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Engine Rebuid of Pulsar 150

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  • Engine Rebuid of Pulsar 150

    70,000 kms on the odo and less than 4 years .......my pulsar 150 DTSi UG3 is ready for 2nd engine rebuild.....reason......eating oil......

    last time block piston was replaced along with crank job and clutch plates change....after that changed the clutch plates once......

    this time i don't want to replace block piston .....i will bore out to one size higher and put a new piston, new valves/stem seals, and valve lapping....thats it.

    my question is will i get increase in performance due to bigger bore....though only one size higher....what else can i do for a gain in performance......will increase in main jet size increase power...is it required or not.....how to increase the total amount of air/fuel mixture going into engine....should i try K & N filter....

    what about reliability.....and engine life...if i use k & N......

    i ride 90 % highway and 10 % city......and highway rides consist of mainly 85-95kmph and with occasional full throttle busts...

    if i put a K&N, what will be the main jet size required.
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  • #2
    Query approved.
    (Been There Done That) x 3.25

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    • #3
      thanks for the quick approval.....
      sigpic

      Tyre Sizes _ Spark Plugs

      Headlight Focus _ Fork Oils

      All India xBhp Couple Riders Thread

      Ashtavinayak + Shirdi
      Purandar
      Raigad
      Dapoli
      Aurangabad
      Kaas Plateu & Thoseghar Waterfalls
      Purandar

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      • #4
        Prince, If you plan to retain the bike for a while and if you can afford it better go for a block+piston kit change. A bore job with next oversize piston would never have the tight tolerances of a full kit. As for performance, look the other way.
        RIDE IT LIKE YOU STOLE IT!
        04' PULSAR 180 DTS-i
        09 ZMA-R

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        • #5
          Originally posted by need4torque View Post
          Prince, If you plan to retain the bike for a while and if you can afford it better go for a block+piston kit change. A bore job with next oversize piston would never have the tight tolerances of a full kit. As for performance, look the other way.
          even i think the same...that a bore job will never give me the clearances a stock kit will give....but my question is whether 1 size bigger bore and new piston combined with a bigger jet.......will i get increased power.....??
          sigpic

          Tyre Sizes _ Spark Plugs

          Headlight Focus _ Fork Oils

          All India xBhp Couple Riders Thread

          Ashtavinayak + Shirdi
          Purandar
          Raigad
          Dapoli
          Aurangabad
          Kaas Plateu & Thoseghar Waterfalls
          Purandar

          Comment


          • #6
            [QUOTE=princesirohi;576793]
            even i think the same...that a bore job will never give me the clearances a stock kit will give....but my question is whether 1 size bigger bore and new piston combined with a bigger jet.......will i get increased power.....??

            After rebore u won't be gaining any power.If u wanna improve performance get some engine mods done.else get a FFE and FF air filter and do rejetting.that will definetly give a increase in performance.FOR BIGBORe contact JOEL

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            • #7
              [QUOTE=2stroker;576909]
              Originally posted by princesirohi View Post
              even i think the same...that a bore job will never give me the clearances a stock kit will give....but my question is whether 1 size bigger bore and new piston combined with a bigger jet.......will i get increased power.....??

              After rebore u won't be gaining any power.If u wanna improve performance get some engine mods done.else get a FFE and FF air filter and do rejetting.that will definetly give a increase in performance.FOR BIGBORe contact JOEL
              even i want to get it done from joel, but i m in pune.......and he is too far away...thats why i want to know if something can be done....without joel....
              sigpic

              Tyre Sizes _ Spark Plugs

              Headlight Focus _ Fork Oils

              All India xBhp Couple Riders Thread

              Ashtavinayak + Shirdi
              Purandar
              Raigad
              Dapoli
              Aurangabad
              Kaas Plateu & Thoseghar Waterfalls
              Purandar

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              • #8
                you can go for 180 ug 4 s kit,thats one of the most practical option.p 200s also is a straight fit.the gearing is diff in the various models,but you will feel the torque and a better low and mid.
                k and n well,a lots of knowledgeable say its not that usefull with cv carb,so i cant comment.
                try the camshaft of p 220 dtsi carb,its more kick for less money.
                best of luck prince.
                sigpic
                RIDE AND DRIVE SAFE AND PLEASE CHANGE THE PICTURE ON INDIAN ROADS.
                my thoughts,my area,my game....
                http://vmtm.blogspot.com/
                IF YOU LOVE MAINTAINING YOUR RIDE..http://nexgenbikes.com/site/

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                • #9
                  Originally posted by drvmtm View Post
                  you can go for 180 ug 4 s kit,thats one of the most practical option.p 200s also is a straight fit.the gearing is diff in the various models,but you will feel the torque and a better low and mid.
                  k and n well,a lots of knowledgeable say its not that usefull with cv carb,so i cant comment.
                  try the camshaft of p 220 dtsi carb,its more kick for less money.
                  best of luck prince.
                  you are saying that i install the block pston of 180 or 200......and thats a straight fit...and cam shaft of 220.....


                  tell me if i fit a block piston of 180 or 200 will the cylinder head remain same or have to change it or do some modifications....wht about the carb...do i need to replace the carb or just the jet....if only jet....what size?

                  and is 220 cam straight fit.....why are u recomending it......is it a high lift cam....??
                  sigpic

                  Tyre Sizes _ Spark Plugs

                  Headlight Focus _ Fork Oils

                  All India xBhp Couple Riders Thread

                  Ashtavinayak + Shirdi
                  Purandar
                  Raigad
                  Dapoli
                  Aurangabad
                  Kaas Plateu & Thoseghar Waterfalls
                  Purandar

                  Comment


                  • #10
                    @ prince

                    You can install a p180's or the p200's block and piston kit, if your stroke length is same.
                    I have a Fiero F2 (150cc)
                    and i am running the Block and the piston of RTR 180 (as the stroke is exactly the same) also running bigger carb as well as bigger jet too.
                    and my HEAD is stock.
                    by this the compression will be higher than the stock 180 as the combustion chamber will be smaller (stock head).
                    If in case your crank cannot bear the high compression (which means the bike knocks) then get the compression decreased by expanding the head size, or just increase the number of gaskets below the block to decrease compression as well as expanding the inlet and exhaust ports.

                    If you retain the stock head, the only mod you'll need to do is to modify the valve recesses over the piston, as the 180's will be slightly wider.
                    will settle you down with much higher torque and better acceleration.
                    K&N is optional.
                    Giving a lot to a fiero.
                    Expecting a lot from a fiero.

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                    • #11
                      can anyone help me.....? any pulsar modifiers here...............????
                      sigpic

                      Tyre Sizes _ Spark Plugs

                      Headlight Focus _ Fork Oils

                      All India xBhp Couple Riders Thread

                      Ashtavinayak + Shirdi
                      Purandar
                      Raigad
                      Dapoli
                      Aurangabad
                      Kaas Plateu & Thoseghar Waterfalls
                      Purandar

                      Comment


                      • #12
                        Originally posted by princesirohi View Post
                        you are saying that i install the block pston of 180 or 200......and thats a straight fit...and cam shaft of 220.....


                        tell me if i fit a block piston of 180 or 200 will the cylinder head remain same or have to change it or do some modifications....wht about the carb...do i need to replace the carb or just the jet....if only jet....what size?

                        and is 220 cam straight fit.....why are u recomending it......is it a high lift cam....??
                        all dtsi heads are same,so it will remain same,i would suddegest you to replace the valves though,not very expensive.carb is same,just add the mainjet of higher mark.a jet of same of the block piston will do-180 block -180 s jet,200 s block-200s jet,carb is roughly same otherwise,
                        220 dtsi cam is a direct fit to all dtsi models and the best camshaft that is ever produced by bajaj till date for dtsi pulsys,its kinds high lift,and minus the decompressor,so you will have better engine rebound effect,you have to throw away the kick though(dosent matter as you are already on ape rr mod).
                        any quary-pm me.
                        sigpic
                        RIDE AND DRIVE SAFE AND PLEASE CHANGE THE PICTURE ON INDIAN ROADS.
                        my thoughts,my area,my game....
                        http://vmtm.blogspot.com/
                        IF YOU LOVE MAINTAINING YOUR RIDE..http://nexgenbikes.com/site/

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                        • #13
                          Originally posted by princesirohi View Post
                          can anyone help me.....? any pulsar modifiers here...............????
                          To the best of my knowledge the stroke length of Pulsar 150,180,and 200 are the same..56.40mm.The bore is 57mm for P150, 63.5 for P180, and 67mm for P200.Old Pulsar 150 uses Mikuni BS 26 Carburetor while the New P150,P180 and P200 uses BS 29.
                          The Pulsar 220 has 67mm bore and 62.4mm stroke crankshaft.The carburetor is BS32.(for carb Version).
                          The Cam of Pulsar 220F is longer duration and can be fitted to P180 upwards without modification. Older P150 may not be compatible,and must be verified with some Knowledgeable Mechanic.
                          When Was The Last Time,You Did Something For The First Time.

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                          • #14
                            Originally posted by psr View Post
                            To the best of my knowledge the stroke length of Pulsar 150,180,and 200 are the same..56.40mm.The bore is 57mm for P150, 63.5 for P180, and 67mm for P200.Old Pulsar 150 uses Mikuni BS 26 Carburetor while the New P150,P180 and P200 uses BS 29.
                            The Pulsar 220 has 67mm bore and 62.4mm stroke crankshaft.The carburetor is BS32.(for carb Version).
                            The Cam of Pulsar 220F is longer duration and can be fitted to P180 upwards without modification. Older P150 may not be compatible,and must be verified with some Knowledgeable Mechanic.
                            +1 there sir,
                            actually ganesh anna(uranium pulsy) told me all these infos.and princ s 150 is ug 3 version only,the cam is direct fit from ug 2 only.
                            sigpic
                            RIDE AND DRIVE SAFE AND PLEASE CHANGE THE PICTURE ON INDIAN ROADS.
                            my thoughts,my area,my game....
                            http://vmtm.blogspot.com/
                            IF YOU LOVE MAINTAINING YOUR RIDE..http://nexgenbikes.com/site/

                            Comment


                            • #15
                              I did the camshaft mod first! It is a direct fit on all DTS-i versions of the pulsar barring the 135LS obviously

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