Query approved.

as your bike isn't revving over 8000 rpm, its to do with the CDI and its all electronic issue, nothing to do with the jet or K&N

tell me, as you said many mechs tried to install it but no avail, does it mean its not installed ??
the overheating shows that the bike is running LEAN mixture, that vibration as well as roughness indicates the same.
don't be paranoid, check your spark plug, post a picture in the spark plugs thread, get your jet changed if its stock, if Karizma's isn't fitting (possibility) then drill a 1 mm hole in your current jet, your problem will be solved.

i hope it helps.

try putting bigger jets atleast 125 ones the stock ug3 runs 117.5 so you will have to jet much higher (125 atleast) to compensate for the extra vol of air supplied ,its also the reason why the engine is not revving higher as there is not enough fuel in the mixture......do not worry your electronics are fine and it has nothing to do with this ,as for drilling the jets there is no point in drilling a 120 jet with a 1mm bit as the hole will be already bigger

If you've time & patience then do this instead of approaching mech by mech & garage by garage.

- First, put all the things back to stock & then the Pulsar SHOULD touch the 8K mark, if it doesn't then there's something wrong with the basics. Like Nano says, it could be with the CDI
- If it touches 8K mark, then plonk one by one, start with K&N, then change the MJ. Do everything step by step & verify the RPM level after each step.

Last but not the least, if the issue is still not sorted out, bring it during one of our Chennai G2G & we can have a look

How much Kms you have clocked?
If its nearing 40k, better to check compression pressure it must be between 90 to 140 PSi (near to 140 is best)
Better get the engine decarbed, valves lapped and piston rings and piston-bore checked.
While reassembly, check for timing chain tension and valvetrain timing. If the chain is elongated or noisy, change it. Set the valve clearances as Intake 0.05 and Exhaust 0.1.

Get the CDI tested from bajaj SVC or try interchanging it with another P180 UG3.

Coming to K&N and tuning, 2.5 upjet is fine enough.

First of all, the ZMA jet is 125.
You need to readjust the chain tension.
Bajaj oil sucks big time.
Adjusting the fuel screw will not help at it deals with just 1/4th of the throttle opening.
By not goes beyond 8000RPM, what are you trying to say?
Do you mean to say that engine shuts off? Or does it seems like bike is running out of fuel?...If yes then you are running lean which can be confirmed by a spark plug reading.

If your bike just stutters as in refuses to rev but doesn't feel like fuel starvation, then its getting flooded ie: too rich

The flooding thing happened with me when I got the free flow intake too. The reason was an excessively large main jet. In this case the spark plug goes jet black at the tip.

Post pics of your spark plug and we can help you more.



@Nano: It is probably not a CDI problem.

+1 for that...........

@thread starter:

I too have faced the issue of bike not going above 8K rpm, howsoever, I accelerate. The culprit was Lean AFR. ZGot it set again to Normal and the bike rocketed past 8K@5th gear.

@NANOtechnology: No the K&N is fitted, directly to the carb.

@Nanno and kb100: sorry the jet size is 125 as "pavanchirmade" said.

@aargee: Before using the K&N my bike went till 10.5k and the top speed was 113kmph, after fittng it i tuned it with the stock 117.5 jet, the same result nothing above 8000rpm. then went for the 125 jet, still the same result.

@nox2505: Mine has clocked 13500kms !!!

@pavanchirmade & @all: It reaches full throttle near 8k rpm, the bike just refuses to accelerate further a few more kmph (+4) and thats it. no suffocation problems nor engine gets shut off. But if its rich i think it should give more power at lower rpms, it knocks (not so severe) at 13kmph in 2nd gear and 33kmph at 5th gear, i feel lack of power. It gives small bursts at 1/4th of acceleration. I can feel the heat with just 5-10minutes of normal driving, and a burning smell a little later. But has a crisp acceleration but not that matches the sound it produces while accelerating.

I have ridden with K&N for around 2500 kms without upjetting but just tuning, no long rides but short ones like a max of 15-20km in one stretch. Will that have a bad impact? and right from the begining my bike used to give some clattering sound during high speed rides or 15 minutes continuous average speed rides 50-55kmph (both in city n Highway), what might that be.

Sorry I dont have a camera nor in mobile with me to show you the snap of my spark plug ! But will inspect and let you know.

What about the CDI problem? One mechanic asked me to check the same when he was just revving.
@aargee: O O I missed a g2g, when can we meet the next?

Thanks guys...

This has to be a lean running bike.. revert back to stock filter, and check performance. There might be a slight drop in mileage, but first check performance with the carburettor as is.

What's your pilot jet's size? Why wasn't that changed? Also what's the needle's position from top? Unless we have a look on a video or something, its little difficult to understand the issue.

Keep checking http://www.xbhp.com/talkies/xbhp-off...2g-thread.html for the meets update.

Generally the stock pilot jet works just fine with the AF screw tuning. No need to shift needles or change pilot jets. I too have a P180 running a free flow intake and I changed the main jet. Also the engine struggling to rev past 8000 rpm has nothing to do with the pilot jet as it is not in the picture at high throttle openings. The pilot circuit deals with just 1/3rd of the throttle opening. Its the main jet that meters the fuel after that.

The topicstarter definitely has a problem with the main jet. Too big can flood and stutter the engine[been there] and too small can lean out and the engine starves of fuel.

The exact problem can be determined only by looking at the spark plug tip.

Then fine. just get the valve clearances set. 125 is too big jet.

Your engine is flooding for sure. Check the spark plug. It must be sooty black.
Change the jet to a smaller size. Get a custom drilled jet if you cant find a suitable size.