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Thread: Help me Upgrade my Old Pulsar 150cc......

  1. #1
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    Question Help me Upgrade my Old Pulsar 150cc......

    Hello Everybody ,

    My name is Raj Sharma and I am from New Delhi. I have old Classic Pulsar 150cc (2003 KS Model) and It has just completed its 40,000 Km. Now i think it need some work to be done on it as it is making some noise and also giving some white smoke if the rpm is around 4k and above. So may be i have to put new parts like head, piston, clutch plates, timing chain, valves etc.

    Installing all the 150cc parts again in it, its better that i can upgrade it to old classic pulsar 180cc. Why old 180cc because i don't want to get into dtsi complication and they don't have power like old bikes have.

    So before doing anything like that i have some questions to experts, which are:-

    1 can i upgrade my old classic pulsar 150cc to 180cc or not?

    2 What all parts need to be changed for complete upgradation to 180cc?

    3 My bike is Kick start so can i upgrade to self start, if yes then what all parts need to be changed?

    5 Most important question, is this upgradation would be success full or not? And can i get complete 180cc kind of power experience or not?

    Waiting for you reply..........

    Thankyou All............

  2. #2
    Super Moderator sunilg's Avatar
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    Query approved.
    (Been There Done That) x 3.25

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    Bro it's better to keep the engine stock be aware mods make more wear and tare to running parts even though you get a bit of extra performance at a heavy cost (replacing running parts ) electric star is a better upgrade go for it try tubeless tyres, alloy wheels(if you wish to) split seat split grabs ; I would ask you to keep the engine stock

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    Quote Originally Posted by raja_roadster View Post
    Bro it's better to keep the engine stock be aware mods make more wear and tare to running parts even though you get a bit of extra performance at a heavy cost (replacing running parts ) electric star is a better upgrade go for it try tubeless tyres, alloy wheels(if you wish to) split seat split grabs ; I would ask you to keep the engine stock
    Who said engine mods make more wear and tear?[and that's how its spelled]
    Engine mods can make the bike go faster and also more reliable too..It all depends on the kind of work being done and the person who will be doing it. If the mechanic knows what he is doing and how to do it then surely any damn mod can be done.Take a look at Joel's R15 mod jobs. They go thousands of kilometers and still run strong! It all depends upon how the whole thing is built.

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    Rusted raja_roadster's Avatar
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    Sorry dude from R15 only i told that; the company approved daytona kits when fixed to the bike may produce more wear and tare thats why if you fix them your warranty gets void and friend that thing you mentioned of joe's R15bike pls send me the url to that thread ya

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    Guys please help me to mod my pulsar you people are talking about R15 which is not relevant to my problem........ Guys please help me, i want my bike to be get repaired asap........ so please give me your comments.....

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    heheh.. this is nice dude.. i 've got the same pulsar 2003 silver 150cc classic with spoke wheels.. and even i am currently in the process of a little bit of restoration work.. although my bike still runs absolutely fine.. i am already half way through painting the thing. got my fuel tank chrome plated.. gonna get my silencer rechromed or just buffed if that does the job..

    now about your electric start.. thats gonna be the easiest upgrade for you.. even i am thinking of it, but i am not sure if i wanna spend the money.. it will be about 3K and the service centre will do it for you.. 3K will include everything i guess, the starter motor, the switch and the cable connecting to the starter, and the components required to connect the starter motor to your engine.. the only extra spending you will have to do from outside is to buy a new battery. the stock batter is 12v 2 amps in bikes without starters. after starter, you will need the 12v 9 amp battery. the exide battery is absolutely fine. but you will have to get a small job done from outside and either get a bigger battery box fabricated, or source one from the pulsar selfstart models and see if it fits.. i think you'd be better off with a new box which should also be available from bajaj. getting it fabricated from outside will be cheaper definitely. if you observe, in the front side of the engine, from the exhaust pipe bends towards the back, you will see an empty space in the frame with place for three screws. that is the empty slot where the starter goes. so bajaj had already provided for a starter upgrade, incase people wanted it.. heheh.

    now about the 180cc engine, i think it should be quite possible but am not sure. but i personally would not prefer that. the main thing that defines my bike and my emotional attachment towards it is the heart of the bike, and thats the engine. changing the engine would be like, it wont be my bike anymore.. it will be someone elses bike.. i'd rather see to few upgrades like upjetting, new freeflow airfilter, alloy wheels and stuff. .i am already repainting my bike to full black except the exhaust and fuel tank chrome plated.

    i'd rather take my engine and build a whole new bike around it than changing the engine.. trust me.. if you do end up changing the engine and finally get on your bike for the first ride, it wont even feel like your bike anymore. it will have become some other bike that you dont know anymore.

    lastly, if the engine change is successful, theres no reason you wont get the 180cc power. but then you will also have to look at changing your rear sprocket.. smaller displacement engines normally have a larger rear sprocket for better acceleration, while bigger engines have smaller sprockets as they have the additional power and the smaller rear sprocket helps in the end top speed..

    want a little fun out of your bike??? do one thing to change the sound of the air intakes. open your seat, and towards the front you will see a rubber housing that is connected to the air intake box below. now you will see that the rubber housing is bent in an L shape and sucks air horizontally and the opening is diagonal which is basically so that the air gets cut like a blade and the sound is reduced and also the L shape dampens the sound as the air just slides in. now what you gotta do is, pull out this rubber housing, cut half of it, like, take a cutter and cut out from the bend. the opening should be absolutely vertical, and just slightly push in the straight and short rubber housing in the air intake box such that it protrudes out half way. now start the engine, and rev it up a little. you will be delighted with the difference in the sound of the air intake. it even sounds better when actually riding instead of just revving in neutral and especially if you are wearing a helmet. that way the wind noise gets cut and you can clearly hear the sound of the air intake. try it.
    Last edited by puneetritehere; 06-02-2012 at 07:44 PM.

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    Quote Originally Posted by puneetritehere View Post
    heheh.. this is nice dude.. i 've got the same pulsar 2003 silver 150cc classic with spoke wheels.. and even i am currently in the process of a little bit of restoration work.. although my bike still runs absolutely fine.. i am already half way through painting the thing. got my fuel tank chrome plated.. gonna get my silencer rechromed or just buffed if that does the job..

    now about your electric start.. thats gonna be the easiest upgrade for you.. even i am thinking of it, but i am not sure if i wanna spend the money.. it will be about 3K and the service centre will do it for you.. 3K will include everything i guess, the starter motor, the switch and the cable connecting to the starter, and the components required to connect the starter motor to your engine.. the only extra spending you will have to do from outside is to buy a new battery. the stock batter is 12v 2 amps in bikes without starters. after starter, you will need the 12v 9 amp battery. the exide battery is absolutely fine. but you will have to get a small job done from outside and either get a bigger battery box fabricated, or source one from the pulsar selfstart models and see if it fits.. i think you'd be better off with a new box which should also be available from bajaj. getting it fabricated from outside will be cheaper definitely. if you observe, in the front side of the engine, from the exhaust pipe bends towards the back, you will see an empty space in the frame with place for three screws. that is the empty slot where the starter goes. so bajaj had already provided for a starter upgrade, incase people wanted it.. heheh.

    now about the 180cc engine, i think it should be quite possible but am not sure. but i personally would not prefer that. the main thing that defines my bike and my emotional attachment towards it is the heart of the bike, and thats the engine. changing the engine would be like, it wont be my bike anymore.. it will be someone elses bike.. i'd rather see to few upgrades like upjetting, new freeflow airfilter, alloy wheels and stuff. .i am already repainting my bike to full black except the exhaust and fuel tank chrome plated.

    i'd rather take my engine and build a whole new bike around it than changing the engine..

    lastly, if the engine change is successful, theres no reason you wont get the 180cc power. but then you will also have to look at changing your rear sprocket.. smaller displacement engines normally have a larger rear sprocket for better acceleration, while bigger engines have smaller sprockets as they have the additional power and the smaller rear sprocket helps in the end top speed..
    Can you please. Post pics of your bike and its tank ??


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    well.. i will post pics of my currently nude bike after i get home, because i have removed the tank and all the plastic parts.. but the tank plating is not yet complete. i will post it as soon as i receive it.. that idiot electroplater has been delaying for almost a week now..

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    well. i coincidentally happened to have one pic of my bike on the office pc before i stripped it.. all the parts will be black in the future. the fuel tank and the rear handlegrip for the pillion will be chrome plated. will use the stock pulsar and bajaj logo emblems. the engine will be repainted black too.


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