Convert AC/DC bike to ALL DC.

[sreerama]

This is the wiring diagram of Lets with the magneto from parts catalogue. Also thinking of using some DC RR with capacitor. Is it possible to use Gixer's if it's a direct fit?

[sreerama]

Re: Convert AC/DC bike to ALL DC.

My friend owns a suzuki access 125 bs 4 model, and would like to convert his scooter to full wave DC. Which i assumes involves removing the lighting coil tap {no lighting tap on access bs 4 coil} and removing the coil ground to make it a floating coil.

As for RR reading through the the thread i gather the RR available in market are the 1. APE RR 2.P180 UG 4 RR are there any other RR which can be bought?

I would like to know beforehand so that i can buy the one available in the market without having to go there twice!

Also from the pic i received frnd he friend,i drew a diagram. following are the connector color coding for the bs 4 access, Will also be upgrading the battery to an 5 Ah one from the 3ah now!

Updated the image with wiring color coding.

[ATTACH]252340[/ATTACH]


Has anyone come across Ape RR made by Minda and Varroc? Minda RR-8002 and Varroc REGR APEN PI65 Cheaper than the OEM RR.

Not going for APE as my primary concern is switching to DC and running an 35 Watt led headlight that's it.

The thread seems inactive, i'll update my progress any way so that anyone wanting to convert their Suzuki Access to DC might find it useful.

Suzuki access BS 4 has a 12 pole single phase stator with single ac output, no lighting coil output tap. they use a RR which outputs regulated via a grey wire to the ac powered headlight etc

In stock condition the stator uses a 20 SWG wire with about 52 turns on each pole.

[ATTACH]252341[/ATTACH]

[ATTACH]252342[/ATTACH]

I have rewinded it using 19 SWG and put a contact point made of aluminum rivet to connect other point of the coil as this was using a single wire to output AC. It's a tight fit and glued in place with fevikwik 203 cyanoacrylate adhesive.

[ATTACH]252343[/ATTACH]

The coil on the ACCESS is quite capable and will work even if you don't rewind it, but i still did it incase i decide to load it a little more. Also the BS 4 access stator is not inside the sealed shut crankcase, its just covered with a plastic cover so removing the coil is hassle free.

Also i will be using a Gixxer 155 RR as i find it to be quite beefy (Heavier & Bigger Heatsink) compared to Yamaha SZR and Fazer, fz 16 etc Also anyone thinking of using fz RR should be careful as it has fused and conducted AC to the instrument cluster etc and killed it for a lot of people. Gixxer 155 has a 5 pin RR but only 4 are used on the bike, and 4 will be used on the access. As long as you don't put insane amount of load like above 90 watts it will be fine. Who uses HID these days anyway? LED Headlight upto 55/60 w will work easily, roughly 7 amps in total load.Will help converting rest to LED leaving turn signals aside as they are used intermittently.

The rewinding 19 swg wire cost me around 150 for 200 gms and some varnish ans shrink,sleeves totaling to under 250.

Will update more as i get time to work on it more.

We have Suzuki Lets Bs4. Recently noticed that the headlight light output is low, when measured got only 7 to 7.5 volts where I expected 12 volts for light. When measured the battery charging voltage it measures 14.4 volts. Swapped RR unit from Suzuki service centre to check if the Headlight voltage improved but there is no gain, so switch back to the original one.

From the wiring diagram, looks like there is no seperate lighting coil and there are 12 poles in the parts manual, similar to the ones mentioned in the quoted post. Single wire from the strator connects to the RR +ve side which is also charges the battery. So looks like either RR is intentionally reducing the voltage to 7.5 volts for headlight AC circuit or Strator is not producing enough voltage. Don't think the later is the case since the charging output is 14.4 volts. Do you have any thoughts on this?

[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).

[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..

[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

[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 ?

[Toshar Deven]

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

[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

[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

[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.

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

[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

[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

[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.

[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