Re: Pulsar 220 DTS-Fi

Out on the road after a really really long time. Did about 1300 Kms last weekend for the xBhp ISG2G at Thekkady.

Recently the clutch plates, clutch bell and load balancer were replaced. The injector Oring had become hard and gotten cut so it was leaking. The Oring was not in stock so a Hyundai i10 Oring was put instead.

I did try the Liqui Moly injector cleaner, but maybe because the injectors were already physically cleaned I did not feel any perceivable different post the injector being cleaned. On the whole the bike ran well, had no issues. Except the next morning after the ride I checked the oil level and was surprised to see it was empty. Guess it's about time for the bore piston kit replacement anyway. The engine has been untouched in the last 60k Kms. Will drain oil to see if really the oil has been consumed. Strangely there was no smoke from the exhaust at all.

Re: Pulsar 220 DTS-Fi

Forgot to update here, about two weeks back I did drain the engine oil and guess what? Only about 700ml of oil drained out. I'm not sure at what point the bike started drinking oil on the return 650Kms ride from Kumily, but I'm quite shocked that it sustained with only this much oil left in the engine, considering that the last 200 Kms were mostly straight roads of high speed (relatively) riding all the way home. The only difference I felt was a slight increase in the vibrations on the last leg of the journey.

For now, I am not doing any high speed/highway runs on the bike, have filled in fresh 20W40 oil to allow the engine to rev freely and am monitoring the oil level every morning before starting the bike. So far in city commuting does not seem to drink any oil yet, but will top up 100ml every few weeks.

Have ordered the silver bore-piston kit at Bajaj, will maybe change it maybe in a few months.

Sigh! Bore-piston kit number II incoming, the first one lasted 68K kms but the engine had been opened quite a few times in that time. Now for the last 60K kms, the engine has been untouched and still, the bore-piston gave up. Not sure if it was bad fuel quality or Bajaj quality that caused the final downfall.

Re: Pulsar 220 DTS-Fi

I had the same issue. Partial seizure was the cause. It won't drink oil in city runs but will start consuming oil on higher speed runs. It is all because of mindblowing Bajaj quality with piston replacements guaranteed every 50K or so.

Re: Pulsar 220 DTS-Fi

My first bore piston kit replace was because of the the svc center "ungli" so I did not pay much heed to it.

But on the second bore-piston kit, I haven't had the engine opened up and have been replacing the engine oil quite on regular intervals. And I haven't been riding with a itchy right wrist last couple of years either. So yeah kudos to Bajaj engineering that the bore-piston lasted only 60K.

However, will reserve final judgement till I actually open up the engine and see because even now there is no smoke from the exhaust. There is more than usual soot on the exhaust, but nothing that would explain how half the oil evaporated on a 650 kms trip.

Re: Pulsar 220 DTS-Fi

Check the air filter box. Chances are that it will be filled with oil!

Re: Pulsar 220 DTS-Fi

Same with me, works fine in city and small haul but highway riding, just drinks the oil, but surprisingly my bike has done only 25k and this problem has been there since 17k, svc mech says leave it, I keep topping up the oil every 500-700 Kim's, though it's a 7 year old bike, btw how much does the bore piston kit cost

Re: Pulsar 220 DTS-Fi

Not too much I think its 4 to 5K total including labor and parts.

Re: Pulsar 220 DTS-Fi

Thanks for the heads up did not know about this, will open the airbox over the weekend.

25K and the bore piston is busted!!! I know Bajaj quality is bad, but not this bad. I guess some external factors could have lead to this.

The 220 bore-piston kit costs 1.8K, add another 1.5-2K for labour and minor parts.

Re: Pulsar 220 DTS-Fi

Hi guys loosing oil,

If you experience a substantial drop in oil level then you'd need to determine the cause of leak. If external(visible) i.e a gasket/O ring then it can be resolved by replacing the same, if internal then you need to determine whether the piston rings or the valve stem oil seals are to blame.

As [MENTION=38603]The Monk[/MENTION] has mentioned if you find oil inside the air box then the cylinder kit is to be blamed, but if you dont then you'd need to go ahead and inspect the spark plug tip for oil stains, if present then you would need to replace your valve stem oil seals.

Ideally if you'd have to replace your cyilinder kit then it would be best to replace your valve stem oil seals as well so that you can run a lot longer before having to open up anything. If its just your valve stem oil seal that need replacing then doing just that would do, spare cost would barely be around 100/-.

Cheers.

Re: Pulsar 220 DTS-Fi

Afaik in a modern 4 stroke oil in the filter box only comes from the crank breather. For a blow by to happen from the carb side your engine health would have to be abysmally bad.if that's the case you will get backfire. Before that you will know your cylinder is done for due to a lack of compression.
Blow by from carb side doesn't seem to be praful's issue.

CHEERS

Re: Pulsar 220 DTS-Fi

When the piston rings are weak, it is not onlt that oil alone would enter the combustion chamber but excess blow by from the combustion chamber would also enter the crank case as a result of which oil would be spewed into the air filter box via the crank breather.

Re: Pulsar 220 DTS-Fi

Oh my bad I thought you are talking about blow by through the carb side similar to 2 strokes. Yeah crank breather spews oil when ever there is excessive pressure build up and also when there is excessive blow by through the rings.

CHEERS

Re: Pulsar 220 DTS-Fi

Not sure if I understand all the technical stuff here, but I don't see any oil stain on the plug tip or the air filter, the plug comes out clean, I also don't experience any serious reduction in power, yes I do feel the top end has reduced, it struggles to cross 135 the rpm in 5 doesn't cross 9k, but this situation has been there for some time, is it possible that the oil is burnt and released as smoke at high speed, sorry if all this that I wrote is bull cr...p

Re: Pulsar 220 DTS-Fi

How much oil do u lose and at what kms?

Re: Pulsar 220 DTS-Fi

Oil would usually settle at the base of the air filter box, you can inspect by removing the drain cap at the base of the air filter box, but that won’t be necessary as your SP is dry.

Reduction in top end is inevitable just be glad if she reaches peak power in final drive.

If oil burns then the SP would be stained and there would also be residue at the tip of your exhaust.

Having said the above my rides a 2015 DTSi and I do loose anywhere from 200~300ML oil on every change depending on the oil used, which I feel is pretty normal. If you’re using Motul oils then the drop in level would be substantial as reported by a couple of users in India and most users in Indonesia.