Re: Bajaj Pulsar 180 (All Versions)



what you are referring to is the hone marks on the cylinder walls , it is supposed to be like that as your engine hasnt done much in 9 years , dont change the cylinder as of yet

Re: Bajaj Pulsar 180 (All Versions)

Check the battery. It should be above 12.2 volts and below 13.5 volts. Don't open anything. Better give it to BAJAJ service centre. Even I faced a simple start up issue. I literally spent Rs.5000 on tools, new battery, new motor starter. When I opened it, I messed up many things like scissor gear, valve kit, timing chain.

If my bike stopped on the road then the valve was broken while riding with vibration but I came home and stopped my bike and after I made some inspection the bike failed to start but when I took it to the mechanic he opened the main head block then showed me the broken valve. It is not a long term riding damage but a short ride of 5 minutes damage with vibration of incorrect scissor gear settings which secretly moved at the background when I removed the clutch case but I haven't noticed it until I removed it couple of times. I still haven't gave my bike to the BAJAJ service as I am planing to repair it by myself.

Re: Bajaj Pulsar 180 (All Versions)

I have a pulsar 180 classic and the issue I am facing is that something all of sudden the bike refuses to start event after 100 kicks and the next day or might be couple of hours it starts in just one kick
This happens once in every 10/15 days
The mechanic tried many things but unable to rectify the problem
One guy told me it’s the problem with compression
Can someone here help ?

Re: Bajaj Pulsar 180 (All Versions)

I have 2009 year old price list of spare parts of Pulsar 180 UG 4 here Pulsar 180 UG4 Spares List where it shows valve kit on page 3 which was broken as shown below in my hand.



The cylindrical surface inside my Pulsar 180's piston has got some scratches like triangle designs as shown in the screen shot as those scratches are invisible in my camera quality pictures. My local mechanic BUMI also said that the piston should slide smoothly inside the block but my piston was stuck and requires pressure to slide inside. So he said it can be repaired using tunning machine to make smooth surface around the piston which takes around Rs. 7000 or I else I have to purchase the whole block and piston. The BAJAJ service person said that they will only replace with new parts and he told the estimated price may reach Rs.15000.





When I said the piston cap I mean the top rusted surface area of the piston as shown in the below figure. I am sure that it can be cleaned with WD 40 spray after using sand paper on it but my local mechanic said that not to use sand paper at the lateral sides of the piston as it would leave tiny scratches but I can use it on the top surface area of the piston. He said that in order to make the piston's lateral sides smooth we need to use tunning machine or purchase the whole block and piston. He said that if I can do it with only WD 40 and if the piston slides smoothly inside the block then half job is done.



The below image shows 22,195 km ONLY which I drove in 9 years as everything is around my house.





My local mechanic also said the other reason that caused my valve kit to break was my bike's vibration due to old scissor gear or incorrect settings of scissor gear as well as timing chain. As I kept my bike always in shining condition so the service person thought my bike was new and ignored to replace the timing chain.

Re: Bajaj Pulsar 180 (All Versions)

The pulsar's block and piston kit is under Rs.3500 iirc. Don't compare prices with yamaha .
what do you mean by 'scratches' . A good block will have 'scratches' (or technically called honing marks) at approx 45 degree angles. If you are seeing vertical scratches/scoring, then it might time to replace the block+piston kit (or rebore and use next size piston+rings, if someone can do it properly. Might save you some money.)
I don't think the cost should go beyond 8-10k max for a full rebuild with new block+piston/bearings/valve kit/ and labor.
You can check out this website https://www.99rpm.com to get an idea on prices of spares.

Am confused by the terms you use such as 'wall seal'/piston cap etc.. I can't say further without seeing/riding the bike. Care to post some pictures if you have any ?

Re: Bajaj Pulsar 180 (All Versions)

changing the piston cylinder will not cost much . buy get it done correctly. 25000km odo is not that old to have a engine overhaul.

Re: Bajaj Pulsar 180 (All Versions)

I haven't done it. I went to all mechanics to fix timing chain but they ignored that they won't do it and so when I drove with vibrations for about 7 km then the wall seal was broken secretly from inside but the bike was still running till I reached home and then when I opened the scissor gear by scissor gear tool to fix its settings then the bike failed to start as the timing chain lock pin is not aligned to the mark and when I took it to the mechanic he haven't aligned it but then he said the reason is different and then he showed me that the wall seal was broken because of strong vibrations because of loose timing chain and old scissor gear which I haven't replaced for 8 years as no service person recommended me when I went for many services. For all the services which I gave I think they gave my bike after washing and changing the engine oil but not inspecting the wear and tear of internal parts. However, I drove only 25,000 km since 8 years. I also gave it to the service last year and they informed me that my bike is in great health. No service person paid attention this year when my bike was really in need. However, I regularly changed engine oil and I am not a rash driver. I drive very less and very rare.

With my eyes I have seen the broken wall seal and slightly rusted piston cap with scratches on the cylinder where the piston slides. These parts may cost around Rs.5000. I hope my bill won't go to Rs.15000 like this man in this YOUTUBE video with title as "R15 engine seized, Big mistake".

Re: Bajaj Pulsar 180 (All Versions)

I dunno exact cost of the cylinder and piston but 15k is way too high. At 15k you'd get half engine or more. 6k seems slightly high but still reasonable including labour. Your mechanic has opened the bike and he hopefully knows what to do. Bajaj service centre has given the maximum possible quote without looking at the bike. Their business is run on fooling the people.

Cylinder can go bad for number of reasons. Even if some dust gets inside, that'll scratch the surface.

Re: Bajaj Pulsar 180 (All Versions)

half knowledge is dangerous than no knowledge. By ignorance u did some damage to engine . Its a machine , it cant go wrong on its own .

Re: Bajaj Pulsar 180 (All Versions)

I finally found the YOUTUBE video where a man paid his total bill of Rs.16000 as his R15 engine is seized as he ignored to replace engine oil. But in my case I changed the engine oil regularly and I only drove 25,000 km since 2009. Do I get the same total bill like him? I am not a rash driver.

It all started when I removed my clutch case and the scissor gear secretly had a spin but I haven't noticed it but I saw it after I removed the clutch case to inspect the timing chain settings. When I kept the clutch case back then scissor gear was secretly rotated from the background and when I went to my ZOOM coaching centre then my bike had vibrations and when I came back home and again removed it to inspect it then at this point I purchased the scissor gear tool and kept the scissor gear settings which is anti clockwise and clock wise rotation of 2 turns from both ends. At this point my bike fail to start. So I bought a new Exide battery but it failed to start. I also purchased motor starter but I later found that the old motor starter is working when I tested it with wires as it spins perfectly. When my bike failed to start so I finally took it to the local mechanic where he opened the engine and showed me the broken wall seal.

At first when I came to all mechanics they ignored to replace the timing chain as my bike was in running condition and now they say that the estimated bill may reach Rs.15000. I was hunting every video to cure my bike and I learnt that ignorance by anyone is the key to damage anything in life. I am not the part of ignorance.

Re: Bajaj Pulsar 180 (All Versions)

I have Pulsar 180 UG4 which I purchased in 2009. Three weeks ago when I had issue with timing chain then all my local mechanics ignored it and even BAJAJ service centre blindly said that they won't do it here. Now when my bike fails to start then my local mechanic opened it and showed me broken wall seal and said that it will take Rs.7000 to repair the existing scratched cylinder of the piston. On the other other side when I made a call to BAJAJ service centre then they said that they will replace only with new parts and my estimated bill may reach Rs.15000. Are they telling the correct price? Hardly I can guess the new parts price as Rs.6000 and their labour charge around Rs.1000.

There are lots of YOUTUBE videos but only few say service charge prices. Someone please let me know how much is the service charge for the full engine fitting of Pulsar 180 UG4 ? I want to confirm before I can pay. I haven't given my bike to the BAJAJ service and my bike failed to start since 3 weeks.

Do I have to remove petrol from the bike as the bike is in idle state ?

Re: Bajaj Pulsar 180 (All Versions)

how do you remove the tail lamp from tail piece

Re: Bajaj Pulsar 180 (All Versions)

I have recently bought a new seat cover for my Pulsar 180, since my 2.5 yr old cover has gave away. Bought it online from Paytm for INR 765, however got a cashback of INR 200, so the effective price is INR 565, which I think is worth its price.


Few pictures of the seat cover:








Paytm link for online purchase:





The same is also available in Amazon and Flipkart as well -

pulsar 180 ug4 mileage and missing problem

my pulsar 180 ug4 shows a missing when i ride it at 3000 rpm and it gives me mileage about 18kmpl i know it was too short
i brought my bike to a mechanic and he replaced vaccum piston and checked spark plugs and filter,but the problem persists and he say that i must buy new cvarburetor
please help me........

Re: Pulsar 180 2014 not going above 6.5k RPM

On ug4 the second spark plug gets activated at approx 4k RPM. It doesn't check the actual rpm but how much accelerator you are pulling. That's the function of that switch.