Re: Pulsar 200 NS Owners Review and Experiences

Aswanth, the CBR does have a weep hole but the R15 doesn't. Hoses last a life time, provided, the maintenance is done right. But, they being rubber, they will crack, puncture and fray due to ambient conditions, dust, heat and a whole lot of other factors, with heat being the prime factor especially external heat. But they as a whole are pretty much robust, so these require replacement whenever necessary, as and when the above red herring is observed on them.

Cleaning radiator fins, is a difficult job to be honest. The best way is to use solvents such as kerosene and water. First use a non pressurized water, from tap, by making sure the radiator is completely wet -- throughly wet. Then use a sprayer, and thoroughly spray the radiator with Kerosene, let it soak for 15 minutes, minimum. Then use use detergent powder, and a soft bristled toothbrush, dab the brush in the powder and start brushing, and do so in a vertical manner, not horizontally. All this takes approx half an hour, and then use water to de-grease the radiator, your radiator will be spanking new. My way of doing things.

Coolant replacement has a strict schedule, 1 year, irrespective of how it looks. Again, my way of doing things.

Hope it helps!

Cheers!
VJ

Re: Pulsar 200 NS Owners Review and Experiences

To my knowledge it's a small and simple fix.
Just open the water pump. Older models has a circlip and single lip oil seal two numbers.
Newer model post 2016 has dual lip oil seal inner one and a single lip oil seal.
It can be pried and removed with a special tool or forcibly with a flat screwdriver (note: ultra flat and small).
This job depends on the severity of the mixing.
Incase of 390 there are two possible ways of coolant mixing.
One through worn-out seals.
Another one through the coolant galleries at the centre case.
Improper gasket sealant or poor quality gasket sealant usage will result in this issue.
Incase of 200
Only possible way is coolant pump seals.
Since 200 uses cork packing gaskets in between centre case.

Althought it's dual lip it too fails by 20k kms approx which wasn't a proper solution.
Every 15,000 kms one could replace the entire pump repair kit with impeller which costs 350 hardly.
So let's consider it as a consumable.Whenever we change the coolant we can change the seals and impeller too.
Upon my own interest have suggested KTM engineers with better material too. (VITON material). If one could find the exact sized seals it will last longer as VITON is rated for 120°C up vs EPDM at 100°C.
Since it's a high spinning shaft I would suggest to go with Viton or Silicon seals.
Will post the seal sizes below. If anyone is from Chennai can approach Chennai Seals, Gandhi nagar near Kasi Theater.

Thanks and regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Beautifully explained Manoj. Viton coated leaves, as a matter of fact is being used on the head gasket for the 390 better thermal stability of the gasket IIRC, in fact a guy abroad did mention the same thing after repeatedly blowing his HG during track sessions.

Another point is the improper case sealing as you'd mentioned, which had been the case and admitted by KTM themselves where it mixes with the engine oil internally and makes a latte eventually. Eventually, they did did a recall for a certain set of 2017 manufactured bikes, IIRC.

Incidentally, the older Dukes had pump seal failures, the newer ones had pump seal along with gasket failures. One more great point you made was the dual lip oil seals, they in fact are a great change, but still the heat and coolant acidity just doesn't make them last longer.

I'd suggest a mechanical seal like that of a CBR would be a great addition and would definitely last longer.

Cheers!
VJ

Re: Pulsar 200 NS Owners Review and Experiences

Agreed.
Initially the coolant gallery walls where thin. Which caused failure of the RTV sealant due to coolant pressure.
The seals too has to withstand temperatures upto 100°C and pressure upto 20psi which is 1.4kg/cm^2.
Post 2017 KTM upgraded the thickness of the gallery walls. But the finishing and tolerances made the RTV sealant hard to stay in place. Since the entire coolant loop is pressurised. That particular area fails.
So the finishing was changed to a coarsely finished one. Which makes the RTV sealant to stay in place.

Have suggested weepholes and larger seals like kwackers. But KTM is stubborn on keeping the pump area compact. So they don't wanna change the design (no company will do R&D and change the design right. Expected).
So we might change the seals like a consumable. Just preventive thought.

There is a 390 forum where it's mentioned RC 250 cup bikes use silicon oil seals with metal structural reinforcement. Will try to find and post the link. He posted the part number too.


Thank and regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Hi,

The seal sizes are as follows
[12 - 24 - 4] for single lip ones.
[12 - 24 - 7] for dual lip ones.

Decode the numbers as [ID - OD - AXIAL THICKNESS].
One could use thicker seals too since axial length is pretty ample.

I bought VITON seals and I'm testing it in my AS200 runs fines till date clocked 5k since the seal change.
I won't recommend it although unless it gets tested in 390 as it's more prone to failure. If this seals shines in 390 then it's good.

The link for the 390 Forum is pasted below:



Thanks and regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Spot on. Talk about it, I was about to paste the same forum link my previous link. I think the thicker axial radii will definitely help the pre 2015 models especially with Viton based, every degree truly counts.

Cheers!
VJ

Re: Pulsar 200 NS Owners Review and Experiences

Thank you both for very detailed replies .

Manoj, is there a difference in the tightening torques for cylinder head bolts in Duke 200 vs. RS/NS200? IIRC, KTM instructs to apply oil to the threads/grease to the bottom of the bolt and tighten it to 40 Nm (approx. 4 Kgf-m). Bajaj's manual for NS/RS says 4.5-4.7 kgf-m without mention of oiling/greasing the bolts. If I have a NS200 and going to rebuild it, can I buy KTM bolts and follow the oil/grease + 40 Nm method? I read that the method of applying oil (when called for) and tightening is more reliable as friction plays spoilsport in the dry torque method.

Re: Pulsar 200 NS Owners Review and Experiences

Oiling/ greasing is mainly to apply the torque properly. Since the threads on case is made of aluminium it's prone to create friction on the threads. This friction will cause the torque wrench to cap off at the set torque. But the block will not get the required clamping pressure.
Also KTM instructs to first tighten all bolts to 15Nm in criss cross pattern. Then to full torque spec. This is to prevent gasket warpage or thread damage.
So to overcome both Bajaj and KTM recommends to apply oil or grease. You can get high temp anti seize grease with brass or copper content.

But to keep things simple your engine oil will also do the job.

Since NS200 uses different head assembly the torque specification is higher I guess. But applying oil is always recommended.

Thanks and regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Hello all.. just completed around 500 km in my 200NS and its really a value for money option with quick acceleration, smooth riding and excellent riding position. Going to miss the first service due to lockdown. Just 2 small queries :
It is mentioned that around 3 litres petrol should always be in the tank so how much bars on the fuel console would be 3 litres. Also how to measure mileage as reserve is not there?
Also the seat feels a bit hard material. Is it possible to add a seat cover? will it fit correctly ?

Re: Pulsar 200 NS Owners Review and Experiences

Atleast 2 bars would be fine...And I don't know about second one,third is yes you can add or get it done by a good seat maker local.

Re: Pulsar 200 NS Owners Review and Experiences

Hi anyone done this kind of jugaad on NS?

Looking cool and decent.

Re: Pulsar 200 NS Owners Review and Experiences

Finally completed around 1.2k km on my NS200 BS6. My initial choices were apache 160 4v, honda xblade but thanks to friends here, I was guided to buy this beauty. Bike is really fast and I think this has 2 modes : 1. TVS Victor mode (yes my previous bike as TVS Victor and some times, I like to ride the bike in slow max 60km speed), 2. The beast mode (quick acceleration and revv till 7k all gears..).
When I drive the bike slow, it rides worse than Victor so I guess the machine is built for hard acceleration and rough driving. I have driven maximum till 110km speed(smooth engine even at 100km/hr). Riding position is superb (seats are hard so have to but some seat covers on). Due to lockdown, couldn't give for first service, so serviced at the local trusted workshop, changed oil, chain service and replaced coolant (all bajaj brand). Now showroom has called and informed to give the bike for first service at designated SVC, otherwise warranty would be void .
I am just curious to know how you all check the mileage for this one as there is no reserve available. Also the fuel bar readings are not that accurate.

Overall an excellent VFM option at this price (1.64 lac onroad, Mangalore)

Re: Pulsar 200 NS Owners Review and Experiences


You might get used to your seats, wait a few more kms.

To check the fuel efficiency, fill the tank up to full. Next, after some 100km or 200km or whenever you want get anther full tank done upto the same level as your previous full tank. Now note the quantity of fuel from the petrol pump meter. Divide the no. of kms done by the qty. of fuel you noted. Thats your fuel efficiency.

Yes fuel gauges on most bikes are in accurate. I think yours is FI so do not go below the last 2 bars or so.

Re: Pulsar 200 NS Owners Review and Experiences

Did a LED retrofit for NS200 yesterday came out to be awesome
Novsight brand and a fanless design
Sharing the light output images

Low beam

High beam

Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Awesome.
How is the brightness, intensity and light spread compared with Philips Extreme Vision halogen bulb. Will it be superior to Philips?
Thanks