Project is almost completed! By davidstipek (Read 1,724 times)

[davidstipek]

Okay... The Custom Framed Suzuki RC110Y Electric Start Chopper is here I used NSR150 Honda Complete rear fork assembly/wheel/disc brake... (Nice Suspension Ride... ;D)

I still have to change front fork assembly to use NSR's here also. Will do 3 things.
1: Raise front 5 - 6" even going from 18" wheel to 17".
2: Give me Disc brakes here too!
3: Add a matching wheel if front to rear one

I have one small issue it seems that in the city rides the Battery will not charge. Thus after a few starts using Starter... Thank God for the Kick... ;D I know the RPM's are not quite high enough to do this quickly. Battery is new Gel 5Ma as specifyed for Electric start in Manual, Starter is new also because... I was being overly cautious

Thus I have (I think...) a solution.

I have a complete Spare Stator Plate and coils. Ignition coil is good (new) Lighting/Charge coil is defective... so... I was going to do a rewrap on it. (have done before)Charging, white/red lead is connected to a 23' coil, other end is connected to Yellow lead Lighting, plus the other coil. This coil (lighting) is 40.5' and connected ground connection at other end.

Now I can do this 3 ways:

1st: I can rewrap as originally done. lighting coil 40.5' then because I have the room extend or make charging coil same length (40.5'). This will either increase Voltage or Wattage.. Not sure which but I believe it will do it at a lower RPM.

2nd: I can wrap the same as above, but increase coil wire from 20ga to 18ga.

3rd: I can float the coil and remove ground. make total length of coil wrap 80 - 100' and change output to 12VDC.

My questions start here..

1. Will this eliminate the Rectifier?
2. Will I need to add a diode in white/red lead and yellow lead's?
3. I will connect white/red to Red fused lead to battery and yellow to white lead? (These were the reaining wires on rectifier.
4. I need to add a regulator in Red lead before fuse and Battery, correct? draw me a simple diagram

I am not sure what increasing coil size and floating coil will do @ same time... other then completely eliminate 12VAC on bike Right now the only place 12VAC is going is to Rectifier. Everything else is wired 12VDC.

David

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[justbuggin2]

I am not sure what you are trying to do but you will still need a R/R in the system what I have done is convert over to an 11 pole system and a bigger battery for an Hog I now have no problems with starting and I am running an EFI system with electric fuel pump

[davidstipek]

I cannot put 11 pole system in place of original stator.
No room

Correct me if I am wrong.
The reason for Rectifier is to convert 12VAC to 12VDC, Right?
If I float coil and remove ground I have done this... (What is rectifier going to do... convert DC Voltage back to AC Voltage?)
I know I will need a Regultor to dump excess Voltage.

As far as Battery, I bought the Biggest and suppose to be quickest recovery that is available here.
My issue seems to be that the charging voltage is below what is required to fully maintain Battery, or even Original acid 5Ma Battery. It seems that at 3500-4000 rpm I get the max @ 12.4V. I cannot keep RPM at this rate I will go broke replentishing fuel...

I have attached a picture of complete Statr as I removed it, before I unwrapped Charge/light coils. Ignition coil is perfect! will not touch it! Somewhere around 40,000 V being created here as touching can attest too ( Knocked me on my Ass! Big Time!!)

David

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[davidstipek]

I (8) wish I could store up this and wire it to a mat so when Salesman rings bell... ;p They get Their Bell Rung! o))

[tvnacman]

I was checking the 7pin regulators the other day , just for the heck of it while checking output voltage I unplugged one yellow wire to see how it would effect output . It maintained 14vdc , it makes me think I could use the 7pin regulator with a single phase stator . I would think it can be used on a floating ground set up as well . This would solve the problem with the 4pin regulator .

John

[davidstipek]

John
check and see what voltage you have @ yellow and white/red stripe leads from Stator... This is where my issue lays. I am not developing over 12VAC.

This was why I had chosen to rewrap both coils on charging/light coil. Maybe even go to 18ga wire as I have plenty of room. I had wrapped wire on coil before I removed old to see how much more could be added... was 45'! I know this is 20ga but still I could it seems make both coils 50' with room to spare...

Again back to you John... I have posted a picture of my complete Stator plate and Coils... is your like this? or is it in Star pattern? with multiple charge/lighting coils and one ignition coil... Can I install.. or is there a conversion to replace my stator with the star shapped one? Remember my flywheel cover has fan wheel attached to blow air thru head and cylinder wall to induct cooling, thus engine is called "Jet cooled"
David

[davidstipek]

[replyingto=tvnacman]tvnacman[/replyingto]John
Another thought... If I wrapped coil base with the idea of ignoring ground and did my first coil starting with yellow lead, then at 50' attached 2nd yellow lead and started 2nd coil (again a 50' wra and at end attached 3rd yellow lead... Could I not use the rectifier/regulator you are refering to?
Hmm... Forget it this won't work!
1. yellow
2. yellow
3. yellow
All 3 coils need to connect at one end and the other needs to attach to 1 of the 3 Yellow leads!
4. red - same Tie together (Battery/Fuse)
5. white - same Tie together (Ignition switch)
6. earth

What is 7 pins?

David

[davidstipek]

Aug 25, 2013 10:11:01 GMT -6 davidstipek said:

John
Another thought... If I wrapped coil base with the idea of ignoring ground and did my first coil starting with yellow lead, then at 50' attached 2nd yellow lead and started 2nd coil (again a 50' wra and at end attached 3rd yellow lead... Could I not use the rectifier/regulator you are refering to? Hmm this is...
Forget it this won't work

1. yellow
2. yellow
3. yellow
All 3 coils need to connect together @ one end and other be connected to yellow lead!
4. red - same
5. white - same
6. earth

David

John

So... I would wrap 3 coils on same frame tieing all ends (at one end ) together then doing my 40-50' wraps and tie @ open ends to each coil with one yellow lead...

I looked @ a 650 Suzuki and it used a 5 wire rectifier/regulator:

3 yellows - Charging Coil @ Stator
red - Ignition switch/Battery (I would tie red and white togther at this point
Black/white stripe - ground Harness/Battery/frame

What resistance do you have between yellow leads? This would tell me how long to make each. Also what gauge wire do you think is wrapped on coils?

If I could use 3 wraps of 40' each, and 18ga wire, I believe I can get all on coil base. Would I need to wrap end of each coil with mylar? I am using coated wire (joking)

What I would like to see is 13-14VDC @ low (500 - 1000 rpm). Right now I have below 12VDC and @ city speeds does not charge Battery fast enough. If I disconnect Battery with bike running it does show same Voltage... Bike will continue to run, so it is creating power, I believe the CDI needs to see close to 12VDC to fire engine... correct?

David

[justbuggin2]

a R/R does not only convert from ac to dc but it also maintain a set voltage now when the motor rpms go up so does the voltage if the voltage gets to high you will burn out light CDIs and other electric items

[davidstipek]

[replyingto=justbuggin2]justbuggin2[/replyingto]Yes
I agree!
But if I already have DCV then I can add two diodes to keep backflow Voltage from Stator and add regulator to red (battery/Ignition switch) lead?

David

[davidstipek]

[replyingto=davidstipek]davidstipek[/replyingto]Guys
In the attach diagram you will see stator and rectifier diagram. Question if Voltage on yellow leads is 12VAC, then is the common end to all coils...Grounded?

If not, would they not create DCV?

Reason I am asking as maybe wrapping Coil frame this way will give me the voltage I need... What you all think?

This is still just a 5 wire R/R what is the 7 wire tvnacman is talking about?

David

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[davidstipek]

[replyingto=davidstipek]davidstipek[/replyingto]Ahh... I was wrong I see the 7 wires dual Ground and power leads, Makes 7!

Now seperate question from the others but along same lines...

1: Could I wrap coils same as 650 does?
2: Tieing all 3 coils together at one end and the other ends to each of the 3 yellow leads from R/R? I can do 3 coils of 20ga no problem.

Last question
3: Is the common end to all 3 coils Grounded? or is it floated?

This may well be the solution I need. Depends if I can do all 3 coils on same frame. (Actually, Yamaha 's Y80 Belle did this. But they did it side by side not layered as Suzuki (Crystal) did with original wrap on RC110)

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[davidstipek]

[replyingto=davidstipek]davidstipek[/replyingto]Does no open have any ideas on this subject?

I need to know the best way to....

1: increase AC Voltage available
2: Or Amps output
3: If I can wrap coil base as 3 x 50' coils
a: If common end coils (all 3) in grounded

If I can do #3 then I can use 7 wire R/R... John you mentioned this Rectifier... Can I do the 3 coil wrap??
David

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