Convert AC/DC bike to ALL DC.

[jeyessh]

im not able to find the APE RR unit is there any alternative to go for?

[princesirohi]

hi all, logging in after a lot of time. that fluctuating light problem is sorted out, it was HID relay malfunctioning.

Stator Coil rewinding done successfully.

battery changed a few days back. ( it was 2.5 years old battery).

how are thing going here.

any new buddy is up on DC conversion.

[Anish71]

Hi Guys!
I have a Honda Dio, i'm very happy with it. The only problem is the insufficient illumination provided by its stock headlight setup.
I want to rewind its coil and convert it into full dc. Will the same process as given in the starting on this thread will be applicable on the Dio?
Will that allow me to install 60/55w halogen bulb??
Guys plz help!!
thanking you all in advance.

[sajjt]

Hi Guys!
I have a Honda Dio, i'm very happy with it. The only problem is the insufficient illumination provided by its stock headlight setup.
I want to rewind its coil and convert it into full dc. Will the same process as given in the starting on this thread will be applicable on the Dio?
Will that allow me to install 60/55w halogen bulb??
Guys plz help!!
thanking you all in advance.

Do as thread starter explained in the first post, u'll not be disappointed for that. If any thing not clear come back with more details.

[sajjt]

hi all, logging in after a lot of time. that fluctuating light problem is sorted out, it was HID relay malfunctioning.

Stator Coil rewinding done successfully.

battery changed a few days back. ( it was 2.5 years old battery).

how are thing going here.

any new buddy is up on DC conversion.

Glad to hear that u've sorted out the issues and the bike is rocking

[Veeral]

Dear Doc,Abhi,Sajan, Nano.
Rewinding done on my pulsar 200. Installed APE rr unit. Everything done by NANO. I am very lucky to have him in my city. i was just standing beside him and was looking at his job.
Thanks a ton NANO.

The problem i am facing is i cant get the headlamps converted to DC. BCU is not allowing me to do so. How do i bypass BCU. As for now mechanic has installed an extra switch to on/off bulb on DC.
PLs help.

[abhijeet080808]

Dear Doc,Abhi,Sajan, Nano.
Rewinding done on my pulsar 200. Installed APE rr unit. Everything done by NANO. I am very lucky to have him in my city. i was just standing beside him and was looking at his job.
Thanks a ton NANO.

The problem i am facing is i cant get the headlamps converted to DC. BCU is not allowing me to do so. How do i bypass BCU. As for now mechanic has installed an extra switch to on/off bulb on DC.
PLs help.

Option 1 - Use older Pulsar's switch gear and bypass the BCU completely.
Option 2 - Use P220's BCU.
Option 3 - Continue using an alternate switch.

[Veeral]

Option 1 - Use older Pulsar's switch gear and bypass the BCU completely.
Option 2 - Use P220's BCU.
Option 3 - Continue using an alternate switch.

Instead of 220's i can use pul Ug'3/4 BCU too ? coz as they are also on DC setup.

[abhijeet080808]

Instead of 220's i can use pul Ug'3/4 BCU too ? coz as they are also on DC setup.

I guess so. Infact, both should be using the same BCU. (P180 UG4 and P220)

[Veeral]

I guess so. Infact, both should be using the same BCU. (P180 UG4 and P220)

Approx cost ??
i cant stay on current Switch coz its on high beam.
Cant use console lights, pilots, upper-dipper.

BTW just replacing the switch panel/BCU will do the job or i'll have to do something else also..

[segagt_0]

help!!!

hello electro guys, just wanted to ask u guys a few questions about by bike's lighting...i own a suzuki gs150r and its lighting is ac. fed up with ac i decided to join the headlights wiring to direct dc from batt(as there is no one here to do the coil rewinding and ape rr not available to make it full dc). but the prob is that the light is a bit dimmer than it was on ac. are there any ways that i can make by headlights brighter on direct dc?? plzzz help guys..

[sajjt]

hello electro guys, just wanted to ask u guys a few questions about by bike's lighting...i own a suzuki gs150r and its lighting is ac. fed up with ac i decided to join the headlights wiring to direct dc from batt(as there is no one here to do the coil rewinding and ape rr not available to make it full dc). but the prob is that the light is a bit dimmer than it was on ac. are there any ways that i can make by headlights brighter on direct dc?? plzzz help guys..

Simply tapping from the batt line to the headlights wont be a solution. U cant use the hls on DC for long without enough charging rates. Stock charging rates are not adequate to support the HL. Note that there's no short cut for this.

For dimming, check for the wire guage u've tapped. Take a fresh thick guage wire directly from batt and drive the hl with the help of a relay.

[segagt_0]

Simply tapping from the batt line to the headlights wont be a solution. U cant use the hls on DC for long without enough charging rates. Stock charging rates are not adequate to support the HL. Note that there's no short cut for this.

For dimming, check for the wire guage u've tapped. Take a fresh thick guage wire directly from batt and drive the hl with the help of a relay.

thanks sajjt..i cant make my bike a full dc because as i said earlier i dont have the availability of a good mech who know this plus cant find ape rr here...so was just wondering to try this mod and check how long the batt can handle this. my gs has got 7 amp batt.

[princesirohi]

hey guys,

I have a problem, the relay (Hi/Low relay) used in my HID installation is failing repeatedly. can anybody suggest a robust relay. i use my flash button quite frequently.

[xxbomb]

Sorry missed this post, 950 rupees is pretty steep. Last week i enquired about rewinding from an electrician and he quoted 350 rupees. As you are telling that the Ruby guys will give me a custom RR too(Is it as robust as an APE rr??), should i go with their RR / Ape one?
Will they do just rewinding??

Hey Ripper...can u share where u got that quote? i need to get work done on my bike, so was searching for info abt it. I'm from bangalore btw.

Get the rewinding from the guy who quoted 350/- and put APE RR. Custom RR given wont help in increasing charging. In simple its not meant for DC conversion.
HID doesn't turn ON with AC setup !!

Sreeni, good writeup & guide.. helps lot of people. . . thnx
& i have one more query, i hav a bonestock rx on which i have p43t dome setup, & i plan to use a 100w Philips brightlight for headlight + upgrade in horns. I'm pretty confident that the stock coil setup wont help.

What do u suggest?..
Coil rewind + rectifier change + dc setup?
Coil rewind + ac setup?

My mechanic told me to get shogun's rectifier for my rx after the coil rewind. Advisible?.. what other options?..

where do u stay in bangalore?..i need some expert advice.

Thnx!...:-)