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Re-build my pulsar 135

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  • Re-build my pulsar 135

    Hello everyone,

    I own 2011 Pulsar 135(Stock), I am happy with the performance it still goes upto 120Kmph, can cruise at over 100KMPH. But I have a few complaints like looks, lights(Intensity), vibrations.

    For the looks part of it, I like naked biked so previously I removed every bit of no essential plastic except front mud guard and rear tire huger. It looked okay. But now I have stripped the bike down for a complete rebuild and repaint (Everything) so a need ideas for nice looking colour schemes(no green or orange please)



    For light intensity part of it, I have a few option HIDs or bigger halogens or LEDs

    HID
    I don't want HIDs for three reasons
    Firstly too out there,
    Second virtually gives no improvements in look as it sits inside the same headlight assembly
    And third it give cool white light which is discomfort for riders on opposite direction{yes I think about others too ;p }.

    Bigger halogens
    No because I will have to get a bigger stator and/or thicker gauge wiring, too expensive to the purpose. And No improvements in looks.

    LEDs
    Sadly No again, no good affordable LED setups available in India, and even If i get one from China or Taiwan they still go in the stock socket no improvements in looks.

    So I decides to make one myself, I bought some 10W and 20W LED(waterproof), a couple of buck-boost converter with adjustable voltage & current and some old CPU fans for cooling(with heat sink although I will have modify it). For the headlight assembly I will go with a mask (Iron man or Transformers) like structure with Eye being light outlets. But the problem is it does not really go well with the instrument cluster, I could get rid of the instrument cluster but I really want to keep it.
    So I need suggestion in this regard also. Can I get a new and smaller cluster which works with pulsar 135.

    I am also getting rid of the keys, I already bought the anti theft device but I need to modify its wiring in order to get it to work in place of my keys. It possible and I am working on it, will update once I finallise it. and anyone has already done it any suggestion would be appropriated.

    Now to accommodate this devices power needs(in long term, as it just uses 5mA in standby) and to be able to turn on LEDs without running the engine (Currently my bike has a device which only allows the current to headlights only when Engine is running, it is connected directly to the stator coil, I will get rid of it and connect head lights direct to battery). But I need a bigger battery for all this, right now I have a 5 Amphour battery which is at the end of its life anyways. So I am thinking going for a 9AH battery.
    But then I need more space under the seat. Which is taken up by airfilter, that I can replace with a conical Air filter(like K&N but not K&N), because they are smaller but I don't want them to mess up my air fuel ratio and I don't want any weird loud noises (not that I don't enjoy the occasional the "Dug-dug" and there are ways to get it temporarily but overall I want my right to be silent) and I also don't want any dust entering my combustion chamber. I need some help here too.


    Now finally the vibrations, they start at around 4k rpm and increase with increase in rpm after 7k they increase so much so that it kinda numb down our sensitivity to vibrations and I feel it less. But they are there a simple check would be to put bike on double stand and increase rpm in neutral you will be able see the bike slide even on stand because of the vibration. and since the vibration are there in neutral too so nothing wrong with chain set and gear box.

    Now when I took down the engine I noticed the timing chain is a little loose that's because the chain guides wore off, I will change them, combustion chamber had a lot of carbon deposit so I cleaned that Piston rings are also worn need to change them as well. I dont think that will change anything w. r. t. vibrations as the issue is there from bikes eternity, my bike has low compression ratio around 9.2:1 i guess, other bikes have ratios of upto 10.5:1

    So do you guys think changing the ratios might help? or doing something to the bore size I don't want increase power I just want to decrease vibrations.

    I also need to name my rebuild so I am thinking Mark 135 if iron man themed or Optimus 135 on transformers, any suggestion would help?

    Thanks in advance.
    Last edited by Expe; 05-03-2017, 12:19 AM. Reason: Corrections

  • #2
    Re: Re-build my pulsar 135

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    • #3
      Re: Re-build my pulsar 135

      what about tank bro... would you like to change that too,,..
      i like curved tank somewhat like rajputana custom did in their bikes...
      you can check it out at royalenfieldzone.com
      i have select a fuel tank which i would like to change..

      in my bike, i will cut off the chassis,( 2" behind from where the rear suspension fitted) to make it single seated,,..
      can you suggest me where i can adjust the RR,,

      btw even i don't like China light,,
      i will change the head lamp assembly with this one...


      you are going to change the air filter with conical one.. but not k&n,,, which one HP or moxi,,,
      anyway i would like to change the air filter too with the conical one, but i am thinking to cover the filter with the spike almunium plate...
      just like this


      and i would not like to paint rather i will cover the tank with the vinly,, and remove the side cover and put a box for battery and one for tool box..

      and in that tool box,, ill add custom made indicators...( rear one)


      can you suggest me any speedometer which can be connect in ug 5 model bike as i don't like the stock one.
      btw i have searched a lot of universal speedo but i am not satisfied with the detail the online company share.( actually i have ug 4 model bike but bec. of bcu problem i had to upgrade it to ug 5)

      one of our buddy told that if i would like to change it i have to change the gear box and all.... can you help me ...

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      • #4
        Re: Re-build my pulsar 135

        btw name it whatever you like bro,, whether marker or optimus

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        • #5
          Re: Re-build my pulsar 135

          Originally posted by chopperlover View Post
          what about tank bro... would you like to change that too,,..
          i like curved tank somewhat like rajputana custom did in their bikes...
          you can check it out at royalenfieldzone.com
          i have select a fuel tank which i would like to change..


          in my bike, i will cut off the chassis,( 2" behind from where the rear suspension fitted) to make it single seated,,..
          can you suggest me where i can adjust the RR,,


          btw even i don't like China light,,
          i will change the head lamp assembly with this one...


          you are going to change the air filter with conical one.. but not k&n,,, which one HP or moxi,,,
          anyway i would like to change the air filter too with the conical one, but i am thinking to cover the filter with the spike almunium plate...
          just like this





          and i would not like to paint rather i will cover the tank with the vinly,, and remove the side cover and put a box for battery and one for tool box..

          and in that tool box,, ill add custom made indicators...( rear one)



          can you suggest me any speedometer which can be connect in ug 5 model bike as i don't like the stock one.
          btw i have searched a lot of universal speedo but i am not satisfied with the detail the online company share.( actually i have ug 4 model bike but bec. of bcu problem i had to upgrade it to ug 5)


          one of our buddy told that if i would like to change it i have to change the gear box and all.... can you help me ...

          I will not be changing the tank, and the tank you suggest are good but they are more suit for a cruiser or a cafe racer kinda bike, I am going for naked sports type.
          I will definitely have a look into their designs on my next project.

          Read more here: http://www.xbhp.com/talkies/blogs/ex...no-engine.html

          In my bike RR is located just under the rider Seat, I guess you can fit it there too.


          I am not a fan of china products as well, but the LEDs that I bought are made in China, even the ones you buy in India, India does not have any LED manufacturing units. even the bulb assembled in India import their LEDs from China or Taiwan.

          http://www.satisled.com/images/l/201...3741388842.jpg

          I will use these Kind of LEDs and Make the circuit myself

          And headlight you suggest has classical look i'm going for somewhat sporty looks. something like this.





          Not K&N because I don't care about (negligible) performance gains, I just need a small air filter to save space. Brand does not to matter. If I don't get anything I might just make one for myself using stock Air filter cartridge.

          As far as the painting I will strip off the old paint and and get new paint on, and I might use vinyls after that.

          And if you are planing to remove pillion seat I suggest out the indicators just behind the rider seat.

          http://www.jcsmotorcycles.com.au/ima...B1-800x600.jpg

          Something Like this, just imagine this bike being a single seater.



          you need to change the speedometer or the whole instrument cluster?


          And I don't think u have to change the gearbox unless the new instrument cluster has All gear indicators.
          Last edited by Expe; 05-02-2017, 11:52 PM.

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          • #6
            Re: Re-build my pulsar 135

            WOW! thanks guys for all the wonderful suggestions.

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            • #7
              Re: Re-build my pulsar 135

              Originally posted by The Monk View Post
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              How do i delete this post?

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