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Thread: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

  1. #1
    Rusted ashwinprakas's Avatar
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    Icon6 Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Hi All,


    Thought I'd share this DIY mod I've done on my P220 with the help of a friend.


    Requirements:



    1. Bajaj Discover 150F/S Handlebar, Holders and Spacers
    2. Bajaj Avenger 220 Brake-line and Clutch cable.



    Procedure:


    Drill holes on the stock upper T plate taking into consideration clearance for the 22mm cone-set bolt, if you pay close attention to the below photo you can observe a reference line drawn just above the bolt.





    As for the switch-set, you may drill holes on the handlebar to match the position pins inside the switch-set or you can just tap the pins so that it goes in and then use 3M double side tape to ensure that they stay in place, which is what I have done.


    Purpose:


    Upright riding position, after putting close to 10k km's on the CT100B I just loved the riding position which reminded me of the Hero Honda Karizma and decided to go for this.


    Downside:


    If you're a function over form guy, then none to be specific as there is no fouling with fairing present.


    As for downgrading from steel braided lines to rubber ones, well I personally haven't noticed any drastic differences, and a shout-out goes to Bajaj for providing Banjo bolts and copper spacers within the brake-line packet.


    Looks:


    You get to be the judge of that;






    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    My Rants!:
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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Thread Approved

    Interesting mod for 220 owners. Would make the riding posture too upright in my opinion. My back hurts sitting straight, just love the slightly forward bent position of the stock 220. Not one for me, but i am sure there will be many takers for this.

    Thanks for sharing
    ashwinprakas and KnG like this.
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    Rusted ashwinprakas's Avatar
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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Quote Originally Posted by The Monk View Post
    Thread Approved

    Interesting mod for 220 owners. Would make the riding posture too upright in my opinion. My back hurts sitting straight, just love the slightly forward bent position of the stock 220. Not one for me, but i am sure there will be many takers for this.

    Thanks for sharing
    Thank you for the speedy approval.

    The riding posture is as upright as it can possibly be, coincidentally the section of the rear seat that is just above the rider seat offers firm support for the lower back region which takes the comfort to a whole different level.

    The handling has also marginally increased as breaking traction at the front is not as scary as it used to be which is something I loved while riding the CT100B. The next and most obvious pointer would be visibility which has also gone way up compared to stock setup as changing lanes are way less intimidating especially with handlebar mounted RVM's.

    But all is not good as there are downsides as well, the first and immediately noticeable one being the shift in footing position, with the stock setup resting the balls of the foot on the pegs used to be the most natural choice but now unless the mid-foot is centered on the foot-pegs you would feel really out of place, which is favorable for older matured riders but not so much for spirited riders as jumping obstacles and locking your body while cornering seems to take more effort than I remember.

    The only reason that makes this mod feasible is that long time owners are reluctant to part with the motorcycle and wouldn't mind investing some time and money on their old machines as when it comes to the ever so rare combination of reliability and frugality it is hard to find a worthy competitor for the P220.
    adityagaur51 likes this.
    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    My Rants!:
    Thoughts & Suggestions about Motorcycling
    Travelogues

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    Icon10 Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Looks neat. I don't want the handlerbar mod but maybe I'll get a windshield if its cheap. Where can get that windshield? Make a post about windshield mod too. Write the cost also? Post a front pic btw. I want to know how weird it'd look on my bike.
    a_poor_blind_kid likes this.
    Pulsar 220 Fi (2008) 28k km

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    Rusted ashwinprakas's Avatar
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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Quote Originally Posted by sandwichk View Post
    Looks neat. I don't want the handlerbar mod but maybe I'll get a windshield if its cheap. Where can get that windshield? Make a post about windshield mod too. Write the cost also? Post a front pic btw. I want to know how weird it'd look on my bike.
    The windshield is from Sahyadri Moto, Pune, they provide the frame as well and its a direct plug and play so no DIY guide needed.

    Here's an article I wrote about them, hope it helps;

    Sahyadri Moto: Adventouring Accessorized

    This is the only frontal shot of the motorcycle I have with me at the moment.

    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    My Rants!:
    Thoughts & Suggestions about Motorcycling
    Travelogues

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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    You had a clip-on setup which most of us discover guys drool for. Pulsar kept updating itself while bajaj downgrade the ongoing 135cc Discover to more economical 100,125 cc. Though they released a 220 type fairing 150cc Discover but its torque and power was below 135cc engine which shares parts with P150.

    Anyways, IMO P220 looks best with stock clip-ons. Your raised handle bar is providing more comfort but for looks I really like stock one. 2 Days ago I read about SS braided brake hose of P220 so I changed mine with one.
    From outside it looks like it will get fit on Discover 135 but after connecting everything I found that SS braided hose is too small for my bike. Somewhow I changed handle bar position to be able to bolt banjo nut in master cylinder but seems like 1111 rupees cable is in tensile stress.
    Going to buy P150 handle bar to change it with my stock one to lower the stress on SS brake hose. It will definitely affect handling and seating position but I always sit with straight back even with forward leaned position so it should not affect my back.

    Advice - Keep your back straight while you ride, eat or stand. I see many people who always sits with their back little bend forward. which may cause back ache later. I have been trying sitting/standing straight which also improves my posture and height . Done three consecutive 700 kilometers trip in 24 hours with this position literately without any back pain. It might be enthusiasm but straight spine works in long term.
    KartikJ4001 likes this.

  7. #7
    Rusted ashwinprakas's Avatar
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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Quote Originally Posted by Toshar Deven View Post
    You had a clip-on setup which most of us discover guys drool for. Pulsar kept updating itself while bajaj downgrade the ongoing 135cc Discover to more economical 100,125 cc. Though they released a 220 type fairing 150cc Discover but its torque and power was below 135cc engine which shares parts with P150. Anyways, IMO P220 looks best with stock clip-ons. Your raised handle bar is providing more comfort but for looks I really like stock one. 2 Days ago I read about SS braided brake hose of P220 so I changed mine with one. From outside it looks like it will get fit on Discover 135 but after connecting everything I found that SS braided hose is too small for my bike. Somewhow I changed handle bar position to be able to bolt banjo nut in master cylinder but seems like 1111 rupees cable is in tensile stress. Going to buy P150 handle bar to change it with my stock one to lower the stress on SS brake hose. It will definitely affect handling and seating position but I always sit with straight back even with forward leaned position so it should not affect my back.Advice - Keep your back straight while you ride, eat or stand. I see many people who always sits with their back little bend forward. which may cause back ache later. I have been trying sitting/standing straight which also improves my posture and height . Done three consecutive 700 kilometers trip in 24 hours with this position literately without any back pain. It might be enthusiasm but straight spine works in long term.
    The clip-on's are are sure nice to look at. But sadly the pro's end there.With the current setup, I get;

    1. Better maneuverability.
    2. Better ergonomics and lesser vibes.
    3. Better RVM positioning.
    4. Better robustness.
    5. Better compatibility with handlebar mounted accessories.

    As for riding position, every handle-peg-seat combo has its own comfortable seating position and straining to try something different would inadvertently affect your handing and response.

    The steel braided lines don't make much of a noticeable difference on normal operation, in my case at the least.

    The Discover series is more robust than the Pulsar, during my college days I used to run interstate for 750~800 km's in a day on my Bajaj Discover 100 4G on a biweekly basis from Kerala to Karnataka and vice versa, and during my internship days I used to ride 440 km's a day on alternate days as I was interning at an organization that was 220 km's away from home, 3 districts apart, the longest continuous ride I've done on the motorcycle is 1300+ km's in a day with a fellow xBhpian riding along on his Pulsar 180. And after all this there wasn't even one visible oil stain on the motor which when compared to my P220 is awesome as a head oil leak on the Pulsar is nothing but a common occurrence best left unnoticed.
    Last edited by ashwinprakas; 01-02-2018 at 08:53 AM.
    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    My Rants!:
    Thoughts & Suggestions about Motorcycling
    Travelogues

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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Quote Originally Posted by ashwinprakas View Post
    T

    The steel braided lines don't make much of a noticeable difference on normal operation, in my case at the least.
    P220 is awesome as a head oil leak on the Pulsar is nothing but a common occurrence best left unnoticed.
    I swapped the handle bar with pulsar to get the SS braided pipe a perfect fit and I really like the little bent forward position whereas previous position which I was on for last 7 years was very Uncle-ish type. As for the brake line - Nothing changed. Did every possible method to get the braking better but I guess it can not get better. now Using a tiny plastic piece between between the MC pump and lever to eliminate the 2-3mm play which made it like feather touch. I now feel humming and rubbing type vibration of pads on my lever which I guess were damped before in rubber pipe.

    My Disc 135 also have a problem of Head leak . Push it very hard and puff.. Let the pressure leak be there. Topping up oil is far more cheaper then getting the head reopened and seal changed.
    - I never had that much long ride, still discovering various seating position to find comfort.

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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    i use this stuff on my pulsar, no need drill...

    Last edited by rudy009; 01-28-2018 at 01:52 PM.

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    Rusted ashwinprakas's Avatar
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    Default Re: Bajaj Pulsar 220 Clip-on's to Handlebar Conversion

    Quote Originally Posted by Toshar Deven View Post
    now Using a tiny plastic piece between between the MC pump and lever to eliminate the 2-3mm play which made it like feather touch. I now feel humming and rubbing type vibration of pads on my lever which I guess were damped before in rubber pipe.
    I would advice against that as the clearance is required for the release port, which if partially blocked would not be noticeable at first but after extensive braking say downhill runs the front would inadvertently lock up the front wheel without any indication.

    You could use the zip-tag method as it does bring a noticeable difference.

    Using a zip tag you have to bring the lever as close to the handle bar as ideally possible and leave it locked overnight, this would bring all the air up to the reservoir and would improve braking feedback considerably.

    My Disc 135 also have a problem of Head leak . Push it very hard and puff.. Let the pressure leak be there. Topping up oil is far more cheaper then getting the head reopened and seal changed.
    - I never had that much long ride, still discovering various seating position to find comfort.
    Head gasket is not that expensive to replace and can be done as a DIY if you're interested, but if you have considerable miles on the odo then get it replaced along with the next head overhaul and you can save up on costs.
    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    My Rants!:
    Thoughts & Suggestions about Motorcycling
    Travelogues

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