only 10 volt so I failed in this project.
After 1 week I buy splendor stator coli which have 3 pole for lighting or charging but result are same 10volt (I checked at battery terminal when ug4 charge connected sorry I forget to check amp. )
Now I reminded the coli at 19 size not counted round , first pole have less round as compared to other ,not done by me but electrician done (I thing he done as stock winding)
I connect yellow wire to first pole wire and white to last pole wire.
Checked ac out put with dmm yellow and green ground show 5 to 7 at high rpm white wire show higher then 20
When I connect dmm to yellow and white ac wire it show above 40 at Higher Rpm at idl many time show zero or 5 to 7
When I connect yellow/white wire directly to ug4 charger and output of charge not changed same 10 volt when battery connected
But when I changed battery to 12v 2.5A it show at high Rpm 13 volt. Not at low or idl Rpm
One more thing when I connect yellow and white wire to as they connected to bike and headlight glow as very low but after little bit race it glow as connectd to battery.
So please suggest me some thing so my get battery charged
My battery 12v 5Amp 3 week old only.

One more thing I have also done I changed all signal light blub into led speedo metter light into led.

Light switch also changed like deluxe dipper switch so now I use dipper.

Sorry for my bad english or any mistake I done in writing.

[rprathin]

Re: Bajaj Discover, UG3, 8 Pole stator DIY

Sir, i found the coil is grounded somewhere on the stator after rewinding. I used magnifying glass to zoom in the possible areas, disconnected multiple poles from each other by cutting the wire very neatly to figure out the problem. After omitting the errors, i slightly removed enamel coating from the wire so that solder gets a good grip onto the wire. After soldering the two/multiple ends I pinched the joints with tinny copper shims using pliers and then re solder the shims on to the wires for a proper joint followed by another coat of varnish to insulate everything. This is not a reliable solution but somewhat better then just soldering which may burn because of engine heat and vibrations. Automotive wiring harness also uses these tiny copper shims at wire junctions, instead of twisting them together. Lets see for how much time it stays on there. I see a lot of people around the world have used this method to join coil wires instead of rewinding the whole stator.

You did the correct way. Normally tin soldering wire which we use have melting point of 188 degree Celsius so it would be fine, the area around coil is way below that temperature for it to become even brittle. If soldering is done perfectly then i bet it would be stronger than the wire itself.

[Toshar Deven]

55w Bi-Xenon projector in work (10A startup current, 4.2A stable current)- Wall at last is 200 ft away.


Bi-Xenon Projector in action


OEM Ape RR unit with 6 wires bought for 1500 INR


I would like to thank @Shreeni0403 @sajjtabhijeet080808 princesirohiAbhijeet Bhattacharjeedrvmtm rprathin and ----consecutive posts auto-merged-----

No soldering won't cause any problems. So if it was showing the ground with stator how did you fixed it, did you soldered the poles? If yes then it might cause trouble in future if not done properly. The copper wire coating might have got scratched while winding causing ground.

Sir, i found the coil is grounded somewhere on the stator after rewinding. I used magnifying glass to zoom in the possible areas, disconnected multiple poles from each other by cutting the wire very neatly to figure out the problem. After omitting the errors, i slightly removed enamel coating from the wire so that solder gets a good grip onto the wire. After soldering the two/multiple ends I pinched the joints with tinny copper shims using pliers and then re solder the shims on to the wires for a proper joint followed by another coat of varnish to insulate everything. This is not a reliable solution but somewhat better then just soldering which may burn because of engine heat and vibrations. Automotive wiring harness also uses these tiny copper shims at wire junctions, instead of twisting them together. Lets see for how much time it stays on there. I see a lot of people around the world have used this method to join coil wires instead of rewinding the whole stator.

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Good Morning :-) I have wounded my stator coil with 19g wire. Previously it was wounded with a thin wire and thick wire, may be for charging and lightning and it was not in CW or ACW fashion, instead the coils were wound in alternative poles. Anyways, it took me total 8 hours to wind all 25 meter 19g wire on the stator in neatest way i could achieve yesterday with hands. It was my mistake to do the rewinding working myself. Sir, i had 3 solder spots in between 3 poles series winding. I had to cut wire between poles to figure out the fault as DMM was showing wire groung with stator. Does this tin solder have any ill effect on performance? I have varnished whole assembly and solder point two times and now it is in Over for quick drying. Will test it after breakfast . Have a Nice Sunday. :-)

No soldering won't cause any problems. So if it was showing the ground with stator how did you fixed it, did you soldered the poles? If yes then it might cause trouble in future if not done properly. The copper wire coating might have got scratched while winding causing ground.

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

Thicker the wire more the current but also lesser the voltage. There might be some image of my rewinded coil in this thread back then i was a total noob. The maximum turns per pole u could squeeze in neatly as possible. Ape rr without connected to battery does shows wierd voltages. The more the turns per pole which will equal to more voltage.

Good Morning :-) I have wounded my stator coil with 19g wire. Previously it was wounded with a thin wire and thick wire, may be for charging and lightning and it was not in CW or ACW fashion, instead the coils were wound in alternative poles. Anyways, it took me total 8 hours to wind all 25 meter 19g wire on the stator in neatest way i could achieve yesterday with hands. It was my mistake to do the rewinding working myself. Sir, i had 3 solder spots in between 3 poles series winding. I had to cut wire between poles to figure out the fault as DMM was showing wire groung with stator. Does this tin solder have any ill effect on performance? I have varnished whole assembly and solder point two times and now it is in Over for quick drying. Will test it after breakfast . Have a Nice Sunday. :-)

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Thats a much needed information. I was wrongly guided - thicker the wire- more the current. I will do all the necessary stuff tomorrow and will post result.
-Open stator cover and coil
-De-soldering of all wires except ignition coil (discover 8 pole stator) and un-winding stock coil by couting number of present turns.
- Varnish treatment to the bare stator, Bake in oven, Re-winding it with 19g wire very neatly, without over lapping, filling poles all up-to to brim.
- connecting both ends of re-winded coil to the APe RR and etc etc.
Btw, i have rad a post on same thread that measuring APE RR output without connecting it wire to battery will destroy it! I have recently bought a original piagio Brand new RR for 1500 rupees. I have also checked it with current 'coil in series' setup but DC output was zero. Is it possible? how?

How much length of wire should i buy? How many turns per pole? Electricians here don't sell copper in weight.
Is there any thread/post of your mod?

Thicker the wire more the current but also lesser the voltage. There might be some image of my rewinded coil in this thread back then i was a total noob. The maximum turns per pole u could squeeze in neatly as possible. Ape rr without connected to battery does shows wierd voltages. The more the turns per pole which will equal to more voltage.

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

18 gauge wire on 7 poles, the disadvantages would be low voltage if there are less no. Of turns. I would say go for 19 gauge wire. Yes i have done on three vehicles tvs pep+, pulsar 180 ug3, Yamaha crux not rewinding but joining all the poles. Pulsar 180 and crux was sold, pep+ is still running on ape rr and rewinding with 19 gauge. All were 19 gauge, i tried 18 gauge on pulsar the disadvantage was low voltage on lower rpms 1.5k-2.5k. with 19 gauge everything was fine.

Thats a much needed information. I was wrongly guided - thicker the wire- more the current. I will do all the necessary stuff tomorrow and will post result.
-Open stator cover and coil
-De-soldering of all wires except ignition coil (discover 8 pole stator) and un-winding stock coil by couting number of present turns.
- Varnish treatment to the bare stator, Bake in oven, Re-winding it with 19g wire very neatly, without over lapping, filling poles all up-to to brim.
- connecting both ends of re-winded coil to the APe RR and etc etc.
Btw, i have rad a post on same thread that measuring APE RR output without connecting it wire to battery will destroy it! I have recently bought a original piagio Brand new RR for 1500 rupees. I have also checked it with current 'coil in series' setup but DC output was zero. Is it possible? how?

How much length of wire should i buy? How many turns per pole? Electricians here don't sell copper in weight.
Is there any thread/post of your mod?

[rprathin]

Re: Convert AC/DC bike to ALL DC.

Thank you very much :-)
It took me 2 hours to understand the stator wiring. I used DMM to check community between light and charging coil and soldered them in series. Then extended the coil with copper wires to APE RR. Don't know what wrong with the coil.
I have asked a pump winder electrician about 18 gauge wire, he said that the wire is think and they sale it for Rs. 10/ meter.
Can i use 18 gauge wire? Can i wind it myself because i don't think that electricians are very precise. I will try my best to fill till stator brim in cleanest way.
Have you done the process with your bike before? Any other recommendation sir?

Sorry but your inbox is full. Please have a look at above post of me.

18 gauge wire on 7 poles, the disadvantages would be low voltage if there are less no. Of turns. I would say go for 19 gauge wire. Yes i have done on three vehicles tvs pep+, pulsar 180 ug3, Yamaha crux not rewinding but joining all the poles. Pulsar 180 and crux was sold, pep+ is still running on ape rr and rewinding with 19 gauge. All were 19 gauge, i tried 18 gauge on pulsar the disadvantage was low voltage on lower rpms 1.5k-2.5k. with 19 gauge everything was fine.

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

I have not seen the Pulsar 200 ns rr so i can't tell.

Thank you very much :-)
It took me 2 hours to understand the stator wiring. I used DMM to check community between light and charging coil and soldered them in series. Then extended the coil with copper wires to APE RR. Don't know what wrong with the coil.
I have asked a pump winder electrician about 18 gauge wire, he said that the wire is think and they sale it for Rs. 10/ meter.
Can i use 18 gauge wire? Can i wind it myself because i don't think that electricians are very precise. I will try my best to fill till stator brim in cleanest way.
Have you done the process with your bike before? Any other recommendation sir?

Sorry but your inbox is full. Please have a look at above post of me.

[Toshar Deven]

Re: Convert AC/DC bike to ALL DC.

Discover 135 Dtsi S

I was reading this thread from years for my own knowledge and finally got green signal from my father to modify our Discover to improve headlight illumination.

- Bought a Hella G3 projector(uses a solenoid power shutter for cut-off beam) for Rs.200 from delhi scrap yard.
- Changed the wiring harness with a new one as it was all spliced and taped by local auto electrician. I used old WH to figure out which color wire goes where and works for what.

- Dissembled the headlight unit, separate reflector and glass but heating the unit in convection over at 100* Celsius for 20 minutes, installed projector with screws, nuts and bolts with help of ruler for exact dimensions.
- Arranged a h7 (DIY d2s socket) 55w 8k unbranded HID from a friend, fixed it inside the projector at exact focal point.
- The tube accidentally fell on the ground and broke, bought another HID bulb from karol bag for Rs. 400, Fixed it again inside the projector with coper wire as bulb retainer and then ballast and igniter were wired.
- I then disconnect the Yellow (AC Current) wire from headlight switch connector and left it for no use, then wired shutter solenoid and switch with relay and made proper wiring setup for work.

Result :-

- Damn good illumination with around 4300k because of 55w ballast.
- The setup worked only for good 20 minutes with bike running at speed 70+ at night. It cause Battery drain and i was in pitch dark with no lights, no horn, no electric start.

More:-

- I now purchased a 35w ballast only for another experiment and used it on the same bulb.

Now this setup is working good for 45 minutes max but the illumination is noticeably lower then 55w ballast. No power for horn and electric start again but the HID is still living on charging current and flickers when i press horn.
My father has no idea till now about the battery(amaron 5ah) drainage.


Need Help :-
- Are there any known and tested technicians in New Delhi who can do coil rewinding as per thread, as my local(south delhi, saket) electrician have no idea about the procedure and they give a really wired expression when i ask them to do so infact they make fun of me by saying why i want to do such stuff with my sasti (cheap) motorcycle . My Disco is no less and it still love to reach high rev on three-digit speed in matter of seconds.

- Should i just leave my DIY headlight experiment and get back to h7 halogen on AC? I have already spent 4k from my pocket money and cant stretch with risk. There are no such threads for Discover 135 electrical. The rollback will take around an hour and i can live with 55w accelerator powered h7 projector but HID will surely be missed.

This is the 55w Hi-lo, 35w Hi-lo illumination respectively and projector during and after final installation.