Re: Reviving my trusted ride... pulsar 150 2002

did you get the bore replaced

Re: Reviving my trusted ride... pulsar 150 2002

It is stock mate... the ones that is meant for p150. Why do you ask?

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Re: Reviving my trusted ride... pulsar 150 2002

No kb100. I could not return it. I don't think I will. I enquired many ASC and they suggested UG3 cylinder lit. The stroke remains the same at 56.4mm while the new dia is 58mm instead of 57mm. I did not notice any knocking except for the exhaust being a little shaky at header which causes air leak i suppose. Strangely i do not sense any backfiring as such. But the exhaust vibrates a lot mate. The baffle seems intact. Any suggestions??

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Re: Reviving my trusted ride... pulsar 150 2002

That looked very bright so asked. Being a CBZ classic owner that was a bit too much for me

Re: Reviving my trusted ride... pulsar 150 2002

Excellent task Boss. Kudos for the great work. I have been hunting for one such thread for couple of months.

I own a Pulsar 150 2003 model and currently using it in Chennai. I maintained it almost well. Recently i have encountered clutch slip issue. Upon contacting the local as well as Bajaj service people, i was ended up with usual statement from them "CLUTCH PLATE NEEDS REPLACEMENT". I also believed that it needed a set of replacement clutch plates because the bike was brought as second hand around 3 years before in Bangalore and I don’t know when the last change was made.
Having hard time getting worst service support even on minor issues from the service guys here, i thought of changing the clutch plates on my own.
My friends suggested me to sell it off and get a new bike. But, I know the pain I will face if I sell it. Not for the resale value it holds, but for the great moments I had with it.
So, i went through online forums, youtube vids for couple of days and made a personal manual to make sure that i will not be screwing up my bike during the task.
Necessary tools and new clutch plates (of Discover 125), Gasket, Glue, Engine Oil were brought and the day has arrived (i.e. exactly on this Christmas). Everything starting from clutch cable removal to refilling oil was crudely recorded. New clutch plates were installed, everything else was put back together assuming that the bike would be ready.
But, i was given with a shock then. I made my test ride after filling with new engine oil and I could feel some notable vibrations in the handle bar even during idling which kept on increasing as i revved up (which used to be very smooth with the old clutch plates and before this change!). However, gear shifting was smooth and clutch travel was progressive. I don’t have the guts to keep riding with these vibrations thinking that it might create a mess.
Any suggestions as what could be the cause for this vibration? During the test drive, I rode it for close to 2 kms with the same afore mentioned vibrations. Would this test drive make any further impact?

Re: Reviving my trusted ride... pulsar 150 2002

Just wondering how a clutch plate replacement can cause vibrations. More surprisingly when the bike is in neutral and standing. It has to be with something else

Re: Reviving my trusted ride... pulsar 150 2002

@nirvaana & [MENTION=62914]petrolhead_chn[/MENTION]: Wish you a Happy New Year.

I have not checked my pulsar after this issue as i was out of station for couple of days. Planning to open the clutch side case on this weekend. Let me try to fix the issue somehow this time. In the mean time, any suggestions on any specific part to be checked?

Re: Reviving my trusted ride... pulsar 150 2002

Happy New Year mate.

Hope there were no mistakes during installation. As you did it yourself probably try reverting to the old setup. That will directly point issue to either wrong installation/issue with new parts.

Re: Reviving my trusted ride... pulsar 150 2002

HI mate. New year wishes to you too. Thank you.

If I understand it right, you installed clutch plates yourselves and you feel vibrations in the bike?
The primary reason could be that the clutch springs may not be seated properly.

Apart from that...

1. Ensure the plates are for your model only. Compare it with your old set for correct number of tooth. Why discover's?
2. Now when you get the plates out, soak it in engine oil for sometime.
3. If the vibrations are heavy I suspect the idle and body balancer gear.
4. Hope you havecorrect play.

Let me know if this answered your query mate.

Re: Reviving my trusted ride... pulsar 150 2002

@nirvaana: Thanks for that. But, I have replaced only the clutch plates (not even pressure plates). Rest all were the same old parts. Also, i don't have the old plates to check since i have already disposed them.


@petrolhead_chn: Thanks bro. Yes. I tried to replace it on my own

I will do those works and check the springs this time.

I could not source the original plates for pulsar 150 classic even from the authorized service centers. One of the local spare shop guy gave me Discover 125's plates and confidently said that it will suit for Pulsar 150 classic. Even, i checked the new plates with my old plates and saw the teeths were evenly matching.

Is it possible to disturb the idle and body balancer shafts unknowingly during clutch plate replacement? What would be the cost of these parts if i go for new ones?

Re: Reviving my trusted ride... pulsar 150 2002

How did you conclude that pressure plates needn't be replaced? Did you take off the housing as well during installation? Hope you put the washer back as well?

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Re: Reviving my trusted ride... pulsar 150 2002

Vibrations has gone this time ..

Thanks a lot guys for your suggestions. I opened the clutch side cover, dismantled all the clutch related stuffs (except clutch housing), oiled the clutch plates and put them back together.. Started and felt the vibrations are completely gone.

Could not find what was the vibration causing culprit though

@petrolhead_chn: Pressure plates were not worn / distorted at all. Also they seemed to have uniform thickness... So i used those again!

Re: Reviving my trusted ride... pulsar 150 2002

[MENTION=62914]petrolhead_chn[/MENTION]: I just happened to see an ad posted in Chennai OLX about a Pulsar 150 sale. Seems like the images in the post are all of yours.. Is that the ad posted by you?

Re: Reviving my trusted ride... pulsar 150 2002

Yes. It is. I am glad you recognized. Why do you ask?

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Re: Reviving my trusted ride... pulsar 150 2002

I was actually shocked since you have put your painstaking efforts in rebuilding your ride and now it has come for sale.