Announcement

**mehuel** · 08-13-2014, 09:21 PM

Re: Help: Converted my Pulsar 150 UG3 to 200 but...

stroke is same for 150, 180, 200 at 56.4. but i am seeing some conflicting results when googled. the manual too states 56.4.

but none the less, if you decide to revert back to 150, its great.

if you continue with 200 mods, go with a new 200 head, with complete setup, valves, guides, camshaft, springs and retainer.
using extra gaskets wont be a permanent solution and isnt advisable. once all this is done, as Prince suggested go in for the bs29 carb.
here you are looking at a damage of 6-7 k.

as for the crank bearing play and piston hitting the head because of that, check for the crank play. excessive bearing play can be noticed by rotating the crank in circular motion while holding the small end in your finger, try to push/pull the crank while rotating, it should not move up and down.
same way check for big end and small end.

needless to say but the 180 head will have to be machined if you stick with it. if you can find a good machinist, 180 head can
be retained, switching to 200 valves would be advisable after getting the porting done and polishing head dome. but remember to get
valve springs too, they are shorter than 180s. cost wise this would be less damaging.

a question though, why not go in for the 180 cylinder kit. you already have the head and valves assembly? and you would be updraging on power front aswell.

**RSM2852** · 08-13-2014, 09:42 PM

Re: Help: Converted my Pulsar 150 UG3 to 200 but...

Originally posted by Bibhu View Post

65x62.4-p200

63.5x 56.4 p180

57x56.4 p150

Bore x stroke for all 3 variants. You can see the p200 has a bigger dia piston so a bigger dia head squish also.

Sent from my XT1033 using xBhp Connect mobile app

P200 is 67 X 56.40. Since the stroke length of P150/180/200 are same, the bore of 200 should be a straight fit without any need to change the head. My friend's P220 is running on RC bigbore of 230cc on stock head, shouldn't and P180 can take 208cc from the same, I don't think the piston should hit the head.

----consecutive posts auto-merged-----

Originally posted by mehuel View Post

stroke is same for 150, 180, 200 at 56.4. but i am seeing some conflicting results when googled. the manual too states 56.4.

but none the less, if you decide to revert back to 150, its great.

if you continue with 200 mods, go with a new 200 head, with complete setup, valves, guides, camshaft, springs and retainer.
using extra gaskets wont be a permanent solution and isnt advisable. once all this is done, as Prince suggested go in for the bs29 carb.
here you are looking at a damage of 6-7 k.

as for the crank bearing play and piston hitting the head because of that, check for the crank play. excessive bearing play can be noticed by rotating the crank in circular motion while holding the small end in your finger, try to push/pull the crank while rotating, it should not move up and down.
same way check for big end and small end.

needless to say but the 180 head will have to be machined if you stick with it. if you can find a good machinist, 180 head can
be retained, switching to 200 valves would be advisable after getting the porting done and polishing head dome. but remember to get
valve springs too, they are shorter than 180s. cost wise this would be less damaging.

a question though, why not go in for the 180 cylinder kit. you already have the head and valves assembly? and you would be updraging on power front aswell.

Buddy it's 67 X56.40 confirmed, which results in 199cc displacement, 65 X 62.4 is equal to 207cc.

**Bibhu** · 08-13-2014, 09:47 PM

Re: Help: Converted my Pulsar 150 UG3 to 200 but...

My mistake. I checked a wrong site.

Sent from my XT1033 using xBhp Connect mobile app

**RevMaster** · 08-14-2014, 07:39 AM

Re: Help: Converted my Pulsar 150 UG3 to 200 but...

Thanks for the replies!

Since I already have the 180 head, I wanted to go with the new 180's crankshaft without any modifications done to it and use it with a new 200 conrod(Both 180 & 200's conrod are of same width and stroke length)and use it with a new 200 cylinder piston kit but the 180's crank is out of stock in my nearby Bajaj ASC so I simply bought the 180 Cylinder Piston kit(Rs.2060) and mounted it on the engine with 2 new 180's cylinder packing(Why 2 you may ask but even though head is for the 180, I dont want the new piston also to hit the head again) and a 180's head gasket. I changed the oil again(Last oil change before 2 weeks with 20 Mins max runtime).

The engine is running well without any hitting/rattling noise and the sound note is awesome! I drove the bike around 15 Kms and gave it a little throttle a couple of times and I can already feel the increased torque but its not as powerful as it was when I rode it with the 200's bore kit but the performance increase is definitely noticeable.

When I rev the engine, I feel like the current 150's carb is simply not enough to feed the engine with enough air/fuel supply so I might have to get a new carb soon to get the max performance from this mod(Well, not a mod really

).

Should I be replacing the exhaust as well If I change the Carb?

And as for the kicker not returning back, I think I need to change a spring near the clutch assembly but that issue was also fixed once I put the missing rubber stopper on the RH footpeg's mounting rod.

The main jet which I'm having now(replaced new) is for the 180 I believe, but I'm thinking to replace it with the Apache 180's main jet as I heard both manufacturer's use the Mikuni carb.

Since I'm using the OE Clutch plates(replaced new), I think it'll wear out very soon so my next upgrade will be the following :

180's crankshaft with 200 conrod(both 180 & 200's conrod are same as mentioned earlier)
220's camshaft and carb
200 Bore kit
Port current 180's head to house the 200 piston.
200 Clutch Assembly

The idle is set to 1300 +/- 100 as per the manufacturer's specs but I'm noticing the neutral light is flickering when in Idle but lits normally when I give some throttle. Does this has anything to do with the neutral wire connector in/near the stator coil?

Once again, thank you so much for all the helpful & constructive replies! I'll write the total costs incurred in the next post.

**RSM2852** · 08-15-2014, 06:56 PM

Re: Help: Converted my Pulsar 150 UG3 to 200 but...

Originally posted by RevMaster View Post

Thanks for the replies!

Since I already have the 180 head, I wanted to go with the new 180's crankshaft without any modifications done to it and use it with a new 200 conrod(Both 180 & 200's conrod are of same width and stroke length)and use it with a new 200 cylinder piston kit but the 180's crank is out of stock in my nearby Bajaj ASC so I simply bought the 180 Cylinder Piston kit(Rs.2060) and mounted it on the engine with 2 new 180's cylinder packing(Why 2 you may ask but even though head is for the 180, I dont want the new piston also to hit the head again) and a 180's head gasket. I changed the oil again(Last oil change before 2 weeks with 20 Mins max runtime).

The engine is running well without any hitting/rattling noise and the sound note is awesome! I drove the bike around 15 Kms and gave it a little throttle a couple of times and I can already feel the increased torque but its not as powerful as it was when I rode it with the 200's bore kit but the performance increase is definitely noticeable.

When I rev the engine, I feel like the current 150's carb is simply not enough to feed the engine with enough air/fuel supply so I might have to get a new carb soon to get the max performance from this mod(Well, not a mod really

).

Should I be replacing the exhaust as well If I change the Carb?

And as for the kicker not returning back, I think I need to change a spring near the clutch assembly but that issue was also fixed once I put the missing rubber stopper on the RH footpeg's mounting rod.

The main jet which I'm having now(replaced new) is for the 180 I believe, but I'm thinking to replace it with the Apache 180's main jet as I heard both manufacturer's use the Mikuni carb.

Since I'm using the OE Clutch plates(replaced new), I think it'll wear out very soon so my next upgrade will be the following :

180's crankshaft with 200 conrod(both 180 & 200's conrod are same as mentioned earlier)
220's camshaft and carb
200 Bore kit
Port current 180's head to house the 200 piston.
200 Clutch Assembly

The idle is set to 1300 +/- 100 as per the manufacturer's specs but I'm noticing the neutral light is flickering when in Idle but lits normally when I give some throttle. Does this has anything to do with the neutral wire connector in/near the stator coil?

Once again, thank you so much for all the helpful & constructive replies! I'll write the total costs incurred in the next post.

Congrats on getting your ride rolling again brother, Why dont you try 220's crankshaft next, it will increase the stroke length to 62.4mm which is roughly 188cc and the engine would become a square translating to better torque and revy nature, Use the camshaft of 180 UG4/220 (both are same) they are kinna high lift, Use a bigger BS32 carb with 117.5 mainjet, I'm sure you will make something like 18.xx bhp and ~18NM Torque too.

**Sakibchy** · 06-05-2016, 09:27 AM

Pulsar 150 to 180 Conversion

Dear folks ,
I have decided to upgrade my pulsar 150 ( ug4.5 ) to 180 . I know this is critical process but can't be undone if correctly installed parts and all. Now the list parts I'm getting :
1 ) crank shaft ( set ) with connecting rod.
2 ) head
3 ) cylinder + piston
4 Balancer
5) valves
6 ) New carb
.. Please let me know is there anything I'm missing. And if any brother has done successfully please it would be great help if you let me know the procedure and what parts I must change . in our country we can't buy any bike above 150cc . some people ride 220 , 180 those who has political connection and hold power . but I bought mine from showroom with all legal papers and registered . but I love the torque and acceleration of p180 . so please I hope someone will come forward to help me

thanks In Advance

**jhprabhat** · 06-06-2016, 08:04 PM

Re: Pulsar 150 - Rebore or new kit (180cc)?

Bro ...I think all the parts required is there ...one of my friend already done this...u can feel the change on first ride itself

**Sakibchy** · 06-07-2016, 08:45 AM