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Front shocker and silencer issue on my Pulsar 200

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  • #1

    Front shocker and silencer issue on my Pulsar 200

    As the thread name suggest my bike(pulsar 200 2008) is having issues with its front shocker and the silencer. Need Advice!!!

    Problem in detail
    1. Front shocker(left) oil seal was broken, today i went to Kirti nagar service centre(Bagga Link) told them the problem. the mechanic over there replace the oil seal with the new
    one. Problem solved!!! temporarily... after coming out of the svc and riding for 5-6 km i notice oil coming out of the shocker again ... u-turn again back to svc... now
    the mechanic says that oil seal broke again because the shocker itself is having problem and need to replace which cost another 900rs which he didnt had in spare so i came back home.

    Now i want to know whether the mechanic was right?? or is there any other way i can fix this problem???

    2. Silencer problem for past few days i have been noticing this weird sound coming from near the engine the sound of metal vibrating and striking against other metal
    i thought it was coming from the engine but the svc guys told me it coming from the silencer. he said there is some mesh(jali) in front part of the silencer which is broken he
    said " iski to jali phat gayi hai ". he told me the only solution(again) is to replace the whole silencer which cost around 8k .

    one more thing i would like to add is that this sound only comes when the engine gets warm and is more pronunced when the engine is loaded(not ideling)
    BTW the engine is running smooth as always, no performance loss( if it would hav been an engine problem then i would have felt somthing), but this sound


    Now i want to know is there any other solution to this problem???
    Do check out my Photography page on fb :)
    http://www.facebook.com/KeshavsFotugraphy
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  • #2
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    • #3
      Originally posted by keshavrana View Post
      As the thread name suggest my bike(pulsar 200 2008) is having issues with its front shocker and the silencer. Need Advice!!!

      Problem in detail
      1. Front shocker(left) oil seal was broken, today i went to Kirti nagar service centre(Bagga Link) told them the problem. the mechanic over there replace the oil seal with the new
      one. Problem solved!!! temporarily... after coming out of the svc and riding for 5-6 km i notice oil coming out of the shocker again ... u-turn again back to svc... now
      the mechanic says that oil seal broke again because the shocker itself is having problem and need to replace which cost another 900rs which he didnt had in spare so i came back home.

      Now i want to know whether the mechanic was right?? or is there any other way i can fix this problem???

      2. Silencer problem for past few days i have been noticing this weird sound coming from near the engine the sound of metal vibrating and striking against other metal
      i thought it was coming from the engine but the svc guys told me it coming from the silencer. he said there is some mesh(jali) in front part of the silencer which is broken he
      said " iski to jali phat gayi hai ". he told me the only solution(again) is to replace the whole silencer which cost around 8k .

      one more thing i would like to add is that this sound only comes when the engine gets warm and is more pronunced when the engine is loaded(not ideling)
      BTW the engine is running smooth as always, no performance loss( if it would hav been an engine problem then i would have felt somthing), but this sound


      Now i want to know is there any other solution to this problem???
      The shocker inner pipe may be bent or there may be scoring on it. Its a common issue if you are running with a busted oil seal. Get it checked. Bends can be straightened and scoring can be removed with polishing in a ledh shop.

      As for the exhaust, if your muffler is gone then you have no choice but to replace it. A cheaper solution is to use the exhaust of the new 180. Half the price.
      HYPERTHRUST CLEARED AND COUNTING
      5.....4.....3....2.....1
      sigpic

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      • #4
        thnx for your reply bibhu... but can you tell me is pulsar 180's silencer is a direct fit on pular 200???
        Do check out my Photography page on fb :)
        http://www.facebook.com/KeshavsFotugraphy

        Comment

        • #5
          Re: Front shocker and silencer issue on my Pulsar 200

          Originally posted by keshavrana View Post
          thnx for your reply bibhu... but can you tell me is pulsar 180's silencer is a direct fit on pular 200???

          Or a ffe from race concepts



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          Comment

          • #6
            Originally posted by keshavrana View Post
            thnx for your reply bibhu... but can you tell me is pulsar 180's silencer is a direct fit on pular 200???


            I have one running on my hybrid pulsar which has a 220 bore and head. So it fits. You have to be a bit careful while fitting it though as the pipe thickness is less. So if not fit properly gases will leak out. Not a big job but a cautious one. However I can not comment on how it will affect the performance of a stock 200 engine as I have never worked on a 200.

            @ Cristo: That is an option too, since the thread starter asked about oe exhausts I replied in the same manner.
            HYPERTHRUST CLEARED AND COUNTING
            5.....4.....3....2.....1
            sigpic

            Comment

            • #7
              Originally posted by keshavrana View Post
              As the thread name suggest my bike(pulsar 200 2008) is having issues with its front shocker and the silencer. Need Advice!!!

              Problem in detail
              1. Front shocker(left) oil seal was broken, today i went to Kirti nagar service centre(Bagga Link) told them the problem. the mechanic over there replace the oil seal with the new
              one. Problem solved!!! temporarily... after coming out of the svc and riding for 5-6 km i notice oil coming out of the shocker again ... u-turn again back to svc... now
              the mechanic says that oil seal broke again because the shocker itself is having problem and need to replace which cost another 900rs which he didnt had in spare so i came back home.

              Now i want to know whether the mechanic was right?? or is there any other way i can fix this problem???

              2. Silencer problem for past few days i have been noticing this weird sound coming from near the engine the sound of metal vibrating and striking against other metal
              i thought it was coming from the engine but the svc guys told me it coming from the silencer. he said there is some mesh(jali) in front part of the silencer which is broken he
              said " iski to jali phat gayi hai ". he told me the only solution(again) is to replace the whole silencer which cost around 8k .

              one more thing i would like to add is that this sound only comes when the engine gets warm and is more pronunced when the engine is loaded(not ideling)
              BTW the engine is running smooth as always, no performance loss( if it would hav been an engine problem then i would have felt somthing), but this sound


              Now i want to know is there any other solution to this problem???
              I too have a P200 and going through the exhaust problem. New one is 8k in kirti nagar and 7 - 7.5k in Karol Bagh.
              For the Silencer noise first check the Small heat shield that is connected to the bend pipe below the engine. If it comes loose, it will make a "chan chan" noise. Tighten the nuts and check if the noise is still there.
              There is also a temporary fix if the exhaust is still making noise. You need to hit the bend pipe with a hammer. My mechanic did it for me and it fixed the noise for a couple of days and then it came back.

              P180 exhaust can be fit on P200 and it works without problem. I have seen the performance go up in a friend's P200 with P180s exhaust. But u will no longer get P200s exhaust roar. Dnt know if it will happen in all the cases.


              If you want P200 exhaust. break ur Exhaust with a hammer and claim insurance. You will have to pay 800bux.. insurance company will take care of the rest . Do the same with your front fork if it needs to be replaced.
              Street racing is for Squids trying to make up for their small equipment

              Comment

              • #8
                Originally posted by riot View Post
                I too have a P200 and going through the exhaust problem. New one is 8k in kirti nagar and 7 - 7.5k in Karol Bagh.
                For the Silencer noise first check the Small heat shield that is connected to the bend pipe below the engine. If it comes loose, it will make a "chan chan" noise. Tighten the nuts and check if the noise is still there.
                There is also a temporary fix if the exhaust is still making noise. You need to hit the bend pipe with a hammer. My mechanic did it for me and it fixed the noise for a couple of days and then it came back.

                P180 exhaust can be fit on P200 and it works without problem. I have seen the performance go up in a friend's P200 with P180s exhaust. But u will no longer get P200s exhaust roar. Dnt know if it will happen in all the cases.


                If you want P200 exhaust. break ur Exhaust with a hammer and claim insurance. You will have to pay 800bux.. insurance company will take care of the rest . Do the same with your front fork if it needs to be replaced.

                You may also try dousing the bike in gasoline and setting it on fire.
                The temporary fix you talk about works if the inner and outer pipes of the 200/220 exhaust header have come slightly separated. When banged with a hammer they jam together for a while. A more permanent solution for this particular problem is to make a couple of fine holes with a welding torch and weld a couple of wires in.

                Don't forget the weight reduction of a 180 exhaust. Its half the weight. Although looks no where near as cool as the 200 exhaust.
                Last edited by Bibhu; 11-07-2012, 11:41 PM.
                HYPERTHRUST CLEARED AND COUNTING
                5.....4.....3....2.....1
                sigpic

                Comment

                • #9
                  thnx to all for replying.
                  i think i will go with the pulsar 180's silencer...
                  Originally posted by Bibhu View Post
                  The temporary fix you talk about works if the inner and outer pipes of the 200/220 exhaust header have come slightly separated. When banged with a hammer they jam together for a while. A more permanent solution for this particular problem is to make a couple of fine holes with a welding torch and weld a couple of wires in.

                  Don't forget the weight reduction of a 180 exhaust. Its half the weight. Although looks no where near as cool as the 200 exhaust.
                  Do check out my Photography page on fb :)
                  http://www.facebook.com/KeshavsFotugraphy

                  Comment

                  • #10
                    Originally posted by keshavrana View Post
                    thnx to all for replying.
                    i think i will go with the pulsar 180's silencer...
                    dont replace your exhaust, do spot welding that would be a better option and preserve your bikes originalityy..

                    Comment

                    • #11
                      what do you mean by that please elaborate... i also do not wish to spend so much on a new silencer, if a fix is possible i will try that first.
                      Originally posted by mustafask View Post
                      dont replace your exhaust, do spot welding that would be a better option and preserve your bikes originalityy..
                      Do check out my Photography page on fb :)
                      http://www.facebook.com/KeshavsFotugraphy

                      Comment

                      • #12
                        Re: Front shocker and silencer issue on my Pulsar 200

                        I had the exhaust prob but thank god dat it got replaced under warranty as my bike didnt complete 30k kms nd was less then 3 yrs.

                        What ill suggest you is go for second hand exhaust 200/220 both are same... i am running on ffe from joel.

                        Sent from my X8 using Tapatalk
                        Not only Great power comes with great responsibility but also with Great RISK !!! Referring to SBKs...

                        Comment

                        • #13
                          The silencer issue is very much common on 200 and 220 past 2 years use-age, if your still within warranty use it and replace it.
                          Else there is one solution, you can search the 220 thread for that.
                          There again might be 2 possibilities.
                          1.Remove the silencer , the header pipe will have two concentric pipes, the inner pipe might have crack in it, causing this problem(this was reported by some members), weld it and your good to go.
                          2.The cat con, the square box directly below the engine, inside it has mesh(cat con) , if metal flakes have broken and vibrating inside the cat con. You can just cut the cat con out and weld the pipes(suggested by mech) or replace. Nothing else to do.

                          I had the second issue, cat con material vibrating inside, i dint like the sound of cutting the cat con box and welding the silencer back, so i went for replacement, i was out of warranty , so i went for RC FFE, costs lesser than the 220/200 silencer.

                          About the fork problem, the stem might be scratched, i had same problem, i replaced the stem, costed nearly 800-850 i think.

                          Cheers
                          Ride Safe
                          Krishna
                          --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

                          Run-in Procedure | Power Loss Solutions | Riding Gears 101 | Biking Brotherhood

                          P                          ulsar 220F                          |2013 Honda CBR250R|KTM Duke390|Yamaha R3|Yamaha R1|Triumph Tiger XRX

                          Comment

                          • #14
                            Originally posted by krish2778 View Post
                            The silencer issue is very much common on 200 and 220 past 2 years use-age, if your still within warranty use it and replace it.
                            Else there is one solution, you can search the 220 thread for that.
                            There again might be 2 possibilities.
                            1.Remove the silencer , the header pipe will have two concentric pipes, the inner pipe might have crack in it, causing this problem(this was reported by some members), weld it and your good to go.
                            2.The cat con, the square box directly below the engine, inside it has mesh(cat con) , if metal flakes have broken and vibrating inside the cat con. You can just cut the cat con out and weld the pipes(suggested by mech) or replace. Nothing else to do.

                            I had the second issue, cat con material vibrating inside, i dint like the sound of cutting the cat con box and welding the silencer back, so i went for replacement, i was out of warranty , so i went for RC FFE, costs lesser than the 220/200 silencer.

                            About the fork problem, the stem might be scratched, i had same problem, i replaced the stem, costed nearly 800-850 i think.

                            Cheers
                            Ride Safe
                            Krishna
                            As far as I know the square box under the engine is the expansion chamber. It is not wise to remove it as it will decrease low end torque.

                            A good condition used exhaust sounds like a good idea, provided you could find one.
                            HYPERTHRUST CLEARED AND COUNTING
                            5.....4.....3....2.....1
                            sigpic

                            Comment

                            • #15
                              Originally posted by Bibhu View Post
                              As far as I know the square box under the engine is the expansion chamber. It is not wise to remove it as it will decrease low end torque.

                              A good condition used exhaust sounds like a good idea, provided you could find one.
                              That is also a viable option, but mostly used exhaust you will find coming from scrap yards from totaled bikes, that's not so confidence inspiring where you have to spend 5-6k rs for that and that too in a few months will develop the same problem. Do remember that this problem is prominent among all 220's and 200's.

                              Cheers
                              Ride Safe
                              Krishna
                              --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

                              Run-in Procedure | Power Loss Solutions | Riding Gears 101 | Biking Brotherhood

                              P                              ulsar 220F                              |2013 Honda CBR250R|KTM Duke390|Yamaha R3|Yamaha R1|Triumph Tiger XRX

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