Ayush Singh

Dear Members,

I've been visiting this thread often, but now I felt the need to register myself and seek some help from the experienced. Also I will be glad to take initiatives in helping those in need.

My Bike
I own a Bajaj Pulsar DTS-i 150 (Spoke Wheeled) bike. I've clocked 68000+Kms and have maintained the bike well. The bike never gave me any major problem until now.

Problem
Few months back while getting the usual service done from my mechanic (who does only what I instruct him to do and honestly is fit only for replacing brake shoes), I asked him to clean the Carburetor which is a Mikuni BS26 CV. He cleaned it properly but over tightened the Jets. The worst he did was playing with the volume screw. After servicing I complained about bad pickup and he adjusted the volume screw at 1 1/2 anti clockwise. And the problem started.

The idle RPM set at 1000 would never remain constant. It would keep on fluctuating. Sometimes after riding the bike for few minutes the idle RPM would increase to 2000 or 2500 and won't get back to 1000 (no problem with throttle cable). If I would decrease the idle back to 1000, the bike would start getting off whenever the gears are changed. I might have tolerated all this but not mileage. My bike never gave me anything below 60kmpl, but now it was showing 45/48kmpl. I was irritated.

Worst
Yesterday, mechanic suggested cleaning the carb and the jets again. I agreed and he opened the carburetor. The overtightened PILOT JET was not getting untightened, mechanic's screw driver scrambled the head and the JET got stuck. After wasting the whole day a guy was able to take it out using drill. The hunt for new jet began, and I was perplexed knowing that the distributors don't have it and there is no chance of getting it. Some mechanic suggested RAJDOOT's JET and it did look similar to Pulsar's. I found Hero Puch's Jet more similar to Pulsar so tried it in the carb. The result was shocking.
There is starting problem. The bike would constantly get off while riding, the sound of engine is different and is bad, riding is not at all smooth, most of the time bike runs in the similar fashion when fuel gets over. Black smoke at 6000RPM is still there, and I'm crying saying my good old bike now sucks.

The Pilot Jet(125) is not available anywhere and this is a threat. I tried Apache's distributor as Apache 160 RTR has the same carb but no help. Yamaha FZ-16 also has BS26 but no spares available as of now. Suzuki GS150R has got the same carb but no dealer in my area. A sales counter said he can arrange Suzuki Fiero's PILOT JET, but I'm not sure it will work in BS26 CV, as to my knowledge Fiero's Carb is not CV.

The JET from Hero Puch is not able to pass fuel properly and that must be the reason for chopped riding.

Please point if I'm wrong in my understanding and is there anything that I can do to get my bike up and running properly. I would appreciate the help.

Thnx
Ayush

Aryan

Query Approved.

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Ayush Singh

Adding on.

I've located a Royal Enfield dealer nearby to my place who has PILOT JET bearing part no. 500866, for Royal Enfield Thunderbird. Thunderbird uses Mikuni BS26 Carburetor, I hope this part would work in Pulsar 150.

wbr
Ayush

Aryan

@Ayush: Have you tried getting the jet(s) from the Bajaj service center?

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psycho 98

Pilots will never come in sizes to 126 its the mains, if that was the case every indian bike would pop wheelies in 1st gear in any circumstances ..

Could you please post the pic of broken jets.

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Ayush Singh

@Aryan: Yes I tried Bajaj Service Centers, they suggest the distributor and none have it.

@psycho 98: The model # of PILOT JET is 125 not the size. Specifically its "G12 5" (printed on JET) wherein Yamaha FZ-16's service manual prints it as "Pilot Jet (125)" and so does Apache 160 RTR's.

bprags

Dude, Fiero was the first bike in the country with a CV carb.

atul_astro

for all you know, its a torn diaphragm kit..get it replaced as well..i had similar problems on a frnd's wind125 and it got resolved with the replacement

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abhijeet080808

Good luck with your pilot jet. Sometimes, you may not get the pilot jet but a Jet Holder Kit is available for Pulsar. It has pilot jet, main jet and main jet holder. Try to get hold of it. Also, if you do not get it for 150, get the 180 kit (DJ121056). Both kits have same pilot jet. And 1.5 turns on a Pulsar is too lean. That is causing the fluctuating rpms at idle. Also set idle speed close to 1400 rpms - 1000 rpm is too low.

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Ayush Singh

Thanks for the support, members.

Today I got PILOT JET for Fiero. The JET had 12.5 written on it and upon comparison with the default JET, it looks identical. The JET was replaced in the carburetor.

After replacement bike ran properly for 200mtrs, it was super smooth, but then the choking started again. It is the same as it was happening with the Hero Puch jet. The bike keeps on knocking and doesn't feels smooth at all.

Further I adjusted the volume screw at 2 1/2 but still knocking continued. Everything looks proper, I'm unable to understand what is wrong. Please suggest why bike is knocking with correct PILOT JET. The MAIN JET was over tightened by the mechanic, but MAIN JET is for high end performance and the bike runs well while accelerating, but when it is cruising at 60km/hr it starts chocking/knocking again.

I'm desperate to solve this problem within a budget, else might have got myself a new carburetor.

Thnx
Ayush