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Thread: Upgrading my Pulsar 180 UG-IV to Pulsar 220 Parts

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    Default Upgrading my Pulsar 180 UG-IV to Pulsar 220 Parts

    Once again hello guys... i'm posting up a thread here to inform that i'm done with the 220 projecter headlight in my 180... Last thread helped me a bit..
    Now guys the mechanic who did the headlight assembly assured me that everything is possible and can be done coz the world exists coz of 'money'...like he charged for fitting 400 Rs. instead of '250' Rupees Maximum..Rest Parts were newly insured bought from my friend like visor and headlight for only 2000 ..seeked for a clamp "Rs.1500" got it and then a iron welding 'Rs.250' to hold the headlight...Name:  IMG_20130203_231627.jpg
Views: 25230
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    Remaining is i never told him 'my mechanic' to make DC setup something which is needed for the headlight and any other wiring accessories as he says the old wires has been connected to the headlight... the two projector lamp's below ones that is dipper is attached with a 12V 55W Bulb where as the upper beam needs 12V 55W White Bulb which was not available.
    How should i get it where as i stay in Sambalpur City of Orissa State..here 2 bajaj showrooms and 1 bajaj shoppee all they do not have and asking to order and wait for a minimum period of 1 month? WTF !!!
    Can i get it online? Heard about Osram, Philips, VisionClear etc.
    Please advice whoever done or gone through this particular work ...

    Secondly i'm thinking of installing a 220 silencer. Will it only give looks or will increase some power? Advisers i request you to give me a complete detail and possible performances kits or any other ..
    till den waiting eagerly for your sujjestions

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    Quote Originally Posted by bmp1993 View Post
    Once again hello guys... i'm posting up a thread here to inform that i'm done with the 220 projecter headlight in my 180... Last thread helped me a bit..
    Now guys the mechanic who did the headlight assembly assured me that everything is possible and can be done coz the world exists coz of 'money'...like he charged for fitting 400 Rs. instead of '250' Rupees Maximum..Rest Parts were newly insured bought from my friend like visor and headlight for only 2000 ..seeked for a clamp "Rs.1500" got it and then a iron welding 'Rs.250' to hold the headlight...Name:  IMG_20130203_231627.jpg
Views: 25230
Size:  87.7 KB
    Remaining is i never told him 'my mechanic' to make DC setup something which is needed for the headlight and any other wiring accessories as he says the old wires has been connected to the headlight... the two projector lamp's below ones that is dipper is attached with a 12V 55W Bulb where as the upper beam needs 12V 55W White Bulb which was not available.
    How should i get it where as i stay in Sambalpur City of Orissa State..here 2 bajaj showrooms and 1 bajaj shoppee all they do not have and asking to order and wait for a minimum period of 1 month? WTF !!!
    Can i get it online? Heard about Osram, Philips, VisionClear etc.
    Please advice whoever done or gone through this particular work ...

    Secondly i'm thinking of installing a 220 silencer. Will it only give looks or will increase some power? Advisers i request you to give me a complete detail and possible performances kits or any other ..
    till den waiting eagerly for your sujjestions

    for the bulbs 55w you can either go for osram night breakers or philips crystal vision H4. however these come in pair
    so make sure you have figured out with what to do with the extra one else it will be sitting idle in the case.
    these can be sourced through Ebay. in else for philips crystal/diamond/extreme vision.. car decor/spare parts shop guys will have it...


    regarding the Exhaust.. i would say dont do anything until you know about it.

    1st.. the design of 180 vs 220 is completely diffrent. how will it change the character of the power curve is completely unknown.
    2nd the 220 ones looks heavy.. why add extra weight..

    till cosmetic makeover you can do whatever you feel like.. anything related to the engine. i'd day either get the machine in the hands of expert
    else be safe. let it be stock..
    "A good long ride can clear your mind, restore your faith, and use up a lot of fuel."

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    Default pulsar 180 UG4 to pulsar 220

    can any one help me to convert my pulsar 180 to 220?
    is there any one who did this mod?
    please help

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    Default Re: Upgrading my Pulsar 180 UG-IV to Pulsar 220 Parts

    Quote Originally Posted by bmp1993 View Post
    Once again hello guys... i'm posting up a thread here to inform that i'm done with the 220 projecter headlight in my 180... Last thread helped me a bit..
    Now guys the mechanic who did the headlight assembly assured me that everything is possible and can be done coz the world exists coz of 'money'...like he charged for fitting 400 Rs. instead of '250' Rupees Maximum..Rest Parts were newly insured bought from my friend like visor and headlight for only 2000 ..seeked for a clamp "Rs.1500" got it and then a iron welding 'Rs.250' to hold the headlight...
    Remaining is i never told him 'my mechanic' to make DC setup something which is needed for the headlight and any other wiring accessories as he says the old wires has been connected to the headlight... the two projector lamp's below ones that is dipper is attached with a 12V 55W Bulb where as the upper beam needs 12V 55W White Bulb which was not available.
    How should i get it where as i stay in Sambalpur City of Orissa State..here 2 bajaj showrooms and 1 bajaj shoppee all they do not have and asking to order and wait for a minimum period of 1 month? WTF !!!
    Can i get it online? Heard about Osram, Philips, VisionClear etc.
    Please advice whoever done or gone through this particular work ...

    Secondly i'm thinking of installing a 220 silencer. Will it only give looks or will increase some power? Advisers i request you to give me a complete detail and possible performances kits or any other ..
    till den waiting eagerly for your sujjestions
    Please provide the link of your last thread

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    Icon10 Pulsar 180 to Pulsar 220, complete conversion!

    Its been long since I thought about posting this, a plan of conversion/ upgrade/ modification or whatever you'd like to call. Let me begin by mentioning about my ride. Its a 2013 Pulsar 180 (UG 4.5), clocked 19000 kilometers on the ODO and used mainly for my daily commute. I also used it for touring until I recently bought an Avenger 220 Cruise.

    The bike has always been highly reliable, though not really enjoyable. Performance, though hasn't been an issue but has never been great either. Since I felt a lack of power low down the rev band, I made it a habit to ride consistently at RPMs mostly above 4000, due to which there was a significant drop in fuel efficiency. I admitted this fact and somehow managed to live with it, until I bought the Avenger. I felt a significant difference in overall performance. The Avenger's low end torque was much much better than the Pulsar, also the throttle response felt great. The difference was obvious considering that the Avenger has a 220cc engine. Eventually I stopped using the pulsar for my daily commute and started using the Avenger. But I didn't want to let the Pulsar die, unused. So I started wondering how to improve its performance. I was already done with using Motul 7100 engine oil in hope of better performance, but there was no difference at all!

    One fine day, I got to ride my friend's 220S DTS-i. I was amazed by its performance, such a significant difference in performance was not really expected by me. Despite of being 5 years old, it performed like brand new. Interestingly enough, he didn't carry out any kind of modification on his bike and got the bike serviced at the manufacturer recommended intervals of 5000kms! Meaning that he spent a lot lesser than me on the maintenance side, still got much better performance. Upon doing some quick research about the bike, I found that it had a lot in common with the 180 UG4. So I thought, "Why not upgrade my 180 to this?". I was already frustrated with 180's performance. The upgrade would not only offer a performance restoration, but also an added boost of power!

    I thought of carrying out the following mods/upgrades. My questions regarding the mods are also as follows-

    1. Engine Upgrade- Can I upgrade the 180cc engine to 220 with Oil Cooler? If yes that what are the parts that would need to be changed and what would be the estimated cost?
    2. Rear Disc Brake-Will it be a direct fit? What things would be needed to be replaced and what would be the cost?
    3. 220 Exhaust- Can the 180 exhaust be used or will I have to buy the 220's exhaust? What will be the drawbacks of going for an aftermarket custom exhaust? And what will be the cost in both the cases?
    4. 220 Fairing- Although I am not quite sure about this, I might, in future upgrade the headlight to that of 220F. What would be the estimated cost for this upgrade? And will it be a direct fit?
    5. 220 Console- Can I get the console of 2017 edition 220 installed directly? What would be the cost?-
    6. 55w vs 35w Halogen- Will the 55w projector headlight of 220 be a direct fit with Pulsar 180's electrical system? If no, then what modifications would be required?
    7. And last but not the least- Will the bike perform at least better than now or will its performance get worse, if all done using original parts and a least possible 'Jugaad'?


    Can anyone suggest a good mechanic for the job in Jaipur, Rajasthan?

    Thanks in advance!

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    Default Re: Pulsar 180 to Pulsar 220, complete conversion!

    Quote Originally Posted by mototech View Post
    Its been long since I thought about posting this, a plan of conversion/ upgrade/ modification or whatever you'd like to call. Let me begin by mentioning about my ride. Its a 2013 Pulsar 180 (UG 4.5), clocked 19000 kilometers on the ODO and used mainly for my daily commute. I also used it for touring until I recently bought an Avenger 220 Cruise.

    The bike has always been highly reliable, though not really enjoyable. Performance, though hasn't been an issue but has never been great either. Since I felt a lack of power low down the rev band, I made it a habit to ride consistently at RPMs mostly above 4000, due to which there was a significant drop in fuel efficiency. I admitted this fact and somehow managed to live with it, until I bought the Avenger. I felt a significant difference in overall performance. The Avenger's low end torque was much much better than the Pulsar, also the throttle response felt great. The difference was obvious considering that the Avenger has a 220cc engine. Eventually I stopped using the pulsar for my daily commute and started using the Avenger. But I didn't want to let the Pulsar die, unused. So I started wondering how to improve its performance. I was already done with using Motul 7100 engine oil in hope of better performance, but there was no difference at all!

    One fine day, I got to ride my friend's 220S DTS-i. I was amazed by its performance, such a significant difference in performance was not really expected by me. Despite of being 5 years old, it performed like brand new. Interestingly enough, he didn't carry out any kind of modification on his bike and got the bike serviced at the manufacturer recommended intervals of 5000kms! Meaning that he spent a lot lesser than me on the maintenance side, still got much better performance. Upon doing some quick research about the bike, I found that it had a lot in common with the 180 UG4. So I thought, "Why not upgrade my 180 to this?". I was already frustrated with 180's performance. The upgrade would not only offer a performance restoration, but also an added boost of power!

    I thought of carrying out the following mods/upgrades. My questions regarding the mods are also as follows-

    1. Engine Upgrade- Can I upgrade the 180cc engine to 220 with Oil Cooler? If yes that what are the parts that would need to be changed and what would be the estimated cost?
    2. Rear Disc Brake-Will it be a direct fit? What things would be needed to be replaced and what would be the cost?
    3. 220 Exhaust- Can the 180 exhaust be used or will I have to buy the 220's exhaust? What will be the drawbacks of going for an aftermarket custom exhaust? And what will be the cost in both the cases?
    4. 220 Fairing- Although I am not quite sure about this, I might, in future upgrade the headlight to that of 220F. What would be the estimated cost for this upgrade? And will it be a direct fit?
    5. 220 Console- Can I get the console of 2017 edition 220 installed directly? What would be the cost?-
    6. 55w vs 35w Halogen- Will the 55w projector headlight of 220 be a direct fit with Pulsar 180's electrical system? If no, then what modifications would be required?
    7. And last but not the least- Will the bike perform at least better than now or will its performance get worse, if all done using original parts and a least possible 'Jugaad'?


    Can anyone suggest a good mechanic for the job in Jaipur, Rajasthan?

    Thanks in advance!





    My dear friend, we the Pulsar 180 owners are in luck because the (erstwhile?) Fastest Indian has many congruencies with our less powerful (not to be read as capable) variant. Now, as far as the power deficit you're feeling- that may be a mental factor due to the usage of the bigger Avenger. Now, even though the 4BHP deficit doesn't seem like much on paper it is quite a lot. I've had myself beaten by an Avenger so many times on the open road despite my more aerodynamic bike and lithe structure.

    Get your bike serviced at a trusted place one (including valve adjustment, carb cleaning etc.)

    1)Replacing the right crankcase cover with the Pulsar 220 unit will give you the ability to install the oil cooler. There's this place in Delhi where it is cheaply available. That is all that is needed as far as my knowledge goes as the 220 doesn't have a dedicated oil pump for the oil cooler. Even in Jaipur, just go to wherever there is a big market for motorcycles and car spare parts. It shouldn't be difficult. The "performance" per se might not increase but it'll surely result in a cooler crankcase after a long ride.
    2)Now this modification results in an extensive parts list. The rear swingarm of the Pulsar 220 has 2 separate brackets- one for mounting the rear brake caliper and another one for the brake line leading to that. Hence the rear rim, the swingarm and the brake pedal have to be switched out. Add to that the cost of the disc plate itself (300/- to 800/-), the total cost of this modification might vary extensively depending on the mechanic and the city. 5000/- to 10000/- is the possible range of expense for this modification.
    3)The OEM exhaust for any motorcycle is carefully designed and extensively tested to work well that particular model. The size of the exhaust is a factor of, among other things, a factor of something called the back pressure of the exhaust gasses. In simpler words, if you plan to change out the stock exhaust, opt for the aftermarket ones because, among other things, the level of satisfaction will be more regarding the sound change. But the increased sound level may get tiresome on long rides. It is always better to stick with the stock piece anyways. I'd say spare about 5000/- for this modification.
    4)The fairing on the 220 has special mounting points on the tank. This means that for this modification you'll need to change the tank of the motorcycle too or at least get mounts welded onto your tank. Too much of a hassle to rice out your bike, if you ask me.
    5)Sadly, being a proud owner of a 180 I don't have a lot of saddle time on a 220 but I don't think swapping your console would make much of a difference. Yes, we do have some things missing on ours but the Pulsar 220 one might include adding a few sensors here and there on account of the extra info which might run into issues. Don't quote me on that, though.
    6)As far as lighting goes, I opted for externally mounted LEDs on my 180. They not only heat negligibly and extract minimal power from the battery but also look so much cooler. Plus they also work very well in the dark. 2000/- to 3000/- for this.


    Now, if the modifications above have a very low chance of failing theoretically. Just make sure to use the right parts and an established mechanic.

    The 180-220 cc big bore kit is available somewhere in Bengaluru but as far as I am aware it costs upwards of 20000/- and then the compression ratio etc changes which means the head has to be changed which compromises reliability... In short, it's a long shot. The above few modifications are pretty much all you'll need to get your Pulsar 180 as close to Pulsar 220 as it will ever get because there is no replacement for displacement, my friend.


    Hope this helps.

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    Unhappy Re: Pulsar 180 to Pulsar 220, complete conversion!

    Quote Originally Posted by RohanT View Post
    My dear friend, we the Pulsar 180 owners are in luck because the (erstwhile?) Fastest Indian has many congruencies with our less powerful (not to be read as capable) variant. Now, as far as the power deficit you're feeling- that may be a mental factor due to the usage of the bigger Avenger. Now, even though the 4BHP deficit doesn't seem like much on paper it is quite a lot. I've had myself beaten by an Avenger so many times on the open road despite my more aerodynamic bike and lithe structure.

    Get your bike serviced at a trusted place one (including valve adjustment, carb cleaning etc.)

    1)Replacing the right crankcase cover with the Pulsar 220 unit will give you the ability to install the oil cooler. There's this place in Delhi where it is cheaply available. That is all that is needed as far as my knowledge goes as the 220 doesn't have a dedicated oil pump for the oil cooler. Even in Jaipur, just go to wherever there is a big market for motorcycles and car spare parts. It shouldn't be difficult. The "performance" per se might not increase but it'll surely result in a cooler crankcase after a long ride.
    2)Now this modification results in an extensive parts list. The rear swingarm of the Pulsar 220 has 2 separate brackets- one for mounting the rear brake caliper and another one for the brake line leading to that. Hence the rear rim, the swingarm and the brake pedal have to be switched out. Add to that the cost of the disc plate itself (300/- to 800/-), the total cost of this modification might vary extensively depending on the mechanic and the city. 5000/- to 10000/- is the possible range of expense for this modification.
    3)The OEM exhaust for any motorcycle is carefully designed and extensively tested to work well that particular model. The size of the exhaust is a factor of, among other things, a factor of something called the back pressure of the exhaust gasses. In simpler words, if you plan to change out the stock exhaust, opt for the aftermarket ones because, among other things, the level of satisfaction will be more regarding the sound change. But the increased sound level may get tiresome on long rides. It is always better to stick with the stock piece anyways. I'd say spare about 5000/- for this modification.
    4)The fairing on the 220 has special mounting points on the tank. This means that for this modification you'll need to change the tank of the motorcycle too or at least get mounts welded onto your tank. Too much of a hassle to rice out your bike, if you ask me.
    5)Sadly, being a proud owner of a 180 I don't have a lot of saddle time on a 220 but I don't think swapping your console would make much of a difference. Yes, we do have some things missing on ours but the Pulsar 220 one might include adding a few sensors here and there on account of the extra info which might run into issues. Don't quote me on that, though.
    6)As far as lighting goes, I opted for externally mounted LEDs on my 180. They not only heat negligibly and extract minimal power from the battery but also look so much cooler. Plus they also work very well in the dark. 2000/- to 3000/- for this.


    Now, if the modifications above have a very low chance of failing theoretically. Just make sure to use the right parts and an established mechanic.

    The 180-220 cc big bore kit is available somewhere in Bengaluru but as far as I am aware it costs upwards of 20000/- and then the compression ratio etc changes which means the head has to be changed which compromises reliability... In short, it's a long shot. The above few modifications are pretty much all you'll need to get your Pulsar 180 as close to Pulsar 220 as it will ever get because there is no replacement for displacement, my friend.


    Hope this helps.
    Dear RohanT

    Thank you very much for giving such an elaborate response. I thought quite a lot about whether to upgrade or not and finally settled with the plan of changing the clutch cover to get the oil cooler installed. Along with that I also decided to get the bike re-painted in Midnight Black (2015 with Chrome Stripes). The latter was done first, but honestly speaking, I was highly disappointed by the paint job. Right now, the bike looks as if it were painted using Asian Paints or Nerolac . There is absolutely no shine and the painted surface is quite uneven too. Just within 7 days of the paintjob, the stickers have already started peeling off. All above that, they charged 3500/- for this horrific job. Moreover when I complained about it, they showed absolutely no interest and were way too rude. I then realized that if they could ruin the bike to this extent in such an insignificant job, they can render the bike absolutely useless if I get such a complex modification done. Moreover no experienced mechanic was willing to take up this job as according to them this was 'UTTER STUPIDITY'.

    Well, I still haven't given up hope of getting the bike modified, the only problem is that the bike isn't starting up since the past 3-4 days, so I can't even take it to the service center. Currently its gathering dust in my parking

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