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Pulsar 200NS Coolant leak inside engine block - Repair
Hello everyone,
There is one belief I have when it comes to two important things in life which is "bikes and wifes can't be given in other man's hands till its last option" and you know chances are the consequences might not be the pleasant if you do.
Now as I have said it the 99% xbhpians would understand why I choose to do this DIY by my self.
The problem started nearly a week ago before I was convinced that this is the coolant leak bcoz at start it looked like some milky texture on the oil guage glass and didn't attract my attention.
Few days later since it was end of rainy season I thought of giving the bike the special washing treatment, took the bike to washing center and cleaned it thoroughly. After washing I always check for all fluids are in at most levels or not and to my surprise my engine oil was looking distinctively green. The moment I looked to coolant reservoir I was confirm that it's coolant.
Next immediate question in mind was what can I do now and how to take the bike to home again, since the washing center is under one kms I took the chance of riding it back and reached home, called service center to ask about the problem but the solution given to me was that I should get the bike to them and which was out of question since it's exactly 27kms from home.
So decided to do some research on the issue till I figure out reaching the service center, found some valuable things and decided to have a look by myself. Having a bit of knowledge about the engines I took the risk and started to search for root of problem.
Started the bike and my first worry was blown main gasket which also may result in mixing coolant in engine block but to my good luck bike was running smooth with out making any weird engine noises if it was gasket.
Next thing to look was the O rings between balancer shaft and water pump impeller, drained the coolant and engine oil and started opening the water pump assembly.
Completely opened the water pump assembly and looked at O ring seals and found they are not in great shape
Now the problem was how to get them out in proper way so contacted service center again and too my surprise they told me they need to open the engine to just take out the O ring seals. Heartbroken I was
Arranged the transport tempo for next day to send my precious to service center and just looked at this
I did had the idea that bajaj had developed the NS engine with using KTM Duke 200 engine base but it's actually the KTM made engine base and the bajaj only put three spark plugs on top of it( I know many things are changed)
The bajaj has this habit of copying things from other established manufacturers like wise in Kawasaki K4, Got to know the starting lot of Duke do have this same problem and I know why
Did some research and pulled out both the defective O ring seals with causion, now comes the most painful part of the job getting the New spare O rings.
The lack of parts at service center and also because of some fools at service center they kept me waiting for one week, after contacting many places finally got the spares.
Did the fitting and pour the engine oil and coolant, kept the bike running for 15-20 mins. The radiator fan kicked in and everything was butter smooth again.
After test riding it for 100 or more kms in three days the oil is still clean and the cooling is also great.
Moderators, I think I don't have enough pics of the job but it's a attempt for fellow guys to understand the problem is not that Big as service centers are misguiding and I do not recommend a DIY as well, I did the job coz I have the knowledge of the things and I did know exactly what I was doing, so move the post to appropriate category
There is one belief I have when it comes to two important things in life which is "bikes and wifes can't be given in other man's hands till its last option" and you know chances are the consequences might not be the pleasant if you do.
Now as I have said it the 99% xbhpians would understand why I choose to do this DIY by my self.
The problem started nearly a week ago before I was convinced that this is the coolant leak bcoz at start it looked like some milky texture on the oil guage glass and didn't attract my attention.
Few days later since it was end of rainy season I thought of giving the bike the special washing treatment, took the bike to washing center and cleaned it thoroughly. After washing I always check for all fluids are in at most levels or not and to my surprise my engine oil was looking distinctively green. The moment I looked to coolant reservoir I was confirm that it's coolant.
Next immediate question in mind was what can I do now and how to take the bike to home again, since the washing center is under one kms I took the chance of riding it back and reached home, called service center to ask about the problem but the solution given to me was that I should get the bike to them and which was out of question since it's exactly 27kms from home.
So decided to do some research on the issue till I figure out reaching the service center, found some valuable things and decided to have a look by myself. Having a bit of knowledge about the engines I took the risk and started to search for root of problem.
Started the bike and my first worry was blown main gasket which also may result in mixing coolant in engine block but to my good luck bike was running smooth with out making any weird engine noises if it was gasket.
Next thing to look was the O rings between balancer shaft and water pump impeller, drained the coolant and engine oil and started opening the water pump assembly.
Completely opened the water pump assembly and looked at O ring seals and found they are not in great shape
Now the problem was how to get them out in proper way so contacted service center again and too my surprise they told me they need to open the engine to just take out the O ring seals. Heartbroken I was
Arranged the transport tempo for next day to send my precious to service center and just looked at this
I did had the idea that bajaj had developed the NS engine with using KTM Duke 200 engine base but it's actually the KTM made engine base and the bajaj only put three spark plugs on top of it( I know many things are changed)
The bajaj has this habit of copying things from other established manufacturers like wise in Kawasaki K4, Got to know the starting lot of Duke do have this same problem and I know why
Did some research and pulled out both the defective O ring seals with causion, now comes the most painful part of the job getting the New spare O rings.
The lack of parts at service center and also because of some fools at service center they kept me waiting for one week, after contacting many places finally got the spares.
Did the fitting and pour the engine oil and coolant, kept the bike running for 15-20 mins. The radiator fan kicked in and everything was butter smooth again.
After test riding it for 100 or more kms in three days the oil is still clean and the cooling is also great.
Moderators, I think I don't have enough pics of the job but it's a attempt for fellow guys to understand the problem is not that Big as service centers are misguiding and I do not recommend a DIY as well, I did the job coz I have the knowledge of the things and I did know exactly what I was doing, so move the post to appropriate category
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