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**sunilg** · 01-20-2011, 12:04 AM

Query approved.

**pavanchirmade** · 01-20-2011, 12:31 AM

Originally posted by Ayson View Post

Hello everyone.

I recently had a crash in which the bike was damaged a bit. I would like some help in fixing it up. Here are the deatils first. It is a Pulsar 180 UG-III, black, everything stock.

The damages are all round and most of those need replacement, like the R. brake pedal, crash guard, handle bar, headlight assy., fairing and windshield, key and lock assy., maybe digi console.... I plan to do all of the work except body and paint work by myself.

I have to check if the digi console is damaged. It doesnt start sometimes and the neutral light sometimes goes on and off. The key assy. is broken and i hope it is due to that. The RPM needle is offset now. And if the mounting holes are broken i wll have to replace it.

1) If i replace it, will i get my old info inputted in the new console? ie odo reading.
2) If it is just the RPM needle is offset, can it be fixed?
3) Any approx cost of the console?

My tank is dented ~3cm radius on the left, scratches on top right, and small poke dent where handlebar swithches contacted it. There are some previous scratches and some paint faded areas due to some unknown event (petrol spill?)

4) Any option other than a repaint?
5) Will Bajaj ASC do dent repair and paint job?
6) Is the ASC the best place for this work and will they get it back to the original factory state?
7) What is a reasonable cost for an entire repaint job for the tank?
8) What would a new tank with "spoilers" cost and will it be compatible?

The rear body plastic has also been scratched a bit. It has lost that clearcoat type thing.

9) Can this part be painted and does it come painted from the factory?
10) What other repair options does this part have?

Please help me out with these questions and help me fix up my bike soon. Also, please give me any other suggestions if you feel like too. Thanking all of you.

Try getting the work done under insurance cover.. in it they replace most of the parts. Metal parts have more value than fibre/plastic parts.

**lijok** · 01-20-2011, 12:33 AM

Ayson - replace the crash guard and handle bar. After straightening them, they wont have the same strength as before and next time when you crash (lets hope you dont) it will land you in trouble...

The plastic body parts, if not severely broken, can be treated with a process sort of like buffing. It will take off a little bit of the material evenly, but the gloss finish will be retained.

Cant comment on the rest... Good luck in getting your ride back to shape...

**Ayson** · 01-20-2011, 12:47 AM

@pavanchirmade
Um, im ashamed to say this but, the crash happened right in between insurance expiry and insurance renewal.

@lijok
I am planning to replace the crash guard and handlebar anyway. They will probable snap the next time if i straighten them now. Thanks for the tip. The headlight area is totaled but the plastic body is not broken at all from what i have seen, but is scratched. Is this buffing type process you mentioned provided by the ASC?

**xionite** · 01-20-2011, 12:58 AM

Originally posted by Ayson View Post

1) If i replace it, will i get my old info inputted in the new console? ie odo reading.

no u won't. the reading on the new console will start at 0000km

Originally posted by Ayson View Post

2) If it is just the RPM needle is offset, can it be fixed?

possible. but from what u've described...
it's very unlikely that only the needle's been damaged.

Originally posted by Ayson View Post

3) Any approx cost of the console?

approx 1500 rupees or so. not sure tho.

Originally posted by Ayson View Post

4) Any option other than a repaint?

as in? replace the tank?
costs about 4 something grand.

Originally posted by Ayson View Post

5) Will Bajaj ASC do dent repair and paint job?

what colour is ur bike?
coz bajaj cannot colour match their own red / long beach blue bikes.

Originally posted by Ayson View Post

6) Is the ASC the best place for this work and will they get it back to the original factory state?

not necessarily. u haven't got any engine stuff that's been damaged.
u can even get the parts replaced at a good mechanic / paintshop.
labour costs are higher at Bajaj SCs too.

Originally posted by Ayson View Post

7) What is a reasonable cost for an entire repaint job for the tank?

about 2000 rupees for a good job.
again, P18O blue n red are difficult to colour match.

Originally posted by Ayson View Post

8) What would a new tank with "spoilers" cost and will it be compatible?

yes... it's a direct fit. but u will have to replace ur crash guard with the P2OO/P22O too.
and since it's been damaged anyway... now's a good time to make the change.
you will have to make a few mounting point for the P2OO/P22O crashguard tho.

Originally posted by Ayson View Post

The rear body plastic has also been scratched a bit. It has lost that clearcoat type thing.

9) Can this part be painted and does it come painted from the factory?

it comes painted.

**pavanchirmade** · 01-20-2011, 12:27 PM

About the console, don't go for a new one. Search around local scrap yards. Talk to some local mechanics about the whereabouts of such scrap yards in your city. I am sure you will find a speedo console really cheap over there. Then if your speedo circuitry is working properly you can use the scrapyard speedo's body. The needle can be realigned easily. In some UG3's the needle would offset on its own which is easy to rectify.

IMO speedo will be the only "very expensive" part in your repair work.

If you can live with the dent then don't change the tank. There's a guy in my city who repairs tank dents. He never lets you see how he does it but he does a pretty good job.

Since you've had a fall and your handlebar is bent, you will not be able to achieve a straight handle. The handlebar "T" bends very easily in a fall. Yours has to have bent. Get that checked. it can be fixed by mechanics. I once had a fall and got the T rectified for 300 bucks.

Every fibre panel comes prepainted from the factory. But if you have a blue/red bike the new panels will look far better and different than the older ones as these colors tend to fade faster.

**Ayson** · 01-20-2011, 02:29 PM

Thank you everyone for the replies.

@xionite
Is is possible to input the current reading into the new console?

I have to see how much the console is damaged after removing it from the mounting. From the surface it looks intact. The neutral light seems to be going on and off. I hope that is due to the connector or the key assy..

The bike is black. I am going to do all the replacing myself. The painting is what i am not skilled at. I hope to get the dent straightened and get a paint experts advice on what to do about the scratches. ie whole paintjob or touchup. I also hope to get a clearcoat, finished to factory standard.

Why would i need to upgrade my crashguard if i get the new tank? Will the new tank cause any turning difficulties?

@pavanchirmade
Ill try to do what you said about the console. Hope it isn't damaged inside.

Im planning to replace the handlebar, no other considerations. No straigtening. The bike rides ok and does not wobble and goes staright with hands off. So i hope nothing's wrong with the "T"? Let me disassemble and see.

I'm planning to start work by this SAT or SUN.
11) Is the tank double-skinned?

**xionite** · 01-20-2011, 03:51 PM

Originally posted by Ayson View Post

@xionite
Is is possible to input the current reading into the new console?

not that i'm aware of.
but it is possible. definitely not worth the trouble tho.

Originally posted by Ayson View Post

The bike is black. I am going to do all the replacing myself. The painting is what i am not skilled at. I hope to get the dent straightened and get a paint experts advice on what to do about the scratches. ie whole paintjob or touchup. I also hope to get a clearcoat, finished to factory standard.

black is easy to touch up etc. u shouldn't face any real issues.

Originally posted by Ayson View Post

Why would i need to upgrade my crashguard if i get the new tank? Will the new tank cause any turning difficulties?

you asked ...
"What would a new tank with "spoilers" cost and will it be compatible?"

the UGIII crash guard is bigger.
if you try putting on a new tank with "spoilers"...
the stock crash guard will come in the way.

have a look...

this is the UGIII
[IMG]http://**********.s3.amazonaws.com/wp-content/uploads/2010/03/Bajaj-Pulsar-150-DTSI-UG3-01.jpg[/IMG]

and this is the UGIV
[IMG]http://**********.s3.amazonaws.com/wp-content/uploads/2010/10/Bajaj-Pulsar-180-DTSi.jpg[/IMG]

the UGIV has a shorter crash guard
(since it shared the part with the P2OO/P22O both of which had 'Oil Coolers')

so u'll need to mod the mounting points a bit.
not a big deal tho.

.

**Mecho** · 01-20-2011, 04:34 PM

Originally posted by Ayson View Post

Hello everyone.

1) If i replace it, will i get my old info inputted in the new console? ie odo reading.
2) If it is just the RPM needle is offset, can it be fixed?
3) Any approx cost of the console?

Please help me out with these questions and help me fix up my bike soon. Also, please give me any other suggestions if you feel like too. Thanking all of you.

Console for UG3 would cost you approximately 2400 INR

Just checked with Deedi Bajaj > Kaimanom

**Mecho** · 01-20-2011, 04:41 PM

(Assuming you are from trivandrum )

If you plan to get a spray paint, I would recommend BOSNY

(for engine parts, alloys and muffler only)

For the rest paint job, take it to Dupont Paint Center..check Jotun at Bakery Jn

They might know a good spraypaint center

There's all variety (Matte, Glossy, Chrome) of variants

Nippon is also good

Check with Santha Paint House.. Trivandrum

**Ayson** · 01-20-2011, 06:36 PM

@xionite
Thanks for you time and quick replies.

Will the new tank cause any turning difficulties? ie restrict turning angle of front wheel?

And, to mount the upgraded crash guard, will i have to drill into my frame? Any details on the process involved?

@Mecho
Thanks for that price. Now i really really hope my console is fixable.

I live in TVM, but the bike is in EKM. That is where i am planning to finish all the work if possible. (That is my native place.) The bike, as of now, is not in a ridable or transportable state.

I have used Nippon Pylox 'muffler black' before from SPH, for some touch up under the tank mounting point. How does that compare to Bosny?

And i require details of shops and paint booths in EKM as far as possible.

**xionite** · 01-20-2011, 07:05 PM

Originally posted by Ayson View Post

Will the new tank cause any turning difficulties? ie restrict turning angle of front wheel?

no it won't. will work without a hitch.

Originally posted by Ayson View Post

And, to mount the upgraded crash guard, will i have to drill into my frame? Any details on the process involved?

the welding guy might suggest it. but don't drill into the frame.

u need to weld on a bracket (with a thread) or a nut onto the frame.

that way you can remove the crash guard whenever you want. just like stock.

**pavanchirmade** · 01-20-2011, 09:28 PM

Bosny works when sprayed from a distance. roughly 1 foot away.

**Mecho** · 01-20-2011, 10:02 PM

Originally posted by Ayson View Post

@xionite

I have used Nippon Pylox 'muffler black' before from SPH, for some touch up under the tank mounting point. How does that compare to Bosny?

.

Bosny is imported from Malaysia if I remember correctly. Nippon Pylox too is imported from there. But I believe bosny has heat resistant paint that I would recommend for your muffler and engine (if needed)

BTW this is a pic of my bike taken in 2007, 2 years after repainting (Repainting silver colored engine, alloys and forks..Its still like this ( over 5 years old nw) And I used bosny for the job. Its costlier too

Nippon around 150Rs
Bosny around 250 -300 (for heat resistant) as of 2007

good luck

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