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**sunilg** · 10-27-2010, 01:08 PM

Query approved.

**ROCKRZ** · 10-27-2010, 01:15 PM

Have you checked the driving sprocket??? I had a similar problem inmy bike.. But this used to happen in 40-60 kmph speeds in 3rd and 4th gear.. The problem turned out to be a wor sprocket.. I suspect that in your case, the problem is not with the gearbox but with the sprockets.. Try re-tensioning the sprockets and lubricating them.. If the noise goes for a couple of hours of riding, the problem is with the sprocket..

**Hunky** · 10-27-2010, 01:44 PM

Hello sir,

Please refer to the P220 DTS-i ownership thread.. some of the problem you said is common with P220 and fixable..

When i press the clutch while driving slow or even while at 50-60 on a straight track, within like 3-4 secs, a rumbling sound develops, kinda like the redundant sound you hear while sitting in a train (dadak dadak ... dadak dadak). I'm pretty sure its the gearbox.

usually Kolkata PBK points towards the idle gear / clutch load balancer. This needs adjustment.

Also there's one more problem i am facing. About a month ago, i left home for a 15 day vacation. When i came back and rode my bike, there was a strange clicking noise from the left side of the engine. Bagga link karol bagh technicians told me that the timing chain needs to be replaced. Got that done. There was no sound for 3-4 days after the fix.

indeed here to (kolkata) with our machines we have noticed timing chain (Rs. 180) tentioner nut (Rs. 200) and timing chain assly gear (Rs. 188) needs replacement at around 8k to 10k kms..

Now again there's some different noise from the engine when i start it idle, without sitting on the bike. There's no such sound while driving.

Personally I would point towards the Starter and Rotter Clutch holder spring and bush.. They may need replacement (Rs. 52)..

Thanks..

**bhavandeepsingh** · 10-30-2010, 11:52 AM

Originally posted by Hunky View Post

Hello sir,

Please refer to the P220 DTS-i ownership thread.. some of the problem you said is common with P220 and fixable..

usually Kolkata PBK points towards the idle gear / clutch load balancer. This needs adjustment.

indeed here to (kolkata) with our machines we have noticed timing chain (Rs. 180) tentioner nut (Rs. 200) and timing chain assly gear (Rs. 188) needs replacement at around 8k to 10k kms..

Personally I would point towards the Starter and Rotter Clutch holder spring and bush.. They may need replacement (Rs. 52)..

Thanks..

Thanks dude, that was VERY intricate and specific. Now i feel a little better because i can at least tell them what could be the problem source.
Much appreciated!

**bhavandeepsingh** · 10-30-2010, 11:53 AM

Originally posted by ROCKRZ View Post

Have you checked the driving sprocket??? I had a similar problem inmy bike.. But this used to happen in 40-60 kmph speeds in 3rd and 4th gear.. The problem turned out to be a wor sprocket.. I suspect that in your case, the problem is not with the gearbox but with the sprockets.. Try re-tensioning the sprockets and lubricating them.. If the noise goes for a couple of hours of riding, the problem is with the sprocket..

I'll get the sprocket changed and get back with the results. Thanks for the prompt input mate.

**shyamsharma** · 10-31-2010, 12:16 AM

i have purchase a pulsar 220 a week back .

the problem is my bike is making some noise when i take the RPM to around 5k or 6k thik thik sound

my bike has just run 700 kms .

**bhavandeepsingh** · 10-31-2010, 12:37 AM

Originally posted by shyamsharma View Post

i have purchase a pulsar 220 a week back .

the problem is my bike is making some noise when i take the RPM to around 5k or 6k thik thik sound

my bike has just run 700 kms .

Try this - try riding the bike in 2nd gear at constant 4k rpm. If the sound worsens or is more noisy, then you are sure there's something wrong inside. My bike's engine noise is just unbearable when driven at constant rpm (4k) at lower gears. Same problem as yours.

Take what advice is mentioned above. Starter and Rotter Clutch holder spring and bush may need replacement. Also you may get your timing chain and tensioner assembly replaced. Net cost around 1200 bucks.

I understand that your concern is that since your bike is new, so it should not have these problems. But when i visit the service stations, i see varied cases - people driving the bike for the past 1.5 yrs and may need only oil change. Also there are people like us who have 2010 models but still are struggling with manufacturing defects. Can't do anything. Just make sure you get this all fixed while you can avail your 3 free services : ) Avoid the labor charge till you can.

I'm sure that engine noise related problems are frequent with the pulsar 220s : (

**bhavandeepsingh** · 11-09-2010, 10:40 PM

Hi,

I'm sorry i'm posting here again...but i wanted to avoid explaining the issue again at the ownership thread.

I've gotten my one way clutch replaced. No more 'Tchirr Tchirr' from the engine for the past 2 days. Hoping it stays that way

1st problem still not addressed @ SVC. Whenever i depress the clutch, the same 'gad gad gad' noise comes from gear box like something is still active even after clutch depression.

Also i have made one more observation.
With - Engine OFF, 1st gear, clutch depressed->
Now, if you move the bike, there is a 'free-friction-free-friction-.....' pattern...Something is really blocking free motion of wheel. When i asked the same at probiking, they told me that this is normal. I have owned a pulsar 200cc before and i never faced such issues with it.

PBK guys just want to avoid difficult jobs i think!!!

In the previous posts it is mentioned the 'idle gear balancer' needs adjustment in this issue. Can you please explain the procedure in brief so that i can explain to the mechanic and get this done.
PS: The clutch cannot be any tighter (both engine side and hand lever side) than it is now...

Please help me XBHP pros!!!

Much appreciated...

**rs_creep** · 08-04-2013, 12:50 PM

Re: Pulsar 220cc DTSI manufacturing defects

i am also facing the sme problem bro while on idle no sound comes but while the engine is hot sond begins tocom from upper side othe engine like tak tak tak tak continious

**bhavandeepsingh** · 08-04-2013, 12:58 PM

Re: Pulsar 220cc DTSI manufacturing defects

Originally posted by rs_creep View Post

i am also facing the sme problem bro while on idle no sound comes but while the engine is hot sond begins tocom from upper side othe engine like tak tak tak tak continious

get ur timing chain checked. It could require replacement.

**Divya Sharan** · 08-04-2013, 12:58 PM

Re: Pulsar 220cc DTSI manufacturing defects

Originally posted by rs_creep View Post

i am also facing the sme problem bro while on idle no sound comes but while the engine is hot sond begins tocom from upper side othe engine like tak tak tak tak continious

That is normal. Just to verify, check whether the sound comes from the silencer or the engine. It may be the catalytic converter cooling down. Happens with all bikes. This happens only when the engine is hot and is switched off. If the sound comes during riding, get your tappets adjusted.

**petrolhead_chn** · 08-04-2013, 01:10 PM

Re: Pulsar 220cc DTSI manufacturing defects

Originally posted by rs_creep View Post

i am also facing the sme problem bro while on idle no sound comes but while the engine is hot sond begins tocom from upper side othe engine like tak tak tak tak continious

How many kilometers is on the odo? When was your bike serviced at SVC last?
You need to adjust the tappet settings to get rid of that sound. Remember to do the tappet setting only on a cold engine.

**rs_creep** · 08-04-2013, 01:10 PM

Re: Pulsar 220cc DTSI manufacturing defects

it comes when my engine is on idle or when i stop my bike on gear it sounds like kat kat kat from upper side of the engine! and som 1 told me to replace the balancer...is it right..to replace the balancer.it only comes when my bike engine begins to becom hot and bike is pulsor 220f new model and only 45000 km done!plz help me service guys says its normal...

**petrolhead_chn** · 08-04-2013, 01:15 PM

Re: Pulsar 220cc DTSI manufacturing defects

Originally posted by rs_creep View Post

it comes when my engine is on idle or when i stop my bike on gear it sounds like kat kat kat from upper side of the engine! and som 1 told me to replace the balancer...is it right..to replace the balancer.it only comes when my bike engine begins to becom hot and bike is pulsor 220f new model and only 45000 km done!plz help me service guys says its normal...

Solution - Tappet adjustment to be done on a cold engine!
Idle balancer gear or the scissor gear do not get busted so easily. If tappet adjustments fails, then you can try alternates.

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Pulsar 220cc DTSI manufacturing defects

Pulsar 220cc DTSI manufacturing defects

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