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Pulsar 150 Engine Rebuild and light upgrades

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  • Pulsar 150 Engine Rebuild and light upgrades

    Hi All,

    Am new to xbhp and become a crazy fan of the same by reading about the bikes day and night.

    I have a query regarding the Halogen bulb and Xenon. I own a P150 2005 model spokes wheel model. Done with 61k in Odometer. Am rebuilding my engine completely as engine parts of worn out and as it need to be rebored (shown few pics below), repainting the base from Silver to black and installing Self start. With all these modifications I would like to go for a better bright headlight as am no where happy with the 30/35W provided with the bike.

    Click image for larger version

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    I don`t want to get caught by the cops by installing the White lights, but am in need of bright lights, while installing self start. Am gonna change my dry cell battery to bigger liquid battery, recoil with higher gauge, change the rectifier to a bigger one and also do rewiring if required. Along with this I would like to use a better headlight.

    My queries are
    1. If I go for 60/65W will the power be better or shall I go for Single Xenon which has low beam Halogen and high beam Xenon.
    2. Also let me know the whether the low bean halogen in Single Xenon will be brighter than normal 60/65W halogen? What is the power of low beam halogen in Single Xenon bulb?
    3. What is the power of High beam Xenon in Single beam Xenon?

    Thanks in advance guys. I would post all the pics of my engine parts soon. Posting few for now.

    Oild burned Piston Head
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    27
    Halogen 60/65W
    40.74%
    11
    HID < 4300k
    44.44%
    12
    Low beam Halogen/High beam Xenon
    11.11%
    3
    Any other
    3.70%
    1

  • #2
    Re: Pulsar 150 Engine Rebuild and light upgrades

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    • #3
      Re: Pulsar 150 Engine Rebuild and light upgrades

      If you want good lighting mods for your bike, I have a friend who does this job, https://www.facebook.com/dvjautotech, here you go. . . This is one of my friend who does good jobs in lightings, post a message in the page and he'll get back to you. . . You can see his work on the page, he does a very neat and good job, he'll tell you the best upgrade. . . Good luck. . .

      Cheers!!!
      Yamaha Rx135 - 2005 - 2007 (stolen :mad:)
      Scooty Pep - 2008 - 2012 (sold)
      Honda Unicorn - 2012 - 2015 (crashed)
      Hero Honda Splendor+ 2015 - present (temporary ride)
      Bajaj Pulsar AS200 - 16th September 2015 - present ride

      10 years into riding :D
      Live2Race. . .

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      • #4
        Re: Pulsar 150 Engine Rebuild and light upgrades

        Get the coil rewinded and with an Ape RR, you can run a 60/55watt bulb all day all night long. AFAIk xenons are marketing gimmick and please don't confuse them with HID. I'd suggest you upgrade to 60/55watt bulb with rewound stator coil. Plus it will make your bike full DC so when you let go off the throttle, the headlight won't dim. BTW as [MENTION=59533]Rakesh Rok[/MENTION] mentioned, Debraj is a nice and knowledgeable guy when it comes to automotive lighting. I gotta admit your engine parts doesn't look that worn out for a bike which done 61k kms.
        I am back!

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        • #5
          Re: Pulsar 150 Engine Rebuild and light upgrades

          Originally posted by Cleaner View Post
          Get the coil rewinded and with an Ape RR, you can run a 60/55watt bulb all day all night long. AFAIk xenons are marketing gimmick and please don't confuse them with HID. I'd suggest you upgrade to 60/55watt bulb with rewound stator coil. Plus it will make your bike full DC so when you let go off the throttle, the headlight won't dim. BTW as @Rakesh Rok mentioned, Debraj is a nice and knowledgeable guy when it comes to automotive lighting. I gotta admit your engine parts doesn't look that worn out for a bike which done 61k kms.
          xenon = HID.

          You might wanted to say nightbreaker or like that, they are marketing gimmick.
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          • #6
            Re: Pulsar 150 Engine Rebuild and light upgrades

            Yeah, I was talking about those white bulbs that were sold as xenon. I was confused as he said halogen low beam, xenon high beam. Because you can't flash HID, the xenon high beam would cause problem if he was referring to HID.
            I am back!

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            • #7
              Philips Bi Xenon HID conversion kits

              I found this in Philips catalogue:

              Philips Bi Xenon Conversion Kit
              Part No : 858154KX2
              Volts : 12V
              Watts : 35W
              Base : H4 (Compatible with PX43t base HS1)
              Qty : Pair
              Description: 4200K High/Low

              Philips Ballast Conversion Kit-D2 Style
              Part No : XD288X2
              Volts : 12V
              Qty : Pair

              Apparently they come in pair. Back in 2011 one of our GS owner sourced it from Toyota SVC, not sure about it now. 4200K HID without a projector setup is apparently illegal as well.

              Edit:
              Philips Lighting India - Xenon HID conversion kit - Philips
              Last edited by SparKot; 11-02-2013, 12:19 AM.
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              • #8
                Re: Philips Bi Xenon HID conversion kits

                Those are expensive and fitting them in reflector would cause glare. Also they need DC supply, it means you will have to rewind the stator coil and use an Ape RR. The rewinding and the ape RR gonna run you for about 3,500 rupees. Phillips kit comes at very high price and there is a debate about whether they are genuine or not. I'd suggest you to stick to 60/55w DC conversion as I don't recommend spending a lot of money of this old bike, it's your money, you can invest too, if you like. BTW you can not flash HID bulbs, so that would be a problem in daytime flashing. To flash a H4 HID bulb the bulb will have to be warmed up, which takes a couple of seconds. D2 are single beam, D2S is for projectors and D2R is for reflector AFAIK.

                Under 4300K bulbs should not cause problem with cops, the founder of https://www.facebook.com/dvjautotech is running a 55watt 4100K (or was it 4200K) HID in reflector and according to him, he has never been stopped by cops for that. Your mileage may vary though.
                I am back!

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                • #9
                  Re: Philips Bi Xenon HID conversion kits

                  I'd say just rewind the stator coil and put a 90/100W bulb. Shouldn't cost more than Rs. 500. Also add another 100 for reflector that you would need to change every year.

                  Secondly far too less vehicles use halogen for low beam and xenon for higher beam. Xenons are suited for low beam and halos for high beam.
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                  • #10
                    Re: Pulsar 150 Engine Rebuild and light upgrades

                    Originally posted by Rakesh Rok View Post
                    If you want good lighting mods for your bike, I have a friend who does this job, https://www.facebook.com/dvjautotech, here you go. . . This is one of my friend who does good jobs in lightings, post a message in the page and he'll get back to you. . . You can see his work on the page, he does a very neat and good job, he'll tell you the best upgrade. . . Good luck. . .

                    Cheers!!!

                    Hi Rakesh,

                    Thanks a lot, have dropped a message to DVJ on my query, will reply to you guys once I receive one.

                    ----consecutive posts auto-merged-----

                    Originally posted by Cleaner View Post
                    Those are expensive and fitting them in reflector would cause glare. Also they need DC supply, it means you will have to rewind the stator coil and use an Ape RR. The rewinding and the ape RR gonna run you for about 3,500 rupees. Phillips kit comes at very high price and there is a debate about whether they are genuine or not. I'd suggest you to stick to 60/55w DC conversion as I don't recommend spending a lot of money of this old bike, it's your money, you can invest too, if you like. BTW you can not flash HID bulbs, so that would be a problem in daytime flashing. To flash a H4 HID bulb the bulb will have to be warmed up, which takes a couple of seconds. D2 are single beam, D2S is for projectors and D2R is for reflector AFAIK.

                    Under 4300K bulbs should not cause problem with cops, the founder of https://www.facebook.com/dvjautotech is running a 55watt 4100K (or was it 4200K) HID in reflector and according to him, he has never been stopped by cops for that. Your mileage may vary though.
                    Thanks Cleaner,
                    Have dropped a message to DVJ auto as per Rakesh suggestion. Am not sure about West Bengal were the founder of DVJ dwells, but here in Chennai our cops catch us just by seeing the white lights only. . And am already rewinding my stator coil, changing battery from dry cell to liquid one and also upgrading to bigger rectifier than the one which exists for Pulsar 150 2005 model(Attached pic below). So, just I need a brighter bulb alone now.
                    Click image for larger version

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                    ----consecutive posts auto-merged-----

                    Originally posted by lockhrt999 View Post
                    I'd say just rewind the stator coil and put a 90/100W bulb. Shouldn't cost more than Rs. 500. Also add another 100 for reflector that you would need to change every year.

                    Secondly far too less vehicles use halogen for low beam and xenon for higher beam. Xenons are suited for low beam and halos for high beam.
                    Hello Lockhrt999,
                    I heard going for 90/100W bulb would burn our reflector and also the wiring? Is this the reason why you asked me to change the reflector every year?
                    Last edited by Sakthi Santhosh N; 11-03-2013, 04:09 AM. Reason: Added Rectifier Pic

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                    • #11
                      Re: Pulsar 150 Engine Rebuild and light upgrades

                      Originally posted by Sakthi Santhosh N View Post
                      Hi Rakesh,

                      Thanks a lot, have dropped a message to DVJ on my query, will reply to you guys once I receive one.
                      , have messaged him as well. . .

                      Cheers!!!
                      Yamaha Rx135 - 2005 - 2007 (stolen :mad:)
                      Scooty Pep - 2008 - 2012 (sold)
                      Honda Unicorn - 2012 - 2015 (crashed)
                      Hero Honda Splendor+ 2015 - present (temporary ride)
                      Bajaj Pulsar AS200 - 16th September 2015 - present ride

                      10 years into riding :D
                      Live2Race. . .

                      Comment


                      • #12
                        Re: Pulsar 150 Engine Rebuild and light upgrades

                        Originally posted by Sakthi Santhosh N View Post
                        Thanks Cleaner,
                        Have dropped a message to DVJ auto as per Rakesh suggestion. Am not sure about West Bengal were the founder of DVJ dwells, but here in Chennai our cops catch us just by seeing the white lights only. . And am already rewinding my stator coil, changing battery from dry cell to liquid one and also upgrading to bigger rectifier than the one which exists for Pulsar 150 2005 model(Attached pic below). So, just I need a brighter bulb alone now.
                        [ATTACH=CONFIG]123294[/ATTACH]

                        -
                        Use the Ape RR, it's a proven system and unlike "bigger" RRs it would be reliable, trust me, you don't want any fried electrical on your bike. 4100K HID would not be white, it would be yellowish white. Or just get 3500K bulb (Good luck finding them in India, though) I have a few D2S bulbs in 3500K but not willing to sell. Since you want to be safe from cops, I suggest you stick to 60/55w halogen setup. Both Osram Night Breaker and Phillips X-tremeVision provides better illumination than normal 55watt halogen bulbs but bulb life is shorter in comparison. Any H4 bulb will be direct fit in P150 bulb socket. Going higher that 55watt will burn down the reflector so you have to watch out for that.
                        I am back!

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                        • #13
                          Re: Pulsar 150 Engine Rebuild and light upgrades

                          Originally posted by Sakthi Santhosh N View Post
                          Hello Lockhrt999,
                          I heard going for 90/100W bulb would burn our reflector and also the wiring? Is this the reason why you asked me to change the reflector every year?
                          Yes. that's right, even if you keep changing reflector every year it won't cost bomb. And if you use relays and high gauge wires it won't be problem for next 300 years.
                          See if you want to put HID on this bike, firstly you'll have to make your bike full DC that means changing/rewinding stator coil, buying Ape RR which costs more than a thousand, new battery around 1.5k, HID kit around 1.5k all in all total will go around 5k.

                          But if you go for 90/100 W bulb all you have to do is rewind the portion of stator coil which powers the headlight and use high gauge wire with relay, Coil rewinding = 100, bulb= 100, wire and relays = 100, labor = 100 to 200. That's it, you don't need new battery and RR.
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                          • #14
                            Re: Pulsar 150 Engine Rebuild and light upgrades

                            Hey, i got the spoke wheeled pulsar too, and i used the cheaper way out. I used the old ALL-DC mod by abhijeet080808. And then replaced the stock bulb with a Maruti ALTO 800's bulb (60/65W)
                            It's been more than 6months and it works pretty good
                            Only downside is if you ride more than 3hours in high beam, the battery starts to drain. But it'll be recharged after an hour of daytime run.
                            (If you already went for the coil rewinding, then you wont have the battery drain issue too.)

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                            • #15
                              Re: Pulsar 150 Engine Rebuild and light upgrades

                              Originally posted by co0lG View Post
                              Hey, i got the spoke wheeled pulsar too, and i used the cheaper way out. I used the old ALL-DC mod by abhijeet080808. And then replaced the stock bulb with a Maruti ALTO 800's bulb (60/65W)
                              It's been more than 6months and it works pretty good
                              Only downside is if you ride more than 3hours in high beam, the battery starts to drain. But it'll be recharged after an hour of daytime run.
                              (If you already went for the coil rewinding, then you wont have the battery drain issue too.)
                              Oh, Thanks yar.
                              I too went with 60/65W bulb after rewinding the coil and adding the bullet rectifier adding to the existing rectifier. Now the headlight is good enough.

                              But my low beam is not that long enough. Its very low, even if I go at 40kmph, the light is only bright nearby, I couldn`t check what is there at a required little far distance which should be there for low beam.

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