Re: Pulsar 200 NS Owners Review and Experiences

Hi,
Exactly the opposite way dual lip on the inside and single lip on the coolant side.
New Duke has no circlip.
Balancer seal can be removed with oil seal pick. Or a thin sharp screwdriver. Ensure you don't create any marks on the aluminum casing.

Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Yes, it's not there in the newer catalogues (I need to throw away the old ones). So I guess the RS/NS lost them as well.

Brilliant, thank you! I thought it would be sitting in a grove/cut-out and the engine as to be taken apart. So this water pump seal/impeller kit replacement doesn't seem much difficult at all .

Re: Pulsar 200 NS Owners Review and Experiences

Hi,

I'm attaching the oil seals and direction of installation.
I guess this will definitely help out people. Facing the issue.

Single lip seals
Single lip seals

Dual lip seal.

Single lip seal installation direction and placement

Single lip seal installation direction and placement

Dual lip seal installation direction


Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Manoj, please take a look at the following image.
Now I'm confused. I understand from my attached image, open side (metal spring side) must face inward, that is facing the dual lip seal.

Sorry for my noob questions.


Thanks
Srvn

Re: Pulsar 200 NS Owners Review and Experiences

Manoj, Thanks for the pics, appreciate it!

Srvn, the circular spring of the seal lip always faces the liquid/pressure in question (oil or coolant).

Below: This is how I initially understood about the assembly.



P.S. Caution to reader, am a non-owner participating in the discussion.

Re: Pulsar 200 NS Owners Review and Experiences

Srvn, what Manoj has mentioned here is the open side of the seal facing the outside, towards you and the completely closed with numbers towards the inner. Simple, take your front forks for example, your fork seal lips are outside so that the inside oil doesn't come out. Same way, you install the open end facing you and the closed end of the seal facing towards the engine. See, this is the catch. On the pump impeller side, the lip is there to prevent the coolant entering inside the balancer hole, and ruin the bearings and mix with the oil. The the backside of the same cover, the lip is facing the engine oil side, so it prevents the engine oil from mixing to the coolant, I hope I didn't complicate it. The simple example is your motorcycle fork seals, gives you an idea. Think of the inside fork oil as engine oil and the outside as imaginary coolant side.

The catch is instead of having two lips and two seals doing service, now you two seals three lips doing the service. Hope you got the point.

And @Manoj Sivaraman, great insights as always. Is KPG included with the kit these days?

Cheers!
VJ

Re: Pulsar 200 NS Owners Review and Experiences

Hi,
Yes KTM and bajaj includes Kluber Petamo Grease which is 193N.
One can use silicone based grease as a alternative.
AFAIK these seals are like a consumable. Needs frequent change every 17~19k kms.
390s fail under these range. KTM recommends to change every 20k. ie. On first coolant change its ideal to have a coolant flush and seals replaced at 20k.
I'll post a better description of the seal direction and the spring function by morning..

Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Reposting it because nobody replied 😅

Re: Pulsar 200 NS Owners Review and Experiences

Check fuel tap, fuel filter (no one cares to replace fuel filter I'm NS200 mostly). Most importantly plugs, check on how carbon buildup is..

Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Hey guys, I would like a little help regarding the steering head bolt size of the NS. Is it 23 or 24? Any help would be appreciated.

Re: Pulsar 200 NS Owners Review and Experiences

Has someone noticed the tiktik sound that comes from the engine of both the Pulsar NS200 and RS200? My friend bought his Pulsar NS200 in June 2019 and he had that sound from the beginning, but it was subtle and wasn’t so noticeable. My Pulsar RS200 2015 model also had that sound and upon closer inspection on January 2020, it was found that my one of my cam lobes has eroded off by upto a millimetre. The mechanic, who is well known to me said that this has happened due to high speed riding and that the engine oil can’t lubricate the cams properly at high rpm’s, although i doubt it because at high rpm, the oil pump works faster which should pump more oil. I always used Motul 7100 20w50 oil. Anyway, i trusted him as i do ride the bike extensively and also take it to the highways at least three times a month and do high speeds. They replaced the cam and now the engine sounds smooth.
Going back to my friend’s NS200, the tiktik sound was somewhat contained till February 2020, he completed 9k kms by then and stuck to Bajaj Dtsi 10000 20w50 as he wanted warranty. At 9k kms he decided to switch to the Dominar 400’s oil, that is the Bajaj Dtsi 10000 10w50 and after that the sound just kept on increasing to a point when the tiktik sound was audible more than the exhaust sound in idle and the sound increased with increase in rpms. I thought maybe the tappet clearance were out, and a simple visit to svc would solve it, so we visited svc on June 2020. We waited until the tappet clearance was done, and started the engine for test and surprisingly the sound was still there. The mechanic who worked on my bike opened the head and upon inspection, it was found that one of the cam lobes was eroded the exact same way as my RS’s. The same lobe, even the pattern and depth was exactly the same. It was really surprising to see a very well maintained bike with 11k kms on odo with an eroded camshaft. The svc guys replaced it free of cost, as the bike was still under warranty and their statement was the same. “The bike gets ridden very fast due to which oil cannot reach the cylinder head properly and lubricate it”.Upon asking if its a manufacturing defect, they are denying any. My friend rides very sedately in city and rides fast occasionally on highways, the rest of the time cruising at around 90-100km/h. My brother owns a 200NS 2013 model with 39k kms on odo amd his bike hasn’t had the issue, although the bike was ridden pretty fast. Since that time onwards, i have seen many NS200s with the same loud tiktik sound which increases upon increase in rpm and i am pretty sure that if not all, most of them have got this camshaft issue. I think that this is a manufacturing defect, and it has affected a big percentage of NS and RS200. It would be very grateful if you throw some light and maybe share your experiences if you have got any. Thanks!

Re: Pulsar 200 NS Owners Review and Experiences

Interesting. Never heard of same issue on bikes from my group so far. Will note this for further checks.

Re: Pulsar 200 NS Owners Review and Experiences

Interesting, my bike has reached only 3k and its BS4. Wonder whether this is gonna happen to mine. I am using stock oil.

Re: Pulsar 200 NS Owners Review and Experiences

Relax, there are many NS200 bs4 that have done 30-45k and don't have such issues. This might be specific to a batch.

Re: Pulsar 200 NS Owners Review and Experiences

Issues.... Rocket boost problem which happens at 7k rpm and than after 8k rpm it's goes like a rocket passing speed of 110-120 in a breeze... 1st problem started at 17k Kms ...* after which I changed the carb at 24k Kms... the 1st carb I changed and again after 35k kms same problem.. I've gone to local mechanic whom I know got it cleaned and everything.. it worked for a week than again the same problem! I've reached 49k kms now.. still at low rpms it's good but Now toh it's worse.. It gasping for power/air/fuel at 6.5rpm! I don't know what it wants but it's struggles at that range, where I guess in that range is usually you get the peak power at those rpm levels.. but clearly I'm not.. ..while downshifting from 6 to 5 or 4.. even if the rpms goes to 9k on 4th gear, it won't push forward, like being stagnant there.. it will decrease speed very quickly but than climbing up, it sucks! I feel like changing the carb but than again after some moments of joy, riding smoothly for*8000/9000kms. Again this problem will come! I'm tired of all this.. sometimes..


What can be solution to this problem with the carb!? I've done changing the butterfly thing but still the same.. every 10000kms changing the carb it's a pain again and again coming up with the same problem... Any help will be great..*

And again another problem I've started facing recently is the tankslapper problem or in other words termed as Speed wobble or death wobbles when cruising around 120kmph.. 1st I thought it was because of uneven roads but no, even at speeds of 90/100 the handlebar tends to vibrate and give a feel of wobbles.. I've checked the cone setups, the forks, suspensions, even changed at fork oils recently at 40k Kms but still nthng could be found any idea what could be the reason of this..! I've Inspected my front wheel for cracks or bent but nothing.. but however in the rear I have this little hump, but it's very small, not noticeble from far only when you look closely when rotating you will see a hump.. no air leakage nothing .. can that pose a problem?

Please Advice... I'm in desperate need in some guidance... I'm literally tired but somehow not giving up on these problems which are temporarily...*