Query approved.

can you please elaborate on what kind of noise are you getting......and your bike had done how many kms....

the sound iritates me. Its as if there is a grinding sound on the left side near the magneto. One comment on the internet talking about the one-way clutch assembly common problems encountered here.

thanks for the help!

thats odd the p220s clutch assembly is situated on the right side of the engine ,

Yes the starter one way clutch going bad can give you the noise..get it checked ,before it disintegrates,and kills the motor also.
Also check if your Chain is Clean and lubricated, and the Drive sprocket(small sprocket) is ok.

Precisely the problem with my 180. The starter clutch makes noise and the engine vibes are more than my colleague's 180. Will get it checked out in the next service. By the way, one of the common excuses SVC guys give for higher engine noise is something with the timing chain. Can someone shed some light on it?
And also, does the balancer gear (or whatever it is called) setting require some attention? Mine has done 7500kms.

always makes sure of the chain lubricated using PJ1. Re: the clutch assembly is there any modification that i can do for not to be noisy? Perhaps change it to a compatible japan made clutch assembly? Would you know anything that can match with other models of Kawasaki?

You dont need to change the entire clutch assembly. This particular problem was with the first few lots of Pulsar 220 DTSi (Prior to January 2010). Later on it came rectified from factory itself. Whoever had the said problem, the problem was rectified for free by service center people under warranty. Don't worry they will not open the entire clutch assembly for rectifying the problem. And it will hardly take the Service Center mechanic 20 minutes to get it done. No need for any modifications as an incompatiable clutch will cause much more problems than the ones you already have and anyways, it is not the clutch which is the culprit here and so in the end, even after your little modification, your problem won't be solved.

End result : Stay stock.. go to SVC and get it done properly.

very well said thank you my friend! Now have to go to Kawasaki Motors Service Center to have it checked. Again Thanks! Pulsar here in the Philippines is bought by the Kawasaki this why we call the pulsar as ROUSER. I will inform you guys as soon as it's done.

my friend any suggestion for I want to replace the stock CDI to a racing CDI. I am thingking of BRT Bentang CDI! I experienced and very very seldom actually only twice it happened that, I was cruising for about 35kph then all of the sudden my engine stopped. When, I was starting it, it won't start and have to wait a minute or so before it started. Also experienced that, while i was running about 60-80kph and have to close throttle because of a hump on the road i hear backfire. This only happens very very seldom. Any suggestions? What kind of CDI does Pulsar 220cc has?

would you have any ideas on how to resolve such problem? Does it has any adjustment? Do, I have to replace anything?

@boxter83:
Backfire and switching Off of engine clearly says an improper tuning or the prescence of a foreign content... Get the carburetor cleaned..

Why do you want to change stock parts with aftermarket ones? Changing the CDI will not solve your problem of stalling. The reason for the backfire might be because you could be running excessively rich air-fuel ratio. What kind of fuel efficiency do you get on your bike there (km per liter / miles per gallon)? A properly set Air Fuel ratio will ensure good power delivery, good fuel efficiency and high engine life. No racing CDI can give you better reliability than a stock one(Entirely my opinion..) I have been running mine stock for the last year and a half (28k km). I have done 1000+ km in a day twice (Max 1158km) and still there is no misfiring / stuttering / engine fatigue / backfiring.

Regarding your CDI query.. I didn't quite get what you meant by "What kind of CDI" but what I can tell you is, the solution to the issue you had earlier (the noise coming from starter clutch) was done by changing CDIs under warranty.

The starter clutches were changed if they were damaged but that is not the solution to the problem. The damage was caused due to faulty CDIs and so CDIs were also replaced under warranty.

You can find other 'General Pulsar 220 Care' info on the links mentioned in my signature. I would recommend that you follow carburettor retuning procedure from the links and re-tune the carb yourself. That will probably solve the stalling / misfiring problem for you.