Headlight Booster

Want more JUICE out of your stock headlight, and do not want to modify your existing wiring. Click to learn more.

HID charging conversion

Are you tired of Battery depletion everytime you uses your newly installed High Intensity Discharge Headlight, Click for solutions.

Fixing OIL drain plug thread

Are you looking for fixing that oil drain plug that went bad and unable to thread that bolt due to loose thread, Here is an easy solution for, CLICK for detais.

Led Light Solution

Wanting to conserve battery power of your motorcycle? Why not change all of your indicator BULBS, such as signal light, tail light and brake light to LED BULBS. Click for more info.


CDI is the heart of your ignition, wanting more power than STOCK but do not want to buy such RACING CDI? You need to know how it work first to understand where to START improving the ignition. Click for more.

Horn Interrupter

Want to have a horn sounds like a machine gun that produces successive sound with only one press of the HORN switch, add spice to that annoying stock horn, CLICK for details.

Reusable OIL filter mod

Paper element OIL filter tends to suffer from clogging, so why not try this filter mod I am using with my small motorcycle for more OIL flow.

Related Posts with Thumbnails

Last Updated: August 18, 2011

Headlight Booster

Want to have more juice out of your stock headlight bulbs? Headlights that are often connected to stator are not too bright that the intensity varies on a designated RPM as such like in suzuki shogun commuter bike wherein at 5000 rpm, the full brightness of the headlight can be attained. The photo below are the before and after in sequence at the same rpm reading of 5000 rpm.NTjH5m on Make A Gif, Animated Gifs

The brighter of the two already have the enhancer. How in the world i did it? considering your headlight attached to your voltage regulator to where it clips the voltage to a desirable level not to break the filament of the bulb by excessive voltage the stator is generating. The higher the Rpm of the engine, the higher the voltage it will generate, and without the voltage regulator, the BULB will instantly get busted.

Last Updated: August 12, 2011

Side mirror signal lights part III

Here are the step by step..(partial) on how to make your imitation KOSO side mirror as signal lights.
First gather all the materials i posted on this part 1 signal side mirror.

 The picture at the right is the NOT moded Koso side mirror.

And after hours of drilling, sanding, and cutting,
the back of the side mirror will look like the one on the right photo.The acrylic cut sheet will perfectly fit as if it was not there.

Motorbike Battery Care, Maintenance & Fault Finding

If a motorbike is used regularly & a few basic checks are performed once a month, a motorbike battery should be serviceable for at least 3 years. Maintenance free & gel filled batteries require very little maintenance once they have been correctly charged & installed.
However, it is worth remembering that, due to their size, motorcycle batteries can be very temperamental if not properly maintained & will not take much abuse. Correctly charging your battery & checking the battery at least once a month will usually ensure trouble free usage.
Based on numerous years of experience with motorcycle batteries, we have found that a faulty motorbike battery will usually either fail within the first month or won't function correctly from the start. Most motorbike batteries that fail after a month have failed due to being incorrectly charged or due to being abused.
Motorbike batteries are very simple in their construction & the return rate for genuinely faulty batteries due to manufacturing faults is less than 1%. It is worth noting that most motorbike battery warranties only cover manufacturing defects or faults, not abuse by the owner or failure to keep the battery charged.

Common Motorbike Battery Facts

~Although most automotive batteries are referred to as either 6 volt or 12 volt, these numbers are only assigned to batteries to make it easier to distinguish between the 2 types of electrical systems & don't represent the true voltage of a motorbike battery.
~A healthy 12 volt motorbike battery should be between 12.5 & 13.5 volts & a healthy 6 volt battery should be between 6.5 & 7.2 volts if tested on a motorbike whilst resting (ignition switched off)
~Once a 12 volt battery drops below 12.4 volts (while resting) it will start to struggle to start most motorcycles.
~Brand new motorcycle batteries are only charged to about 80% of their full capacity (around 12 volts) which is why they need a top off charge before they are initially used
~Even a motorbike battery that isn't connected to a motorcycle will gradually lose it's charge. Once a battery is filled with electrolyte (battery acid), the chemical reaction that produces electricity starts to work & the process of 'self-discharge' begins. Batteries not connected to a vehicle will discharge slower than connected batteries
~A motorcycle battery charger specially designed for the purpose should always be used to charge a motorbike battery. Car & general automotive chargers use a higher rate of charge which forces a higher current into the battery very quickly. This can lead to overheating & plate damage as motorbike batteries are not built to take this kind of charge. A motorbike battery should be charged at about one tenth it's amp/hour rating (for most motorbike batteries this means about 1-2 amp's per hour).
~Distilled or de-ionized water only should be used to top up a conventional or lead acid battery. Other kinds of water (like tap water) contain elements which will permanently damage the plates in a battery

Last Updated: August 08, 2011

Installing MOTO R analog tachometer

This is the procedure of how to install TYPE R or MOTO R analog tachometer on motorcycles, The photo shown, (disregard the blurred image)
There are 5 wires comig out from this tachometer, namely
1.Green wire
2. Black wire
3. Yellow/black stripe wire

4. Red wire
5. Solid yellow wire

The two wires that is being hold by black tube is for the tachometer backlight numbers 4 and 5.

The other 3 wires left is for the input and the supply of the tacho itself, The GREEN wire (1) sometimes mistaken by others is used mainly by china as GROUND, this is also being used by some scooters made by them..(2) which is BLACK also mistaken as ground is actually the POSITIVE line of this tachometer. (3) is the input of the tachometer...This must be tapped on the primary side of the IGNITION COIL after the CDI output....and not from the secondary side to where your spark plug leads to....

FET type motorcycle voltage regulator

This is another voltage regulator for motorcycles that uses Field Effect Transistor for better charging efficiency of the system, although still using half wave bridge system on charging the battery, the control to which the system monitors the battery condition. What makes it better is that is a MOSFET controlled device rather than the crude SCR shunt type that is on most bikes until recently and also is a 50A rated device.
MUCH better voltage regulation and runs cooler too due to more efficient devices and control circuitry.The SCR shunt type consumes more energy in the Regulator itself than the bike is using and dumps a ton of current into the heatsink (feel yours & just see how hot those things run!!!! - don't touch it - you'll burn yourself - seriously!) The problem is exacerbated because their efficiency goes even lower when they get HOT so it's a vicious circle. Heat is the number 1 killer of these devices.
Incidentally its a misconception that shunt type work harder with increased load i.e. higher-wattage lights, etc - actually, the higher the load on the output, the less work the shunt regulator does in dumping that excess energy and will actually run cooler!!

The FET has extremely low resistance in conducting state and this results in a lower dissipated power from the device while conducting load current, as opposed to the SCR which shunts the maximum current across a significant volt drop, resulting in a higher dissipated power - and resulting temperature, much more so than the FET device. 

The picture shows a typical FET type voltage regulator for motorcycles, as opposed to the SHUNT type to where an SCR is used to control the windings to generate more than enough on the system, here an FET is used tag as Q5 in the diagram, IC2a is the control circuitry of the battery charge and discharge. D1 and D2 is the rectifier that converts the AC voltage of the stator to DC that charges the battery.

Last Updated: August 01, 2011

Voltage regulator, A summary

Before attempting to use all circuits here regarding voltage regulator for motorcycles, let us first differentiate the two system. Not all machine are the same especially with the design of the voltage regulator. There are single phase system that uses half and full wave charging system, and three phase system that uses half wave system..By looking at this block diagrams, you will be able to determine what system your bike uses by following the connection. FJPGVS6ZRZW7

First and foremost, the single phase, the picture above illustrates a single system half wave regulation, you can see that the one end of the stator is connected to ground, via earth ground, the coil has also a center tap on the winding for your headlight and the output will also be regulated by the voltage regulator..this kind of regulator is a single phase half wave system, if the end of the winding is no where connected to ground then the system will be a full wave.

Iron Cast Wheel repainting

We all know that cast wheels made of iron is prone to rusting. This what happened to my sinski scooter cast wheel, and so its time to repaint it. Firstly, we have to scrap all rusted parts with knives, sandpaper, and put anti rust primer on it to stop the rust. I have not put out the tyre from the cast wheel so i'll be using the power of masking tape to mask unwanted area not to be painted.
The picture shows my iron cast wheel with red primer been applied. I also mask the area of the tyre ready for paint spray. But wait there are still some area of the tyre not covered. Well, its time to have some old newspaper for the covering of the whole tyre.