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Post by 2btiger on Mar 20, 2009 12:53:37 GMT -5
I am almost done with what I think are the necessary upgrades for my scooter. The last part would be upgrading to an 11 coil stator, 7 pin rectifier, DC conversion and HID install.
Now I've looked through several threads and have a decent idea of the conversion but I have not seen a comprehensive explanation of all 3 upgrades working together ( coil, dc, HID).
I have unique situation where I have full access to the whole wire harness on my scoot, so I'll assume no multimeter needed for tracing.
At the end of this I hope all Dawgs who have had success with one, two or all these can come up with an explanation/ tutorial that someone can explain to a 5year old learner like myself.
Thanks in advance guys.
Tiger.
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Post by gy6rocket on Mar 20, 2009 15:05:00 GMT -5
Well since I am asked about this conversion about once a week, and there seems to be a general lack of information available about the conversion, and I am doing some art development for a website, and am just feeling good today, I decided to expand on an earlier drawing I did about the GY6 ignition. So without further a due, may I present the full color GY6 11 coil conversion wire diagram. Hopefully this answers a lot of questions. You can thank me with dawg bones, this took over an hour to create. Right click > save as for high resolution file.  |
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Post by kink on Mar 20, 2009 15:41:41 GMT -5
you are the man.
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Post by kink on Mar 20, 2009 15:42:34 GMT -5
PS: if anyone knows someplace with an 11 magnet rotor in stock please let me know. i've been searching for a while now.
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Post by 2btiger on Mar 20, 2009 16:17:56 GMT -5
Bless your little heart gy6rocket, have a couple bones on me. I've copied pasted printed and framed this diagram in addition to your others. They now hang in my office as I have no garage, just a shed lol.
I am now looking to Pepboys or Radio Shack for new wire blocks since I really don't want to splice or use several new connections, just looks tacky.
Rocket (can I call you rocket), I hate to ask for more, maybe not just from you but I've also sensed Dawgs shudder at the thought of a multimeter, so if anyone has a site, or diagram or tutorial of a basic meter, I think this is the best place to put it.
Kink I got lucky with a guy selling the set on ebay, but we really need to put pressure on our dealers since they seem to be out of stock everywhere. I see threads get hot about Cams and dealers and ebay are swamped with cams, I see hot Carb threads and all of a sudden we start seeing carbs like X-Mas. Unfortunately 11-coil upgrades, one of the simplest, just doesn't make the11 magnet flywheels come out, go figure. I'll keep hunting and if I find anything I'll let you know.
Peace & Pistons.
Tiger.
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Post by gy6rocket on Mar 20, 2009 17:57:01 GMT -5
I just picked up this model at microcenter on sale for $12.99  Its a great meter and has a back light for those dark areas. www.vellemanusa.com/us/enu/product/view/?id=350297#I would recommend it as it works great and does not break the bank. Make sure to get digital, as analog are much harder to read, especially for a newbie. |
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Post by 2btiger on Mar 20, 2009 18:20:02 GMT -5
Thought we could use the simplest video done by a child.
There are several others for more help if needed, if you did need em' have fun.
Tiger.
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Post by 2btiger on Mar 22, 2009 9:26:50 GMT -5
Ok guys I found a little time today to start working on my electric system. Every thing is fine but I did find an interesting splice in my stock circuit ( 6 pole stator, 4 pin rectifier), seems that the yellow wire has2 splices , one spliced into another yellow leading to the enricher and the 2nd leading to a brown which appears to be power for the lights both front and rear.
If I follow the diagram for the 11 pole/7 pin upgrade correct, I should break the enricher splice and run it directly to the white wire of the 7 pin rectifier? And the black wire to the brown (main harness + positive) ?
If I've got it wrong pleas correct me. I understand circuits on paper, I'm not ashame to admit practical application makes me a little nervous.
Tiger.
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Post by gy6rocket on Mar 22, 2009 9:49:07 GMT -5
Yes you need to pull everything off the AC circuit (headlamps and enricher)
The 7 Pin Regulator has a wire for the enricher (white)
Everything you have stated is correct.
Splicing the brown headlamp wire to the black ignition wire will result in having your headlamp switches run on DC.
Don't forget the relay for the HID!
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Post by 2btiger on Mar 22, 2009 10:16:32 GMT -5
Thanks for the confirmation. Great found a rouge black wire in the shroud from the stock stator wires, got to take a break before I trace it. I can hardly wait until I have time to totally rewire this thing. Going to get a few new connecting blocks/ harness clips in an hour or so, any suggestions would be accepted. ;D
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Post by kink on Mar 24, 2009 6:46:08 GMT -5
yeah my winter project for next year is a complete rewire of the bike. too much extra crap in there...
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Post by timmyjane on Mar 24, 2009 9:27:03 GMT -5
why do you have to use a 7 pin? the Znen/Lance/fly scooters all come with the 11 pole stock and they only have a 6 pin. what is the difference?
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Post by kink on Mar 24, 2009 9:52:57 GMT -5
the other wire is used on some systems to monitor the battery for charging purposes. if you are using a good quality battery on a 12 volt system this should not be an issue (or so i have been told by others who have done the swap).
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Post by brahdahood on Mar 24, 2009 13:06:02 GMT -5
gy6rocket - did you have to change out the Flywheel for the 11 pole? I currently have an 8 pole Stator and Flywheel, I need to know if I have also order a Flywheel to accompany the 11 pole.
Much Thanks!
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Post by kink on Mar 24, 2009 13:52:43 GMT -5
yes, the number of magnets on the flywheel must match the number of poles on the stator or it won't work.
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Post by brahdahood on Mar 24, 2009 22:33:45 GMT -5
How can you tell the difference on the flywheels? besides the stamp of 125 and 150 on it.
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Post by kink on Mar 25, 2009 6:47:07 GMT -5
presumably they will have more or less magnets glued to the inside... i haven't ever actually seen one or removed the stock one on my scooter.
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Post by 2btiger on Mar 25, 2009 8:10:24 GMT -5
ASSUMPTIONS: 11 coils = 11 or so magnets. The new magneto will be bigger or more shallow to accommodate the new stator.
Sorry I forgot to take pixs of the new flywheel but I'm ordering a 2nd one (I always try to get parts in pairs) since it's electric an electric failure is an irreparable reliability failure.
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Post by kink on Mar 25, 2009 9:40:45 GMT -5
ASSUMPTIONS: 11 coils = 11 or so magnets. The new magneto will be bigger or more shallow to accommodate the new stator. Sorry I forgot to take pixs of the new flywheel but I'm ordering a 2nd one (I always try to get parts in pairs) since it's electric an electric failure is an irreparable reliability failure. I agree with you that 11 coils = 11 magnets. It needs to be that way in order for the phase of the AC output to work properly with the ignition. I'm pretty sure the flywheels are a standard size and depth regardless of the stator. The stators may have more poles, but they aren't physically any bigger. The poles are just clustered closer together around the radius. The magnets on the flywheel are tiny and don't take up a lot of room either so there is no reason to modify the flywheel. Also the cooling fan is mounted to the outside of the flywheel and it has to remain a standard size to work properly. As far as ordering sets of 2 parts: that is a fantastic idea especially given how difficult it is to find some of the electric parts. However, coils CAN be repaired by removing all the coil wire and rewinding them. You can also increase their output by winding more wire around the coil, at the expense of increased heat and drag on the engine. This is an old motorcycle trick that I found out about from a friend of mine who builds custom bikes out of salvaged parts. |
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Post by gy6rocket on Mar 25, 2009 23:15:19 GMT -5
This is correct. Jack the fuzz documented how to rewind an 8 pole stator for more output in the 'electrical systems 'must read' thread.
Yes you need new coated copper magnet wire. Also using a smaller gauge magnet wire will allow for more turn per pole increasing output. Also how neatly the rows of coils (or turns) are arranged will increase output. Oh this is taking me back to electronics block class in high school when I constructed and wound my first DC engine!
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Post by xs650 on Mar 25, 2009 23:53:25 GMT -5
This is correct. Jack the fuzz documented how to rewind an 8 pole stator for more output in the 'electrical systems 'must read' thread. Yes you need new coated copper magnet wire. Also using a smaller gauge magnet wire will allow for more turn per pole increasing output. Also how neatly the rows of coils (or turns) are arranged will increase output. Oh this is taking me back to electronics block class in high school when I constructed and wound my first DC engine! It took me a while to find it with search. Maybe this will save someone some time. scootdawg.proboards59.com/index.cgi?board=talk&action=display&thread=8929 |
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Post by gy6rocket on Mar 26, 2009 0:26:17 GMT -5
Here is a graph from that thread about why an 11 coil is superior to a 4, 6 or 8 pole style. the 11 coil uses 3x banks of 3 coil windings. (9 coils) for charging and 2 coils for ignition output, (9+2=11). The 3x banks of 3 coils creates, 3 phase current which is shown in this bottom row of this chart: (BTW) Rectified + Filtered AC = DC current  DC output is much more stable. When testing with my mutli meter each 3 coil bank outputs about 4.5vac - 5vac depending on the engine RPM, resulting in the post regulator system dumping 13.5vdc - 15vdc into the battery. Unless you dump over 12v into the battery , it's not really going to stay charged. |
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Post by leinahtan36 on Dec 13, 2010 0:20:09 GMT -5
hello there from philippines i wanted to do this mods on my gy6 stator but i cant find the link the thread starter had created
do this modification really works for hid system on gy6?
thanks in advance and advance merry christamas to all.
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Post by sledwrecker on Aug 4, 2012 5:27:39 GMT -5
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Post by orphansoul on Aug 4, 2012 14:31:06 GMT -5
You'll get more answers if you start a new thread instead of digging up one from 3 years ago. It may be better to go to an HID forum and ask that question. They know the systems better than most on this forum. |
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Roketa MC-60 
Tiger Cub
