Mr.Boss. Aplogolies for hijacking your thread. But being a pulsar topic and you also wanted to upgrade. Hence took the privilege to share my experience here itself. The bike being experimented here is a UG2 Pulsar 150 Dtsi. It has analog meters, spoke wheels, disc brake in the front, no LED tail lamp and no BCM. Re-soldering the stator wire to accommodate a 4 wire rectifier in place of the old 4 wire RR unit was relatively simple. In the self start model it was not required to remove the flywheel to detach the stator plate assembly.
How to re-solder the wires?
In the stock setup the Blue-white is the input to the rectifier side. And the Yellow - red wire is the input for regulator side. Both these wires originate from the same coil of wire. One end of this coil is body grounded. The other end is the Blue-White wire. The Yellow - Red wire is tapped somewhere in between in the same coil.
1. De-solder the body ground from 1 end of the coil set.
2. De-solder the Yellow-Red wire
3. Connect the de-soldered end of coil in step 1 to the Yellow-Red wire.
Use heat shrink tubes or sleeves and a few drops of glue to safely route the wire between the coils. This is all needed to pack the stator back to the vehicle.
Use a Piaggio Ape 4 wire rectifier unit.
How to connect with the Rectifier unit?
1. Remove the old RR unit and its capacitor
2. Connect the Blue-white and the Yellow - red wires to the grey wire in Ape rectifier
3. Connect white wire to the yellow wire in Ape rectifier
4. The ground wire Ape rectifier can either be body grounded or connected to the battery negative directly
How to supply 12V DC (in place of 12V AC) to the headlight wires through the key switch?
There are 2 ways to do it.
1. Out of the 4 wires in the connector for old RR unit the yellow wires carried 12V AC to the switch. The nearest source for 12V DC from the ignition switch is the rear brake light switch or the indicator flasher.
2. The same yellow wire could be identified at the switch terminals near the handle bar also. 12V DC can be tapped directly from the ignition switch too. The regulator unit of Pulsar 135LS can also be used. The wires are Blue-white in place of Grey in a Ape rectifier.
Attached pictures of the stator plate