Then that must be it. Coz I was briefed about it when I got my 220. I assumed it was for all Pulsars.

me too buddy...there are so many threads here on xbhp of engine failures...seizures etc on pulsars ....wwhich are just 20000 to 30000kms old.......there is a reliability issue with pulsar engines specially if driven hard.

Hello ppl,

I happen to take my bike to Reddy at Goregoan... he checked the bike and said that he doubts if its the block piston issue but cant assure as he will have to Open the head to check and comment.. But he did mention that since I have completed 36k kms on the bike, I will have to Open the head of the engine as the rings, valces etc needs to be checked and replaced due to wear and tear...

I also asked him whether I can opt to rebore the piston or probably try to put Karizma block piston, but he said that it is not possible in Pulsars.
he said that re boring is possible only in 2strokes and not 4strokes...But I thought that boring the piston was possible and many of the xbhp members have posted their threads with regards to the same.... Please suggest...

As I mentioned that the oil level keeps on dipping within 8 -10 days itself, he has asked me to ride the bike for 1200 kms and then come for oil change so that he will measure the oil while draining it and comment if engine is drinking oil...

Joke of the day!!! Change ur mech...

I know.. Even I was shocked to hear that .... But I am sure many of the xbhp members know who Reddy is... He is a well known mechanic, rather he is an atomobile engineer, worked for Bajaj Service center for some time and now runs his own mechanic shop.... Many of the xbhp members often get their bikes serviced/repaired from him...
Please advise fellas...

upto what extent can the standard block be rebored??
does anyone own a rebored pulsar here??

You mentioned black smoke. The reasons why you would have black smoke are the following

1. clogged air cleaner
2. incorrect carburetor float level, maybe too high
3. incorrect main jet that is too large.
4. carburetor mixture too rich

These do cause oil consumption to some extent.

The fact that you are losing a lot of oil is worrying. Before you go in for an overhaul check the above 3 issues. Also check the

1. spark plugs
2. valve timing

It is worth checking these problems before going in for an overhaul. Make sure you take the bike to a good mechanic and as Ken Cool has mentioned, check for warranty.

I showed my bike to a new mech and he said that the block piston noise is audible from the engine and that an overhaul will be required.he said that we can either re bore the piston or we can put a new block piston set...

My doubts :

1.What would be better, putting new block piston or boring the current one ?
Milegae is not a great issue, but a little.If I loose on 5kmpl, I am ok with it cuz I mite bore to next oversize i.e. 0.25mm or next to that i.e. 0.5mm... The more two options are 0.75 or 1mm... Could someone plz throw light as to how much milage will decrease if I bore to max cuz I am looking for some increase in power...
Will there be descent increase in power ?

Also I asked him whether I can put 180 cc or 200 cc block piston kit, he said that I will have to put a new head too cuz it mite not be possible without that ...
I have read some posts where ppl have changed the block piston of 150 or 180 to 200 ,does it require the head to be changed to ?

0.25mm - 0.5mm - 0.75 mm and max 1 mm

Hello folks,

I still havent got the bike fixed as Reddy has gone to his native and will be returning in the first week of June...
I have this other mech called Sniper Automotives at Dahisar from where
beruoist got hi bike fixed... The link to his thread is below

I showed him the bike and he said that he will bore the piston but I will be going in for a new one itself.... I havent ever given the bike to this mechanic, so I was just curious to know whether I should get the engine overhaul done from him or should I wait for Reddy to come back and give him the bike....
Please advise... I am a little confused.

I am also in the same boat. I have p180 ug3 purchased dec 2006.At 10000km my 5 th cog has been changed. The engine was at damn good at that stage.No scratches the honing marks were still visible. At 22k on the odo I gave the mech for decarbonization. Guess what 2-3 heavy scorings on the barrel which can be felt by sliding the fingers. Too much of carbon on the piston crown and in combustion chamber. I mean way too much. Full of carbon in the exhaust valve with no mating marks in the valve angle and valve seat. It suggest the valve is not closing properly. Inlet valve has more than 2mm of carbon and the valve seat pressed against the valve causing heavy impression on the valves. 1st and 3rd angle is full of carbon 2 nd angle has pit like impression.It seems like valve guide has gone bad causing oil to come in. some golden color varnish deposit on the sides of the piston. This indicates there is a gap between the barrel and the rings.
Initially i thought of going with overbore .25. there is no seizure marks. The scratch can be due to the carbon particles i believe. The mech suggested me to polish the cylinder and put over size piston rings on the same piston. There is no traces of blowby to the crank case. He will replace the valves and guides with new rings set. Estimated damage is 1.5k Also the silencer is rusted. It started to come off like wafers. I hate bajaj

Update: only mild polish to remove scratch marks. No over size rings. He purchased std rings as over size wont fit properly in the std bore. The culprit is valve oil seal gone bad causing oil seepage through valve. valves will not b replaced. I have got motul 5100 and NGK GP plugs.

Is there anybody to help me and reply to my post please ????