Guys,

Easy overgearing on .520 for the Pulsar 220, is still a mystery we couldn't solve. But I think we might have a way out soon...

Earlier, I was told that the Duke 390 has a 14/45 setup on .520 pitch, through various reviewers. That may be the 2013 version, or maybe the test bikes before the launch. But now, the KTM India website lists 2014 Duke 390's sprocket kit as 15/45 on .520 pitch. See below:-

KTM 390*Duke*ABS 2014 - Highlights

This front sprocket of the new 2014 Duke 390, may or may not fit the Pulsar 220. Can anyone try to fit it?
Your try may give a data, that other bikers can use for years as I will update this in Post#1 of this topic, with credits.

Meanwhile, I'll also try to get myself a worn Duke 390 front sprocket from Probiking... And I can compare fitment with my P180, as its front sprocket mounting is quite similar to P220.

It will not fit Sam, The mountings of D390 Front Sprocket is of another pattern as web search reveals. Also, what will happen if we downsize the pitching? Is it possible in a P220? If yes, then what will fit?

Ok. Downsizing is possible in P220, no issues with that except for one. You'll have to source a really long chain, any less than 130 links won't fit, & again I'm doubtful about this figure too as its just some maths I used, with no reference to new sprockets' size.

That's why it is wiser going for a .520 15 teeth sprocket. You won't need to change the chain at all. Now, maybe only the imported spare parts dealers can help, I guess. Anyone lives near KRP, Delhi or PRS, Mumbai?

Ok. Downsizing is possible in P220, no issues with that except for one. You'll have to source a really long chain, any less than 130 links won't fit, & again I'm doubtful about this figure too as its just some maths I used, with no reference to new sprockets' size.

That's why it is wiser going for a .520 15 teeth sprocket. You won't need to change the chain at all. Now, maybe only the imported spare parts dealers can help, I guess. Anyone lives near KRP, Delhi or PRS, Mumbai?

It will not fit Sam, The mountings of D390 Front Sprocket is of another pattern as web search reveals. Also, what will happen if we downsize the pitching? Is it possible in a P220? If yes, then what will fit?

Guys,

Easy overgearing on .520 for the Pulsar 220, is still a mystery we couldn't solve. But I think we might have a way out soon...

Earlier, I was told that the Duke 390 has a 14/45 setup on .520 pitch, through various reviewers. That may be the 2013 version, or maybe the test bikes before the launch. But now, the KTM India website lists 2014 Duke 390's sprocket kit as 15/45 on .520 pitch. See below:-

KTM 390*Duke*ABS 2014 - Highlights

This front sprocket of the new 2014 Duke 390, may or may not fit the Pulsar 220. Can anyone try to fit it?
Your try may give a data, that other bikers can use for years as I will update this in Post#1 of this topic, with credits.

Meanwhile, I'll also try to get myself a worn Duke 390 front sprocket from Probiking... And I can compare fitment with my P180, as its front sprocket mounting is quite similar to P220.

I would be highly interested to know what will unfold with this experiment, Sammy. Two things, if the front is a direct fit, it's a huge cost save, especially for the P220. Secondly the Duke 200s shaft is a direct fit with the 220 both front and rear. But I guess even D200 and 390 sprocket splines are comparatively different? Any take on this anyone.

Cheers!
VJ

yesterday same kida came it to mind about over gearing by pulsar 220FI...waiting for the experiments!!^^^

You can over gear 220FI ,use 220 dtsi sprockets

Samsung Galaxy SIII i747

Gearing is a measure of all the components that determine the rate at which an engine's crankshaft's revolutions are transmitted, into the vehicle's speed. It comes from the word "gears" which are rotating cogs, which decide what speed the machine picks up, at a particular rpm.



A Sample photo of the front sprocket of my bike (Pulsar 180 UG3) is given below:



Sprocketing means changing the front & rear sprocket sizes to affect gearing. It's one of the simplest and easiest mods. The basic info says that:-->

1. Bigger rear sprocket or smaller front sprocket, results in gearing biased towards acceleration, with some lag in top speed.
2. Smaller rear sprocket or bigger front sprocket, results in gearing biased towards top speed, with some lag in acceleration.

Gearing does NOT result in more or less power. It only affects how the power is laid, by changing the balance between top speed and acceleration. So, if one wants more top speed, and is prepared to lose acceleration a bit, or vice versa, then sprocketing is advisable.

Taller gearing results in better highway mileage, and short gearing results in less highway mileage. This is due to the fact, that in longer gearing, the machine travels longer distance for a particular engine speed (rpm), and vice versa.

Gearing maybe affected by: Sprockets' size change, rear tyre's size change, gearbox modification, clutch drag, etc.
Gearing is NOT affected by: Weight/ load change (pillion, etc.), front tyre change, free flow air filters/ power mods, etc.

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Change Measurement: Final Gearing Value: The sizes of front and rear sprocket (measured in "no. of teeth" the sprockets have) determines the final gearing.
It is calculated by Rear Sprocket Teeth divided by Front sprocket Teeth. Like Pulsar 180 UG4 has a 14 front and 39 rear setup. So, its stock final gearing is 39/14 which is equal to 2.786.

Final gearing is for comparison between different sprocket combinations, this way:

45/15= 3.000 (Let's call this "Setup X")
44/14= 3.143 (Under gearing, compared to "Setup X", means more acceleration)
39/14= 2.786 (Over gearing, compared to "Setup X", means more top speed)

Higher Final Gearing value signifies moving gearing towards acceleration (short gearing), and vice versa. So, when changing both sprockets from stock, the new gearing value should be calculated to determine which way you're going with gearing.

But if you overgear too much, you might need a very long stretch to achieve a good top speed, or you might not achieve it at all. So, for a stock bike, a gearing change should be within 10% at maximum, that's it!

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Rear Tyres size change affect Gearing: Rear Tyre change (size) may affect overall gearing, if the profile (height) is affected due to this change. A higher profile increases gearing, while a lower profile decreases it.
A tyre with size 120/70 has a normal height of (120mm x 70%) which is 84mm. But, the broadness of the tyre rim can change the "final height".

A broader rim gives less tyre height, as tyre is rubber, and it expands over the broader rim, causing lesser ride height & lower gearing. And of course, vice versa too. For example, if you fit the R15 rear tyre on your Pulsars, you might not change gearing at all, because although the R15 tyre is of lower height, but the Pulsar rim is narrower than R15's, and a narrow rim raises the ride height.

Front tyre size change doesn't affect gearing, although it may contribute to a different ride height, weight and different speeds on the speedometer.


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Direct Sprocket Fits:

Remember that your stock chain can be successfully adjusted for upto 2-3 teeth changes in sprockets. Beyond that, you may or may not require a new chain OR you may be required to remove some links from the chain. For the sake of pillion travel, the chain play should be adequate. After re-installing the chain, move the bottom portion of chain upwards, it should go upto 10-15mm only, not more or less than this.
Remember that you might need to purchase the whole kit instead of just the sprocket depending on where you purchase it from. These sprocket combinations are direct fits to the mentioned bikes:

Apache RTR 160/ 160 Fi: Stock Setup: 13/44 teeth.

To overgear RTR 160, use the 14 teeth front sprocket from Yamaha YZF R15/ Fiero F2. (Thanks Aparajith)

Apache RTR 180: Stock Setup: 14/46 teeth.

To overgear RTR 180, use the 15 teeth front sprocket from Bajaj Pulsar 150/ 180 UG3 only! But, buy a sprocket holder ring and the nuts to suit, as the RTR ones do not match the Pulsars' sprocket. (Thanks FlyingJian & lijok)

To undergear RTR 180, use the 13 teeth front sprocket from RTR 160, its a direct fit. (Thanks Utkarsh Stunty Sharma)

Pulsar 220 DTS Fi (Old model): Stock setup: 14/37 on .520 pitch.

To undergear it, use:
P200's rear sprocket, 38 teeth,
Karizma's rear sprocket, 40 teeth, (Thanks Prafultripathy)
KTM Duke 200's rear sprocket, 43 teeth, (Thanks joelkraju)

Pulsar 200 DTSi: Stock setup: 14/38 on .520 pitch.

To overgear it, use P220's rear sprocket, 36-37 teeth,
To undergear it, use Karizma's rear sprocket, 40 teeth, (Thanks Prafultripathy)

Pulsar 180 and 150 UG3: Stock Setup: (15/43 and 15/44)

To undergear it, use Discover 135 Sports' Front Sprocket, 14 teeth. But you will need Discover's lock plate and nuts. (Thanks Prabhakar 150)

To overgear it, use the complete chain-sprocket kit of Pulsar 180 UG4 or Pulsar 200 (first ver.), which is 14/39 and 14/38 respectively.
You can remove the metal chain guard and instead, use plastic chain guard from Discover 135 Sports (Rs. 74) after drilling a hole in it, as its maintenance free O Ring chain. Don't put oil, just put chain spray on it. Remove 2 chain links from the chain, if you can. Otherwise, it will require link cutting later on as the chain wears out. (tried by Samarth 619 on P180 UG3)

For ONLY slight gearing change, you can use P150 UG3's kit in P180 UG3 (for undergearing) and P180 UG3's kit in P150 UG3 (for overgearing).

Yamaha YZF R15 Version 1.0: Stock Setup: 14/42

To overgear it, use rear sprocket, 40 teeth from Yamaha FZ 16. (Thanks anirudh_fz1)

Daytona Kits for R15 (may be expensive):

To undergear it, get the Daytona Kit's 13 teeth front,
To undergear it, get the Daytona Kit's 44 teeth rear,
To overgear it, get the Daytona Kit's 40 teeth rear.

Yamaha FZ16: Stock Setup: 14/40

To overgear it, use front sprocket, 15 teeth from Honda Unicorn or Bajaj Pulsar 150/180 UG3. (Thanks iamvik and)
To undergear it, use rear sprocket, 42 teeth from Yamaha YZF R15. (Thanks anirudh_fz1)

Daytona Kits for FZ16 (may be expensive):

To undergear it, get the Daytona Kit's 13 teeth front or 42 or 44 teeth rear.

(For both R15 version 1.0 and FZ16, Daytona kits provide a choice of 40/42/44 teeth sprockets for rear, 13 teeth for front, and either a 122 or a 130 link chain, so you can choose your new gearing accordingly)

Honda Shine 125: Stock Setup: 14/~

To overgear it, use front sprocket, 15 teeth from Honda Unicorn. But, you'll have to shave off the sides of the sprocket so it matches the chain pitch. (Bike India)

Honda Stunner 125 Carb: Stock Setup: 14/~

To overgear it, use front sprocket, 15 teeth from Honda Unicorn. (Thanks cmahajan)

Honda Unicorn 1st and 2nd Gen: Stock Setup: 15/42
Honda Unicorn 3rd/4th onwards: Stock Setup: 15/43

Direct Fits - With Chain pitch .428 (Unicorn Chain)
Front 14T from Hero Honda Ambition/CBZ/Xtreme
with Rear 38T (Ambition)
with Rear 46T (CBZ Classic)

With Chain Pitch .520 (Karizma chain):
13T/40T of Karizma
13T(ZMA)/38T(P200)

Hero Honda Karizma: Stock Setup: 13/40 on .520 Pitch.

To overgear, use a 38 teeth Rear Sprocket from P200, but P200 chain length is not sufficient. Adjust your Karizma Chain after installing. (Thanks Shreeni for above info)

Pulsar 150 UG2 (Analog Meter): Stock setup: ~/44

To overgear, use a 40 teeth rear sprocket (with 6 fitment holes) from LML Freedom. It requires cutting 2 links from the chain. (thanks hotshot.vipin)
(The rear sprockets of FZ, R15, Pulsar UG2 and earlier, LML Freedom, have 6 fitment holes. Others mostly have 4.)

Duke 200: Stock setup: 14/43 on a .520 chain pitch.

To overgear your Duke 200,
1. use a 36 teeth sprocket from P220 DTSi. (confirmed, thanks joelkraju)
2. use a 37, 38, 39, 40 teeth sprocket from P220 DTS Fi, P200 older, P180 UG4 or Karizma. (not confirmed, but these sprockets should definitely fit I think.)

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Gearing Commander Website: Guys, we can find final ratio by using any combo of sprockets by using (Rear no. of teeth/Front no. of teeth) formula.
But what if we change a lot of things like, both sprockets, rear tyres, Primary Ratio, rear rim, etc.?
Fear not, there is a solution. You can find out all about the gearing even before trying it out. Plus it has stock info on gearing of many bikes. You can use the below website for calculating gearing by entering everything that affects gearing:->

Gearing Commander: Motorcycle Speed, RPM, Chain & Sprockets Calculator (Credits: Sir Old Fox)


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I'll be adding more info. Please suggest improvements to this topic by sending me PM's/ posting here. --Samarth