I’ve resisted this modification for awhile. But after reading reports of failing regulators / rectifiers (RR) and stator coils – not just on the Bajaj Pulsar 200NS, but not an uncommon failure on almost any motorcycles, I’ve decided to add a voltmeter to the bike so that I can keep a constant eye on the health of my motorcycle’s electrical system.
By the way, did you know that the number one cause for RR and stator coil failures is NOT the addition of electrical accessories, but rather a bad battery? The typical electrical loads additional (reasonable) accessories demand from the bike’s electrical system is usually very, very well within what the electrical generation system can handle. But when a battery goes bad, and if a single cell within the 12V lead acid battery shorts (a typical 12V battery has 6 cells), this draws a significantly increased amount of current from the bike’s electrical generation system. This large current draw puts a tremendous strain on the electrical system until something – typically either the RR or the stator, or both – gives way and burns up. So remember this – periodically replacing a battery BEFORE it goes bad is good preventive maintenance for your bike’s electrical system. And this is one reason why I choose to replace old batteries instead of waiting for them to go bad.
After my IU power re-wiring, my motorcycle could now rest for more than 6 weeks without starting up and the battery is still good for firing up the engine. I’m happy now. However, in the meantime, I’ve received several well-meaning advise from fellow motorcycle riders that such a modification – the re-wiring of the power of the IU to only come on when the ignition is turned on – is not allowed / illegal under the Singapore Land Transport Authority (LTA) rules.
I tried searching online to find out if there is any truth in this. But search as I might, I couldn’t find any official rule or law stating whether this modification is legal or not. LTA does publish a list of allowable and non-allowable (illegal) modifications one can perform on their private vehicle, but the IU power wiring was stated nowhere. The only “sources” (if I could even call it a proper source) that I found were forum postings of people discussing the legality of the modification. There were even some forumers who claimed that LTA informed them that the modification makes the vehicle illegal and will fail the (required) annual inspection when brought in to one of the inspection centres.
Honestly, unless the government’s goal is to be “big brother” and wants to track the vehicle 24/7 (if that is even possible with the current generation of IU units), I cannot phantom why such a re-wiring – for the purpose of conserving battery on a lightly used vehicle – would be illegal. So, not satisfied and not wanting to get into any legal trouble with the authorities, I wrote in to LTA and enquired.
I wrote about my killing of the motorcycle battery by deep discharging it some time ago. I also later found out that it was the IU unit that was eating up my battery juice when the bike is turned off. Previously, it took only FIVE days (5 DAYS!) of not firing up my motorcycle to completely drain my battery to levels where even the instrument cluster refused to work. And it didn’t just happen once, it happened a whole of 3 times before I swapped out the IU power wiring to only power up the IU unit when the bike is turned on.
Now, I’ve been a little busy of late and admittedly haven’t been riding my motorcycle. Boy! I sure missed my Pulsar! Anyway, it has been SIX weeks (6 WEEKS!) since I last fired up my Pulsar’s 200cc engine. So, out of curiosity, and before I fired up the engine again, I removed the seat cover and measured the voltage of the 6-week-neglected battery.
12.57V! That’s a VERY healthy voltage!
So with some excitement, I put the seat cover back, and mounted my motorcycle. I inserted the key and switched it on – so far so good! And then I hit the started button.
Ahh! The sweet roar of my Pulsar coming to life after 6 weeks of neglect was pure music to my ears! Needless to say, I took her for a spin today, with a huge smile hanging on my face.
Since I published the blog posts on my dead motorcycle battery, I have received a couple of queries asking me what I used to charge my lead acid battery and where I bought it from. And after I told them that I built it from some electronic scrap parts and it cost me close to nothing, they were surprised.
So, I’ve decided to write this post to share with you on how you can build your very own DIY home made battery charger for almost free – well, if you already have most of the parts like I did. And even if you don’t, you can probably get it quite cheaply from an electronics parts store such as those in Sim Lim Square. Continue reading “$1 DIY Motorcycle Battery Charger”
Arghh! I couldn’t start my motorcycle again this morning! The last time I fired up my Pulsar 200NS was Tuesday – that’s only 5 days ago. Granted, I haven’t been riding much. But still, it was ONLY FIVE DAYS!
Since the last battery death and replacement, I’ve double checked all my additional electrical components, and am ABSOLUTE CERTAIN that, apart from the IU, none of the other additional electrical circuits are powered up when the bike is turned off. I’ve even went so far to remove my remote controlled alarm – which I suspected could be the cause of the battery drain.
After I killed my motorcycle battery with a deep discharge just barely 3-months after installing it, many have asked me if I considered replacing it with a technologically newer lithium-ion, or specifically lithium-iron-phosphate (LiFePO4) one. For awhile, I did explore to use the opportunity to “upgrade” to a lithium-based battery. But before that, let’s consider the merits and pitfalls of it… Continue reading “Lithium-Ion batteries in Motorcycles?”
I had only replaced the battery on my Pulsar 200NS motorcycle 3 months ago – just before I took it on a 2-month tour around SE Asia. My previous battery was about 2 years old and I didn’t want to risk a bad battery on the trip.
But shortly after returning to Singapore, and while performing maintenance on the bike, I had absent-mindedly left the key in the ignition and in the ON position. That severely drained the battery and was left with less than 5V. After an eventful jumpstart, stalling the engine down the road, and a good samaritan assisting in “push starting” my bike using his own motorcycle and his leg, I managed to get to KL and back without incident.
If you’ve read my previous post on my extra wiring, I’ve introduced an automotive fused relay to my 200NS. This relay controls power to my auxiliary devices such as LED fogs, USB power, and remote alarm signal.
Long weekend project…. Got a pair of these LED fog lights for my bike and a handlebar on-off light switch. Was figuring out where to put the light switch as my handlebar has no more space… So ended up installing the switch on the engine crash bar instead – just beside the LED fog light.
For those who may be technically interested, the LED fog has 3 modes – high, low, and flashing. Draws 850mA on high, about 250mA on low, and approximately 480mA on flashing mode. So my 5A fuse provision for this is definitely way more than enough.
Had previously installed my bikecam and USB power port at a bike shop. What the mechanic did was to hard wire the bikecam and USB outlet to a “Ignition ON” wire on the bike. No fuse. When I asked him what if one of these cheapo made-in-China stuff short circuits? He told me that the main fuse will blow lor.
I never liked the idea of blowing the vehicle’s fuse with these “add-on” stuff. Because, the quality of these stuff are sometimes questionable, and blowing the fuse will leave you stranded.
I’d much rather have a separate circuit with its own fuse to support these aftermarket electronic add ons. So, I headed to the drawing board and came up with this…
Edit: Subsequently repalced the 30A fuse with a 10A, and the 20A fuse with a 5A one instead.