Re: Bajaj Pulsar 180 (All Versions)

You can change the oil inspection window if yours is totally blacked out.

If there is no smoke and the motorcycle runs right and holds the adequate amount of oil with minimal drops then all is well.

As for gearing I ride a P220 and run a 40T up rear, how on earth are you fine with running a P220's 36T at rear. Anyway remember, it is not about how fast you go but rather how far you go, so keep the speedo in check whereas let the odo keep climing at a steady phase.

Re: Bajaj Pulsar 180 (All Versions)

I am planning to give my bike for service later as I am not ready with money and on the other side I am busy writing my notes. However I found the reason of my broken valve from this YOUTUBE VIDEO "Why do engines blow?" by Cameron. At video time 9:14 he clearly described that when the timing chain becomes loose then it gets into contact with the valve and piston and that will snap the valve. So I haven't replaced the timing chain for 9 years with 22,000 km and timing chain became loose and that obviously cracked the valve. Another thing is that when I purchased the new battery then one EXIDE service boy came to my home and removed the spark plug as my bike failed to start but after he removed the spark plug and turned the switch ON my bike stopped cranking or coughing but started sounding like TAK TAK with or without the spark plug. Even before I purchased the new battery my bike used to give nice coughing sound for few seconds and failed to start as my old battery was weak.

My question is what caused the valve to break? Did the EXIDE person broke it or my loose timing chain broke it even before I purchased the battery? However, EXIDE battery person job was to check the battery voltage and leave but he removed one spark plug and started the bike and the bike completely fail to respond? Just before he came I started the bike with little good sound for few seconds by it failed to start. The moment he removed it then it totally fail to show starting sound but showed sound like TAK TAK.

Right-Side Up vs. Upside Down

Have anyone ever tried Upside Down Forks mod for pulsar or any other variant?
I've gone curious after watching this video from MC garage on youtube
Right-Side Up vs. Upside Down – Why Are Inverted Forks So Good? | MC GARAGE

Re: Bajaj Pulsar 180 (All Versions)


DIY is my thing but I didn't get lucky this time. Its all done.
I appreciate the information you have provided.

Re: Bajaj Pulsar 180 (All Versions)

If you plan to do it yourself make sure to buy an extra 2 bottles as the oil may spill as it happened to me and so I bought extra bottles and done it like pro as it takes more patience to tighten the bottom hex nut. You need to have the driver tool and customised spanner with welded nut at the bottom of the spanner. A quite SUNDAY free time is enough to fix it. I briefly described here in this link with my other ID as Natfx7

Re: Bajaj Pulsar 180 (All Versions)

Aaaaah My phone/browser is behaving bad for now, nevermind.

Hello lovely experts! I'm new in here. I have a month ago bought a 2nd hand P180 UG3 (2008 model/manufacturing), that one which came with clip-ons handlebar. I think it was the first and last model of UG3 that had those features upgraded before UG4 came out, nevermind. I bought it at only 18,000 Rupees and had around 64240 on odo. Everything is going almost excellent so far.

First thing I want you all to know that I have been reading this whole thread since the start and it took me a little more than a month to full complete/read it, I wanted no question be asked by me that had already been asked since it is really annoying and I understand, hence I did that. I heartwarmly want to thank all of you who unknowingly helped me understand 'should do' and 'shouldn't do' things for this model.

Right now everything is going fine, I'll let you all know if I face any strange problem.

One thing I am extremely afraid of happening is keep riding the bike while engine is low on engine oil, when this is unbeknownst to me. I am asking this because I can't get a glimpse of engine oil quantity through that small circled window at the bottom right side of the right side of the crankcase because it is completely blacked out and I don't want to open the crankcase just to wipe the smudge from that since the pickup is good enough that means at least for now clutch part seems to be okayish (It is with P220F's sprocket set hehe) and there is no problem reaching upto 9.5k RPM in neutral (since there is no road around my area, Bilaspur (C.G.) with enough straight stretch to do so in practical and the speedo sensor cable seems to have went kaput as the last time it stuck on 107 km/h for 5 seconds resulted in 111.9 km/h in GPS and I am right now very afraid to do more speed for now) to see if the piston/cylinder compression is good or not. My question is, can I relay on the RPM info by checking max RPM once per week or so to know that the engine is not burning any unnecessary engine oil (there seems to be no white smoke at all even at 9.5k RPM fortunately, for now) because if oil does burn anyway then either it signifies cylinder wall or piston to be kaput which in turn will obviously reduce compression that in turn should reduce the bike's capability to reach at same RPM at same level of air-fuel delivery as before the system went kaput? I am sorry this sounds so stupid but I am very interestes to know other methods if there are any, so that I could know if the bike is running under sufficient engine oil or should I just get that hey-get-a-sneak-peak-of-engine-oil circled window cleaned ?
Thank you everyone in advance.

Re: Bajaj Pulsar 180 (All Versions)

Had you correctly set the position of output shaft of transmission and crankshaft before inserting back the scissor/balancer gear ? I don't exactly remember but I have seen in a youtube video that one of the teeths of final drive/gear of crankshaft(the one which is above the oil strainer/cleaner) has a mark on it and that teeth must be at the top. I think some of issues you were getting after that may be due to this misalignment if this all was the case.

Re: Bajaj Pulsar 180 (All Versions)


Thank you for the info guys.
I'll go for Motul and new seals for both the forks.
Will get the 'cone-set' checked and replace if necessary.

Re: Bajaj Pulsar 180 (All Versions)

I change my coneset and overhaul forks every 15k km's, I rather go with that than have my seals blow when I least expect it to.

Re: Bajaj Pulsar 180 (All Versions)

Ashwin, how often should the cone set be changed? Or will simple re-greasing every x kms be sufficient ?

Re: Bajaj Pulsar 180 (All Versions)

320 ML it is.

And thumb rule is that both forks should be overhauled at the same time with both oil and dust seals changed.

Since you're taking the shocks off it would be a good time to change the coneset as well if not already changed.

Re: Bajaj Pulsar 180 (All Versions)

It's 320 ml per fork for UG4 and above. So total 4 bottles. Old models need only 160ml per fork.

You need to change seal on only side where it's broken. No need to change both if one is good.

You can also get fork oil from motul. Price is similar to Bajaj.

Re: Bajaj Pulsar 180 (All Versions)

Hi

I have bajaj pulsar 180 UG4 (2012)
After 40,000 kms, it seems one of the oil seal of the front fork is broken and leaking.
Its time to change the fork oil and seals in both the forks.
Is it 160 ML per fork or 320 ML per fork?
The showroom mechanic says 320 ML per fork, where you get 4 bottles (160 ML each)
And another mechanic nearby home says 160 ML per fork is enough. So 320 ML for both the forks.
I'm confused. Please help...

Re: Bajaj Pulsar 180 (All Versions)

Like I told u earlier,those 45degree 'scratch' marks are there for a reason..they are honing marks.what you don't want are vertical scratches,which it present will be seen both on the piston skirt (or in your terms lateral side of piston).
Now,if you valves are damaged,especially broken,then those broken pieces might have probably damaged the bore and piston.
the prices quoted seem on higher side at svc..You basically have two options:

1. New valve kit (replace everything i.e. Valves,valve guide's and seals) they usually get this done at the lathe shop ( aka turning machine)
Along with this a rebore of existing block to next size with a matching new piston.
Spares in this case will be valve kit,and new piston+rings (1000rs. Approx)
Lathe cost for valves and rebore around 1000rs, plus maybe 500 for mechanic

2. Same as 1. with new valve kit
but a new block and piston which will cost 3k approx.
Labor charges around 1000rs


Add any other parts like cam chain,tensioner etc..
If you are getting the crank or con rod replaced,add those costs as well.

So understand your options and get a clear estimates with split up so u know what parts are being replaced.

Re: Bajaj Pulsar 180 (All Versions)

I don't have any battery installed since years , i use the kick start.