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Do mention the no. of km you have done in these 6 years.

Looking at the condition of the rear tyre, it looks like you have used it well past its best before date. It would be prudent that you change the rear tyre at the earliest in the interest of your own safety and that of people around you using the same roads as you do.

Also, if front tyre is the same one provided from factory(6 years back), regardless of remaining tread level, please change this one too.

Regarding the exhaust, the older generation of Pulsar exhausts were prone to rusting. If you are not happy with it, feel free to swap it with a new one.

For more info check the Pulsar 180 ownership thread here:

Welcome to xBHP tintin .

Adding to what Antz.bin suggested.

1. Are you facing anything other than cosmetic and minor exhaust note change. Since you said that insulation material is already out, it would be best in the interest of your bike's longevity to get a new one.
2. Front tyre looks OK to me unless you have any cracks on the side wall or any major deep cuts in the threads. Back looks too worn out and you risk puncturing it even by a small sharp stone. Check MRF, they have come out with new models today.
3. For rain problem, check your spark plug connector/cap space. Check your spark plug and clean them with fine emory paper, that should solve most of your trouble with it.

Your bike needs some pampering for the good job it has done for so many years.

Major overhaul

At 30k km your bike needs much pampering and servicing for running for next 30k kms.

First of all do all these work if you want to feel your bike like new:-
1. Change the rear tyre today itself, if you have the money. No second thoughts about it. Go for tube type as while opening and fitting of your old tyre the tyre wala would have used tile lever which would have scrathed the edges of rim and thus tubeless tyre will not seal properly.
2. For front tyre just check the thread by picking with your finger nails and if they feel soft then use them or else change them.
3. Change the spark plugs and spark plug cap.
4. Open the head clean them and also polish the valves. This will smoothen out the bike and sound will also get smooth. Also compression will be restored to factory level.
5. Check clutch and if worn change the plates.
6. Silencer change them and if possible go for black powder coated model. Usually original is too expensive and there is a way out, VIDHARBHA is the OE supply to bajaj for silencer, so if you get silencer from VIDHARBHA,directly then it will get cheaper. I had changed my friends pulsar 180 silencer to VIDHARBHA black model and the silencer is as good as new after two years.
7. Check chain kit and if worn change to ROLON or DIAMOND. Change if worn or else clean the old one and lubricate with gear oil.
8. Check front shock oil and if not repaced for 10k km then just change to MOTUL fork oil.
9. Check rear shock and adjust them or if weakened then change.
10. Check handle racer and if worn, change them.
11. Check front disc oil and if more than a year old change to new DOT 4 oil.

This may look much work, but actually many of them will not be required if you have done regular servicing.But head cleaning, clutch plate check and chain kit check will ensure your bike to regain its original performance.
Do the works at a time as it will ensure that your bike will be tension free for another 30k.

As in cars 60k service is expensive and is having much work to do, similarily in bikes 30k service is an important one and this will ensure the longeitivity of bike.

Re: Major overhaul

hi fellows, did major work on bike, thanks to everyone for their advice and suggestion. replying so late because i did it in different number of services.
also i have few queries.

first list of work done :-

1. replaced rear Tyre with new MRF mogrip meteor (tube type as suggested by [MENTION=28527]sibun[/MENTION]) rs 2100/-

2. replaced engine cylinder assembly (since bike was consuming oil and overheating) costed approx 7000/-

3. replaced break caliper assembly and disk of front brake . since the front tyre was very tight and was not completely rotating even a single rotation.
service guy told me the piston and spring of caliper have malfunctioned therefore need to replace them. replaced disk plate since .
while rotating tyre the wheel felt more tight at one particular point. cost approx for this 2000/-

so all in all entire pampering on the bike (or tampering on my wallet ) costed roughly around 12000/- . attached are the pics

now my queries again-
1.) after doing cylinder replacement i noticed greasy content under the engine. service ad-visor old to replace oil seal underneath. which he did, but even then
under side of engine and area near gear lever remains greasy. is this normal in all bikes or the issue still has not been resolved ? see pics


2. i did service entirely at authorized service station of bajaj, i am just confused was the rate charged justified?

regards,

tinitn

Re: Major overhaul

Some prices seem high but that should be okay, I do most of my own service so not sure about the price. At first I was shocked to see 7000 for the replacing the cylinder, then I saw the bill, they replaced a lot of other things like clutch plates, clutch lever etc. From the bill I can see that they have changed the gaskets properly. The oil is from the chain maybe, remove your chain cover and see. If it's coming from the engine, you're screwed. Maybe it's just a seal that needs replacement. Give it a good wash and then see where the oil is seeping from.

BTW what is "laithe charge"? They charged for head repair already. What is "shoker seal"? front fork seals or the rear suspension?

One confusing and funny bill I'd say.

Re: Major overhaul

I hope you are aware of the engine run-in procedure. Change oil at 500kms and ensure to adjust tappets and valves after 500kms again if necessary

Replace the sprocket oil seal. This seal sits behind the front sprocket. It should cost about 30/- appx. Get it done from a local mechanic.

The rates are genuine. Do not worry.

Re: Major overhaul

Now that the part i completely screwed up . became aware of it just now by visiting many threads, and also remembered that mechanic told to drive below 50km/h and replace engine oil after 1k.

to tell you the truth , as soon as bike came from workshop (after overhaul ) i revved up the engine and drove up to 90-100 kmph for around few minutes. and the engine got cut off after a while. then i let the bike cool for few seconds then it started again.

service after overhaul. did service after overhaul at around 2.5k (oil change) , against 1k as said by mechanic. now mostly my bike is driven by brother he told that during this period he drove maximum max 60km/h occasionally revving up-to 70km/h. though while servicing advisor said everything is fine he said now you can drive normally
and told me to come back again for service after 5k.

though i am not seeing any major problem in the bike from engine side, the main question is the damage already done and any further advice ?

Re: Major overhaul

I was so glad you sought opinion in this forum and went ahead in following the same. Alas! You've given us disappointment mate. So much for such money spent. Please be careful in the future.

Do not worry! If the job is done well at the ASC there should not be any trouble. I've also read about aggressive engine break-in which the bike is ripped at variable speeds continuously. And since you replaced the entire bore/piston kit instead of rebore a run-in of 500kms-750kms would be sufficient.

I suggest you to-

1. keep an eye on exhaust for wierd smoke for next 500kms.
2. give your ears to your engine for tappets and valve noises.
3. take it out for a long drive of atleast 100kms at variable speeds (less than 70kmhr) and check for any symptoms and monitor behavior.
4. change engine oil immediately

If all is well you are good. I wish you do not get in to any trouble.

BTW, did you get the oil leak fixed? Check the sprocket oil seal.