Re: Pulsar 220 DTS-Fi

On the contrary, my rear brakes have performed top notch since day 1. Only after about 1L kms the piston in the rear brake caliper seized, so I got my rear caliper assembly replaced, I did not put the Bybre one it involved additional costs and changes which I was not too keen about. So I got the KBX model for the rear again and the braking has been superb again. And for the first time I had changed the rear brakes major kit as well.

But every service, they are supposed to open and lube the caliper assembly for both front and back.

Re: Pulsar 220 DTS-Fi


Which they don't in most cases

Re: Pulsar 220 DTS-Fi

Then you are supposed to give them 'danda'

Re: Pulsar 220 DTS-Fi

hello, i've faced an odd issue with my bike, (odd because i've not come across anyone else's post regarding similar problem)
yesterday on my way back i hit a pothole pretty hard and my speedo console went blank, techo needle stuck at its last position and display and its light turned off, though the headlight and switch gear lights were working fine and randomly became alive before dying off again and while it was off the high beam indicator kept blinking (the high beam was turned on). on reaching home i turned ignition on/off several time and all systems worked fine when the handle bar was at locked position and i noticed that by moving the handle bar at certain position the same thing happned again, (perhaps handlebar's movement was causing interfering with some wiring) the fuel pump was priming but was starter switch was unresponsive, however the display was not completely blank the neutral indicator started flashing (in the same manor like high beam indicator was the last time) and an error message appeared "ECU 3.1".
i'm attaching an pic of it bellow, any guesses on what might've gone wrong?

Re: Pulsar 220 DTS-Fi


IIRC your ECU connector has come loose. You need to push the wire back in position. But if it persists then it probably indicates a malfunctioning ECU.

Re: Pulsar 220 DTS-Fi

Tried to change BRAKE PAD by myself and got struck while pushing the new pad in .
Took it to the mech who told the piston got struck and tried to remove the BRAKE FLUID and found out there was nothing left .
BIKE HAD RUN MORE THAN 20000KM LIKE THIS
Now the mech said to service the KBX unit but said it may not be good .
What is the cost of full unit?
Also I want to change brake lines and that reservoir.How much it will cost ?
Is there any aftermarket option from OE supplier ?

Bike is running fine and only one problem which I choose to live with
Max speed is 120 only that too with proper shifting at each gear or else around 115 kmph .
(Felt that's OK but still in 6lane road additional 10kmph would help)
Current odo is 45500 .

Re: Pulsar 220 DTS-Fi

You couldn't have run a km without brake fluid, much less 20k.

Brake lines understandable, why the reservoir?

Re: Pulsar 220 DTS-Fi

Bro it got damaged when I had a fall .
Unscrewing it was difficult and an eyesore to look at.
What would be the cost of the full set up?
There was very few ml left and that leaked after some time (might to be an air lock in the lines)

UPDATE :
Left the bike at bajaj.
SA insisted to change the full set up as the reservoir could be leaking .
They didn't have the part so will source them and deliver it by tomorrow .
They told an estimate of 3500.

Re: Pulsar 220 DTS-Fi

Got my bike back.
Caliper assy F- 1118
Master cyl F -1038
Hose assy -968
Clutch switch -60
Labor -250.
Total came around 4291 incl bearing change .

Breaking now doesn't have the aggressive bite as before .
And even after changing clutch switch starting problem is there mech said to change the Starter switch .

Re: Pulsar 220 DTS-Fi

I think you got the new P220 brake parts right ? It should feel better than the parts on FI version.

Re: Pulsar 220 DTS-Fi

Yeah I got BYBRE .
But I felt KBX had a stronger bite means feedback from lever was more strong &sudden back then and now its smooth.
May be I was used to that previous brakes so felt like that.

UPDATE: starting problem resolved!
They had failed to connect two sockets which is under accelerator cable so had troubles .
After disk caliper change bike reaches 120 quickly may be they were in constant contact .
Going to change rear one too as the SA refused to change the pad sighting it may also get jammed and its better to get Bybred at rear too.

Re: Pulsar 220 DTS-Fi

Just their way to make money

Re: Pulsar 220 DTS-Fi

Yeah I will try with local mech.
Read your travelogue in T-Bhp and it was good.

Re: Pulsar 220 DTS-Fi

I had the same problem once. Brought the bike home doing to tochan for 20km. A wire was loose near the battery. Mechanic solved the problem in a minute.

Sent from my Micromax A116i

Re: Pulsar 220 DTS-Fi

Hey all,

Browsing through other threads so i just thought I'll mention a couple a problems I'm facing here(Aug 2007 220fi 75k old).If nothing a solution will at least add to the list of known problems. :P

So when I start my bike in the morning/after a gap of say 3-4hours,it starts fine i.e. idles, but when i start accelerating(even smoothly) the engine acts if its not getting enough fuel(dhuk-dhuk @4k+rpm) for maybe a couple of kms.

Another problem,if i press the left side of my bike with my thigh or if I lean left,the fuel supply cuts off?Is it a short or is a fuel line getting blocked. Any idea why that could be?

Waise what are the symptoms of a dying fuel pump? And has anyone done a electrical/electronic system overhaul what all does it include?