Hi folks,
My Vijai Super being my dily runner to office, had lost attention due to personal & family chores piling up. Anyways it was still doing good until I felt some misfires once in a while during sudden closure of throttle from a constant speed. Gradually the occurance of misfires increased and in the last month I was never able to cross 40kmph (while it did 100kmph 6 months back). One fine evening while I was just about to reach home from office there was a loud pop and the scooter never started again. It was all because I was posponing the adjustment of points immediately after the first occurence of misfires. Well no that I am forced to open up the flywheel to replace the points, I thought it was the right time to rewire for DC setup so that I can have a battery and a better horn for daily use.
The parts you need now are
1) A new point (had 1 already)
2) 1 long & 1 short lighting coil of LML Vespa (Rs 75 each)
3) Tools - Soldering iron, screw driver, 6-7 spanner, a plier or a nose plier
After replacing the point, unscrew the condensor. No need to de-solder the black or green wire.
Using the soldering gun de-solder the brown, red & violet wires soldered to the coils. You dont need these wires anymore. You can pull then out of the black sleeve (Keep just 1 unwanted wire in the sleeve for now).
The coils for Brake lamp & Tail lamp will be replaced with the coils from LML Vespa or HLighting coils of Vijai or Lamby. New Vespa lighting coils & the Lamby lighting coil are shown below
Carefully undo the tab that retains the brake and tail lamp coil. Take help from a friend to hold the coil plate while you slowly tap the coil out of the stator. You may use a Nylon mallet or a piece of wood and a hammer here. It is time to clean the stator plate. You may use a carburettor spray or some kerosene and an old tooth brush.
Insert the longer ligting coil into the brake light slot & the shorter one into the tail light coil slot and bend the thin steel tabs so that the coil is held tight. Be careful not to bend the tabs too much that the coil gets squeezed or the bobbin breaks. Put back the condensor in its place. The mechanicals are done and we are half way through.
Now comes the electricals. One has to de-solder that end of the OE lighting coil which is grounded. One has to connect all the 4 lighting coils in series. Care should be taken that the outer end of one coil is connected to the inner end of the neighboring coil.
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Take 2 long wires, almost 70 cms long on the safer side & of the same core thickness as the brown wire. Solder them to the free ends of the lighting coil. Remove some insulation from the 2 new wires and wind it around the left over free wire in the sleeve and pull the new wires through the sleeve. And you are done with the coil wiring. You may use a multimeter to check for continuity of all the soldered joints and the wires.
...to be continued (with wiring an AC regulator or a Rectifier unit)
Note: This conversion could be extended to a Cento also.