Query Approved.

Hi ,

My friend has a 200 Bore kit running on a classic 150 afaik he has no issues except the power curve, the midrange has dramattically changed but the tp end suffers with the stock CDI. get in touch with Coolkar for more info. hed be able to help.

Thank you very much for the prompt reply. I have sent a message to Coolkar.

Infact, I am planning to do this asap as I want to take this beefed up ride to Ladakh this season, if all goes well.

It would be great if the midrange goes up. Regarding the issue with top end, how worse does it get with stock CDI? And can it be changed with the one which matches it to improve it as well. What could be the approx. cost involved.

Pardon me for my ignorance, do you have any photo to show what a cylinder's exterior would look like? Is the exterior what we see as the outside of the engine or what we see is just an encasing for the cylinder which fits inside it?

Thank you everyone for being so patient.

I would appreciate the seniors to guide me to a thread/source which tells about the whole procedure/bottlenecks; technical as well as financial. Today I had enquired with Bajaj about the cylinder-piston kit and I was told it costs around Rs. 2100 only. So even if the kit for 180/200 costs Rs. 2500 or so, it is a steal if it is a direct fit. And, I am sure if it was that easy and economical to do it, people wouldnt buy 180cc or higher and would just buy 150s and upgrade this way. Where's the catch?

Just penning down my thoughts
Anyday I would prefer a new part especially when it comes to cylinder, pistons, rings, swing arms etc.

So you've 2 choices here; either plonk the 200CC cylinder instead of 150CC or buy a new 150CC cylinder to use. Using a 200CC cylinder isn't that harm provided all the technical aspects are taken care. However, one should understand that this is illegal until the RC book is changed.

If you look at the RC book, it contains the cubic capacity, registration number, chassis number & the engine number. But after plonking the 200CC engine, all of them matches with the RC book except the cubic capacity. At present there's nothing harm doing this, however, in case of any insurance claims OR when it comes to any legal aspects you may be bound to face the worst case scenarios.

Yes, I understand the legal issues. But if that is done, will there be problems getting the RC book changed accordingly?

Also, can someone tell by looking at it from outside that the cylinder is 200cc and not 150cc anymore?

When I spoke to a Bajaj guy over the phone regarding the price of cylinder kit, I had asked him if I could use 180cc kit, he said it could be done but would not improve performance at all. I could not understand why he said so. But I did not want to piss him off by asking any more questions.

I think legal issues can be taken care off later, for now I just need the technical/monetary aspects of such modification and what is the success rate I should expect. I would not want it to come out a pudding after spending a lot of money. I would rather sell this one off and buy something better after some time. I have another bike anyway which serves me well.

Ok, firstly, its quite an easy job as you are only changing the bore + piston + head assembly. One more thing you would have to do is you would have to go for dual spark plugs, meaning the DTSi head., so electrical changes are there. Specifically your pulsar coil and HT coil. You at the minimum require the Pulsar pulsar 150/180 second version CDI. And plonking in the latest CDI is a big headache as you would need your bike to run on DC and you need many sensors on the bike.

So be sure that the electrical work is being done perfectly.

All the best for your modifications.

all the cylinders look the same. only difference is, the 200 will have DC embossed, 220, DK embossed. no idea on the 150 and 180. IIRC, it has the cc value embossed.

^ the Pro Has spoken. Ganesh's (undefineme3) Pulsar is a complex hybrid running esteem's piston set. no one knows the true cubic capacity of hs engine :P

Its the 220 DTSi's piston now. and yes, cc not yet known

@ thread opener: If you check old Help me posts, you would find one of my threads. I guess it would help you a bit.

A big thanks to you for the reply which has answered a number of queries. Today, I had gone to a mechanic to get the chain-set replaced and I talked to him about the modification as well.

He told me that head would cost 4-5K. The cylinder kit would cost around Rs. 1800-1900. Then add to that the labour charges. May be CDI as well? And, a number of things which I am still unaware of will also crop up at the time of execution. All in all, I think the expense at least would be 10-15K or even more, still I dont know what will cook up since I myself dont have knowledge about the same.

After having made this estimate, it does not seem to be cost-effective to me for now. I may go for this in the future when I have money and time for this.

Having replaced the chain-set today, I find the ride to have improved. Found that some rings were missing in the chain. It is the top end that suffers a bit because there is a minor compression loss it seems. The oil level drops because I rip it a lot. The mechanic told me not to bother about kit or anything for now and use it as is, just keep checking the oil level at regular intervals. He was against replacing the cylinder kit for now and said that since the compression loss is very minimal with no visible white fumes from the exhaust, I should change only the piston rings and valves. He said no need to rebore or anything. Wanted to know if he is correct on this. If I just buy piston rings and valves and get them changed from this mechanic (not authorised by Bajaj), can there be complications later or the chances of success are high since I would use genuine parts. What else can go wrong? I am asking this because in most of the threads I came across, people have suggested against opening up the engine itself and they say it is good to sell off just when the problems start with the bike.

Now my bike does 90 kmph at the most. Will it be fine taking it to Ladakh. I also have a Bullet Standard which I bought recently. Although people are suggesting me to take the Bullet taking into consideration that it is new and also more powerful to handle such terrains. But my mind trusts this Pulsar more and I want to take this to the trip. Am I right in my decision.

90kmph??
Have u checked the clutch plates??
Ill sugest keep it stock if you are taking it to Ladakh.
Come back Do 180/200/220 anything .

Yes, 90 kmph only. The clutch plates/pressure plates have recently been changed.

Regarding doing it 200/220, I dont think it is worth the money or effort at the moment; may be some time in the future, if at all I am bored of my life.

Speaking in terms of practicallity...

@FranklySpeaking
Just plonk the 180 cylinder, head, and piston; you will save yourself alot of time and money...
Why do you want to change so much of it when it is advisable to just convert it to 180, or instead change the WHOLE engine!!
It is really not practical to get the 200 or 220, what if it does'nt turn out to what you want it to be? I advise you to go for the 180 option, its just my opinion. Cheers!!