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Awesome work bro..... Do update us with the performance and mileage updates post run in.... IMO the exhaust will look better on ug4.... And that footrest part was too good.... Total khilli
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This Tail Is Japani Tail (spell as you like) -
Yes that should have never been done, but I hope the engine is fine now without any impact, so the best way to passify the future impact is to use a good oil flusher.Originally posted by James View PostComment
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finished running-in..??Comment
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Everyone are talking about filings in crankcase and how to remove it.
But Pulsar's comes with Magnetic Engine oil drain bolt which will attract all metal particles. So it wont create any issue and we need to make sure that drain bolt is wiped with a piece of cloth during oil change before fitting. 
This has to be done in every oil change.sigpicComment
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Originally posted by manohar_manu View PostEveryone are talking about filings in crankcase and how to remove it.
But Pulsar's comes with Magnetic Engine oil drain bolt which will attract all metal particles. So it wont create any issue and we need to make sure that drain bolt is wiped with a piece of cloth during oil change before fitting.
This has to be done in every oil change.
You are correct, but magnets do not attract all metal particles.Comment
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The crank case which was filed and re-shaped , is made of Aluminum and it's pieces will not be attracted by the magnetOriginally posted by manohar_manu View PostEveryone are talking about filings in crankcase and how to remove it.
But Pulsar's comes with Magnetic Engine oil drain bolt which will attract all metal particles. So it wont create any issue and we need to make sure that drain bolt is wiped with a piece of cloth during oil change before fitting.
This has to be done in every oil change.When Was The Last Time,You Did Something For The First Time.Comment
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Holy mother of God...
It would have been better to have got the engine unmounted before doing the mod!
Also its always a good idea to clean the engine of all muck and grunge before you attempt a rebuilt!Super CommuTOURer� - Talk less, Ride more
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� Satyen PoojaryComment
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Jugaad! But what was the issue that didn't allow direct fitting of the block?Comment
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The crankcase's left portion was bigger, and right one had a slightly smaller diameter. Stock block was smaller, and Joel's block was bigger, which did fit the left half circle, but not the smaller right one. It was a problem from Bajaj.Originally posted by pavanchirmade View Post
And I got the oil replaced. Will replace once more after 500 kms.
The bike is doing fine so far, its better after the oil change. Performance is good, vibrations might have increased slightly after the mod, I think.
Guys, I was too stressed that day (Friday the 13th) to take my own decision. And the mechanic did add a cloth below it, some time after the pic was taken.
@ Prince: No, its not yet run in. Its barely about 70 kms now. My college is just about 5 kms. I wish to keep my bike for the good times and memories I spent with her, specially the college times when I used to study. Will get a bigger one sooner than later, but won't sell it.
I do wish it prevails after all this. Will search for a good oil flusher.---
Brotherhood, Rules, Freedom. Xbhp.
Indian riding = Alertness, Anticipation and Adjustment.Comment
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video please...we need to hear the joeled p180s sound..
200 was just awesome..
what about mileage?sigpicmy bike is my signComment
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A walk around and slight revving video will be available by tomorrow here.Originally posted by JASMINE RIDER View Post
And mileage will be calculated soon, but I think it will be good for now, due to being in run in period. I did a tankful at installation, and ran only 70 kms after it.
Ajmer is a small city. Just 5 kms run to my college, 5 to railway station, 10 kms to the city's other end.
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Brotherhood, Rules, Freedom. Xbhp.
Indian riding = Alertness, Anticipation and Adjustment.Comment
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Most of mass produced bikes have crankcases with different width depending on batch production...most of the time these aluminum casings are outsourced and hence the difference. the dimension for the opening have a minimum and max grading and pieces that are compliant with it are accepted in inward QC....so a correct casing mating with a casing at max will definitely have this disproportionate size.Originally posted by Samarth 619 View Post
Still with your stock bore there was no issue,since it is within spec, but with a big bore config with re sleaving the clearance was inadequate.
Next time you have any work with engine or with parts open, use a Vacuum cleaner in on position continuously, to suck the removed/filed pieces ,and prevent it from falling inside engine .
The aluminum pieces falling inside may not do much damage,so after the initial oil change you are good to go.....I had seen pieces of iron /aluminum, powdered aluminum dust,and also a piece of thick thread when I had drained oil from new bikes..Last edited by psr; 07-24-2012, 10:06 AM.When Was The Last Time,You Did Something For The First Time.Comment
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@ PSR: Thank you sir for confirming this. Will change oil once more at 500 kms. Expecting it to get better, although its not bad right now.
Here's a glimpse of my Hilly/ scenic commute to college, and then my Pulsar 208cc revved slightly:
Bajaj Pulsar 208 cc Rebored + New Exhaust. Parts from Joel Joseph. - YouTube
It does sound good while actually riding it, if not so much in neutral revving. I mean, when the load increases, the bike's revving tone changes into a slighty louder one.---
Brotherhood, Rules, Freedom. Xbhp.
Indian riding = Alertness, Anticipation and Adjustment.Comment
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Lucky to have such a scenic route to drive everyday...Originally posted by Samarth 619 View Post@ PSR: Thank you sir for confirming this. Will change oil once more at 500 kms. Expecting it to get better, although its not bad right now.
Here's a glimpse of my Hilly/ scenic commute to college, and then my Pulsar 208cc revved slightly:
It does sound good while actually riding it, if not so much in neutral revving. I mean, when the load increases, the bike's revving tone changes into a slighty louder one.
Have you up jetted the main ? it is required since you had gone for the 180 to 208 transition....engine may feel ok at low RPMs but will run very lean at higher RPMs leading to higher engine temperature, leading to engine oil going bad soon....
At the next oil change try to check the Centrifugal oil filter for the aluminum powder,and get it cleaned...When Was The Last Time,You Did Something For The First Time.Comment
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