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

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

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

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

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,
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

Hi Manoj,

If I get it right, water pump impeller seal (coolant side) is dual lip and balancer side seal is single lip? Is it possible to remove the balancer side seal without dismantling the engine?

Circlip is mentioned in both BS4 RS200 catalogue (which uses dual lip) and Duke 200's - they later removed it?

TIA !

Re: Pulsar 200 NS Owners Review and Experiences

Hi,
The new dual lip seal with 4 grooves or tabs should go in first, with the grooves or tabs facing inwards (ie.facing your engine balancer).
Apply kluber petamo grease provided inbetween the seal lips and shaft too.
Use box socket to drive the seals (always gentle taps are adequate for driving it in)
Then install the single lip seal with the metal spring tensioner facing outward (ie.the coolant pump impeller side).
Again use grease inbetween the two seals.
Second seal occasionally will be hard to get pushed in due to air or grease between two seals. Take your time drive it in slowly.
Also not you can't use the circlip due to extra thickness added due to the new seal.
Then reinstall the impeller.

Regards
Manoj Sivaraman..

Re: Pulsar 200 NS Owners Review and Experiences

Hi [MENTION=88012]Manoj Sivaraman[/MENTION] / [MENTION=39214]B7ACKTHORN[/MENTION],

Facing coolant mix with oil again after 14K kms from the previous pump seal replacement, purchased new water pump seal kit, as you said I find single lip oil seal and a new dual lip water seal in the kit.

Could you kindly assist me as to what is the order of seal placement, as in which seal goes in first and the orientation (dual lip seal got groove kind of thing) of both seals.

Also in case of using the new dual lip seal, should the circlip lock ring not be used?

Thanks
Srvn

Re: Pulsar 200 NS Owners Review and Experiences

Well I washed my bike after a few days and then after letting it dry for sometime I started the engine and let it idle. After letting it idle for sometime approximately 7-8 mins I noticed that the revs started to drop from 1400 to below 1000. The engine was struggling a bit to idle. Is this normal because I never noticed this before as I normally donot let the engine idle for more than 3-4 mins.(Due to current covid situation I cannot use my bike regularly so I tried letting idle a bit longer.)

Re: Pulsar 200 NS Owners Review and Experiences

Hey, I hope everyone doing great and all are ok.

Few things I want to mention for you as well for anyone who's starting their bikes after three months or not using for longest period of time

First & most important wash your bike

1. Inspection fuel lines for cracks or leaks

2. Inspect fuel tank for all the debris sitting at bottom if the fuel you filled was contaminated.

3. Check the engine oil & coolant levels

4. Check control cables

5. Check tyres if old for cracks as the bike was stationary all the summer at one place

6. Lube the chain

7. Don't worry about the battery if anywhere within the range of new to two years old, if older and the bike doesn't start you might need to get it charge by professionals

7. Start your engine & don't rev it up immediately, let it idle for good 10 mins



I think that should do & you are good to go

Re: Pulsar 200 NS Owners Review and Experiences

Hi,
Where in Pondicherry. Myself from pondicherry owning a AS200. If possible let's discuss in person..
Happy to see a bhpian from Pondicherry.

Regards
Manoj Sivaraman..

Pulsar 200 NS Owners Review and Experiences

Duplicate post, deleted it.

Re: Pulsar 200 NS Owners Review and Experiences

Hi guys,

I am writing you from Turkey. I have Bajaj Pulsar 200 NS FI Euro3. 20000 kilometers. I have a problem with my motorcycle.

Clutch lever stretches and hardens while accelerating in the 2nd, 4th and 6th gears.

I adjusted the clutch wire. I changed the clutch plate. My problem is not solved.

I need your help.

Pulsar 200 NS Owners Review and Experiences

Hello guys! Hope everyone is during well in this troubling time..

I haven’t used my bike much in last three months, and in two weeks I will have to go back from Pondi. Would appreciate if could get some pointers on what I should focus on as the bike has been lying almost insides for quite some time, I do ensure that in two weeks I do around 10-15 km on it. But will now have to do around 350km in a stretch.

Had my bike serviced before coming to pondi, and haven’t driven it more than 100km since then.

Any things I should keep in mind and get done before I leave ?

Already ordered the chain Lubricant.



Apart from this, I noticed that when I turn my Handle completely right, The engine starts to accelerate and the rpm reaches around 3-4000 rpm. Seems the race cable is getting pulled but I am not able to exactly figure out where it is getting pulled from.