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Bajaj Pulsar DTS-i 150 Pilot Jet broken

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  • Bajaj Pulsar DTS-i 150 Pilot Jet broken

    Dear Members,

    I've been visiting this thread often, but now I felt the need to register myself and seek some help from the experienced. Also I will be glad to take initiatives in helping those in need.

    My Bike
    I own a Bajaj Pulsar DTS-i 150 (Spoke Wheeled) bike. I've clocked 68000+Kms and have maintained the bike well. The bike never gave me any major problem until now.

    Problem
    Few months back while getting the usual service done from my mechanic (who does only what I instruct him to do and honestly is fit only for replacing brake shoes), I asked him to clean the Carburetor which is a Mikuni BS26 CV. He cleaned it properly but over tightened the Jets. The worst he did was playing with the volume screw. After servicing I complained about bad pickup and he adjusted the volume screw at 1 1/2 anti clockwise. And the problem started.

    The idle RPM set at 1000 would never remain constant. It would keep on fluctuating. Sometimes after riding the bike for few minutes the idle RPM would increase to 2000 or 2500 and won't get back to 1000 (no problem with throttle cable). If I would decrease the idle back to 1000, the bike would start getting off whenever the gears are changed. I might have tolerated all this but not mileage. My bike never gave me anything below 60kmpl, but now it was showing 45/48kmpl. I was irritated.

    Worst
    Yesterday, mechanic suggested cleaning the carb and the jets again. I agreed and he opened the carburetor. The overtightened PILOT JET was not getting untightened, mechanic's screw driver scrambled the head and the JET got stuck. After wasting the whole day a guy was able to take it out using drill. The hunt for new jet began, and I was perplexed knowing that the distributors don't have it and there is no chance of getting it. Some mechanic suggested RAJDOOT's JET and it did look similar to Pulsar's. I found Hero Puch's Jet more similar to Pulsar so tried it in the carb. The result was shocking.
    There is starting problem. The bike would constantly get off while riding, the sound of engine is different and is bad, riding is not at all smooth, most of the time bike runs in the similar fashion when fuel gets over. Black smoke at 6000RPM is still there, and I'm crying saying my good old bike now sucks.

    The Pilot Jet(125) is not available anywhere and this is a threat. I tried Apache's distributor as Apache 160 RTR has the same carb but no help. Yamaha FZ-16 also has BS26 but no spares available as of now. Suzuki GS150R has got the same carb but no dealer in my area. A sales counter said he can arrange Suzuki Fiero's PILOT JET, but I'm not sure it will work in BS26 CV, as to my knowledge Fiero's Carb is not CV.

    The JET from Hero Puch is not able to pass fuel properly and that must be the reason for chopped riding.

    Please point if I'm wrong in my understanding and is there anything that I can do to get my bike up and running properly. I would appreciate the help.

    Thnx
    Ayush

  • #2
    Query Approved.
    :)

    Comment


    • #3
      Adding on.

      I've located a Royal Enfield dealer nearby to my place who has PILOT JET bearing part no. 500866, for Royal Enfield Thunderbird. Thunderbird uses Mikuni BS26 Carburetor, I hope this part would work in Pulsar 150.

      wbr
      Ayush

      Comment


      • #4
        @Ayush: Have you tried getting the jet(s) from the Bajaj service center?
        :)

        Comment


        • #5
          Pilots will never come in sizes to 126 its the mains, if that was the case every indian bike would pop wheelies in 1st gear in any circumstances ..

          Could you please post the pic of broken jets.
          "Engine tuning is not an exact science, but with some practice and patience you'll get comfortable with your skill and be able tune for any conditions mother nature throws at you"


          Still the Boss -- RX 135

          Comment


          • #6
            @Aryan: Yes I tried Bajaj Service Centers, they suggest the distributor and none have it.

            @psycho 98: The model # of PILOT JET is 125 not the size. Specifically its "G12 5" (printed on JET) wherein Yamaha FZ-16's service manual prints it as "Pilot Jet (125)" and so does Apache 160 RTR's.

            Comment


            • #7
              Originally posted by Ayush Singh View Post
              as to my knowledge Fiero's Carb is not CV.
              Dude, Fiero was the first bike in the country with a CV carb.

              Comment


              • #8
                for all you know, its a torn diaphragm kit..get it replaced as well..i had similar problems on a frnd's wind125 and it got resolved with the replacement
                83' RD350 HT
                96' RXG
                97' RXZ
                91'RX100>09'RX165
                2010' HH ZMR

                Comment


                • #9
                  Good luck with your pilot jet. Sometimes, you may not get the pilot jet but a Jet Holder Kit is available for Pulsar. It has pilot jet, main jet and main jet holder. Try to get hold of it. Also, if you do not get it for 150, get the 180 kit (DJ121056). Both kits have same pilot jet. And 1.5 turns on a Pulsar is too lean. That is causing the fluctuating rpms at idle. Also set idle speed close to 1400 rpms - 1000 rpm is too low.
                  Your biking tells a lot about the person you are!

                  Comment


                  • #10
                    Thanks for the support, members.

                    Today I got PILOT JET for Fiero. The JET had 12.5 written on it and upon comparison with the default JET, it looks identical. The JET was replaced in the carburetor.

                    After replacement bike ran properly for 200mtrs, it was super smooth, but then the choking started again. It is the same as it was happening with the Hero Puch jet. The bike keeps on knocking and doesn't feels smooth at all.

                    Further I adjusted the volume screw at 2 1/2 but still knocking continued. Everything looks proper, I'm unable to understand what is wrong. Please suggest why bike is knocking with correct PILOT JET. The MAIN JET was over tightened by the mechanic, but MAIN JET is for high end performance and the bike runs well while accelerating, but when it is cruising at 60km/hr it starts chocking/knocking again.

                    I'm desperate to solve this problem within a budget, else might have got myself a new carburetor.

                    Thnx
                    Ayush

                    Comment


                    • #11
                      Originally posted by Ayush Singh View Post
                      Thanks for the support, members.

                      Today I got PILOT JET for Fiero. The JET had 12.5 written on it and upon comparison with the default JET, it looks identical. The JET was replaced in the carburetor.

                      After replacement bike ran properly for 200mtrs, it was super smooth, but then the choking started again. It is the same as it was happening with the Hero Puch jet. The bike keeps on knocking and doesn't feels smooth at all.

                      Further I adjusted the volume screw at 2 1/2 but still knocking continued. Everything looks proper, I'm unable to understand what is wrong. Please suggest why bike is knocking with correct PILOT JET. The MAIN JET was over tightened by the mechanic, but MAIN JET is for high end performance and the bike runs well while accelerating, but when it is cruising at 60km/hr it starts chocking/knocking again.

                      I'm desperate to solve this problem within a budget, else might have got myself a new carburetor.

                      Thnx
                      Ayush
                      As far as I remember, jet marked 12.5 is the correct one. Have you checked the diaphragm in the carburetor? It may be torn. Else, it can be a case of fuel contamination - happened to me once.
                      Your biking tells a lot about the person you are!

                      Comment


                      • #12
                        The mechanic is not keen on opening the upper side of the carburetor, he says placing the diaphragm back to its place is very difficult, also I queried about spare diaphragm but the dealer said its impossible to get one.

                        I don't think there would be a problem with fuel as I get the tank filled from one petrol pump and they are authentic. Also, there ain't any water in the tank as I got it checked a few days back.

                        Comment


                        • #13
                          Adding on:
                          I found the volume screw to be useless, i.e., there was no variation in RPM, this means the PILOT JET was not correct. I wonder how could that be possible given it has the same specs as that of pulsar.

                          Now, I'm trying to get the Pilot Jet from Royal Enfield Thunderbird which has the same carb.

                          Comment


                          • #14
                            Originally posted by Ayush Singh View Post
                            Adding on:
                            I found the volume screw to be useless, i.e., there was no variation in RPM, this means the PILOT JET was not correct. I wonder how could that be possible given it has the same specs as that of pulsar.

                            Now, I'm trying to get the Pilot Jet from Royal Enfield Thunderbird which has the same carb.
                            IMO, please get the original jet pin only. Do not experiment further. As I have said, there are two ways to get the jet pin -either as a single pilot jet (180pin will also do) or as a set of main jet and pilot jet. Place a order with the dealer. They can get it directly from Pune in a few weeks.
                            Your biking tells a lot about the person you are!

                            Comment


                            • #15
                              Abhijeet thanks. I already got one from Enfield dealer and it has the same part no. with Mikuni, so the possibility that it should work was high.

                              However, things failed again. The bike is still chocking and running bad at slow speeds.

                              I've called Bajaj's factory today and they said only Pilot Jet is not available. As you said they recommended the Jet Kit (Pilot Jet, Main Jet holder+jet) priced at Rs 126. He gave me the part no as 36DH1203.

                              I would appreciate if some one can confirm the part no for Pulsar 150 Jet Kit.

                              Till now money spend = Rs. 400/- with no help.

                              Comment

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