Re: Is the Pulsar 180 UG3's 5th gear upgrade possible ?

Topic Approved.

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And I can't find my workshop manual either, its lying in the house somewhere.. Different part numbers might not mean much finally.


Try explaining this to a Bajaj mechanic and be ready for anything, if the entire gearbox needs to be upgraded to 220's, be ready for it.
As far as I know Bajaj, some or the other combination must work for you.

Re: Is the Pulsar 180 UG3's 5th gear upgrade possible ?

Thank you Sir for approving.

Here is the link for 180 UG3's spare parts and catalogue.
https://ibb.co/mhAYxe

..and for 220F/S.


I want to do this because theoretically according to gearingcommander replacing 5th gear (drive and driven) alone is adding speed of 3.2 - 4.3 km/h ( 6k - 8k RPM, with 220F's sprocket set).

I could be wrong though but I believe that this could be the more efficient way of adding speed 'quickly(I mean reducing the time to reach a certain speed)' than simply overgearing it by using different sprockets because when we overgear it by sprocketing then we have to depend on the torque that is available at end of the output shaft (where we fit front sprocket, I know we can't change/upgrade the power by sprocketing but we can adjust the available torque though) since there is always power loss from crankshaft to the end of the output shaft, so should be the loss of precious torque at the real wheel. If we overgear in transmission unit by adding taller gear then we are overgearing at lower level (since transmission area is closer to where the power is being generated(crankshaft) unlike at the front sprocket) and after doing so, we can have more torque at the end of the output shaft than the stock configurations. I am not even close to have even 1% knowledge of an expert and I respect if this so called theory of mine is actually proved wrong by any user in here, feel free to say anything.

Since getting the crankcase and input/output shaft opened and removed will cost me at least 500-1000+ rupees, I wanted to know in advance if this could work or not. Wait a sec...I think if I could somehow compare the width of the inner diameter of '5th gear driven' of the P220F to the width of the inner diameter of '5th gear driven' of P180UG3 and if it turns out to be equal then it means it will have to work.

Okay, I am heading toward the spare parts shop and will try to compare those stuffs and will tell you after that.

P.S.: Samarth 619, Thanks for replaying Sir, it took me two months to read the whole thread from start till end, of 'World of Sprocket', 'Pulsar 180 (All versions)' and your precious 'Pulsar 208' one. I am telling this to just let you know that due to you and others, I have known many (if not most or all) of the issues you and others have faced regarding P180UG3 mods in this forum and I am fortunate enough to read those posts and be able to teach me all the solution that this forum has provided, many thanks to you and everyone for that.

Re: Is the Pulsar 180 UG3's 5th gear upgrade possible ?

[MENTION=98967]rainydriver[/MENTION], I know how you feel. I've also wanted to change the ratios of all 4gears in my Victor.
The centre distance of the shafts is a combination of the driver and driven gears. So if you want to change ratios then the sum of number of teeth (24+26) should remain the same(23+27,22+28,...etc). The module of the gears(teeth size) also must match exactly. This requires customizing of both driver and driven gears.

Even if you manage to accomplish this, the rpm shift between 4th and 5th gear will increase meaning you take longer to reach top speed.

Practically, taller 1st and 2nd gear would be better if you love to keep the revs above 5.5k.

Feel free to PM me if you need to know more theoretical stuff. I'm a mechanical engineer by the way.

Regards
Pranav