Re: Pulsar 200 DTS-i

Are you going to replace front MC as well? I'm doing it because I have to replace the major kit within the MC and have decided to replace the entire unit.
Also if your exhaust smokes, check for oily residue at its tip, it could be that the piston rings have worn out, which means opening up the block anyway

Re: Pulsar 200 DTS-i

Thought of sharing it here, to download pdf version of Pulsar 200dtsi spare part catalogue visit Motorbikes . Thanks to @tanay and @mehuel for SPCs.

Re: Pulsar 200 DTS-i

ok, so the new cylinder kit is in, with new valves, cam chain + tensioners, new clutch.
crank was ok with minimal/acceptable play.

now for the issues, i suspect the timing to be wrong. i dont know how to explain this
but in idle th engine should sound like a continuous beat, like say - tik tik tik tik tik tik.
what i am getting is more like - tik tik takak tik tik tik takat tik takak. sorry but this was the only
way i could explain.

some questions -

-> could it purely be timing issue? if so, how to resolve?

-> the bike stalled every 10 - 15 kms on my way to office yesterday (55 km commute one way) at 55 - 60kmph.
should i confine my rides to shorter distances till the run in is done.

-> there is an annoying red light on the right side of rpm, that keeps popping. is it engine overheating?

-> i have put in 1300 ml of engine oil of what i understood from that spanish(i suppose its spanish ) workshop manaul? is that right?

Please advise

@ tanay - not sure whats wrong, but disk has clearly worn off, will go in for the MC replacement at later stage. MC Price RS 1100, braided cable RS 600.

Re: Pulsar 200 DTS-i

The red light on the console is a low fuel warning cum high rpm limiter indicator. If you have less than X liters of petrol then the red light is always on.
In your case, the red light keeps popping on and off, if I understand correctly. So it may be the engine rpm. I doubt you'd be hitting the revlimiter during run-in so I'd say some rpm sensor problem?

Or maybe the fuel sensor is acting wonky.

My owner manual says 1150 ml during oil change, 1300 ml for an engine overhaul. So 1300 is fine.

Re: Pulsar 200 DTS-i

Get the Silencer of pulsar 220. it will suite old 200.

Sent from my GT-S5570 using xBhp Connect mobile app

Re: Pulsar 200 DTS-i

ok, so 500 km done after engine works.

i was skeptical about the timing, so checked cam gear marking at TDC, and i am a bit relieved.
all seems good there. but now i am not so sure about the crankshaft to camshaft aligning , that is next on the
to do list. looking for some tools for that.

on the other hand, bike was running smoothly once it was above 4500 rpm or so, with no engine noise, compression also felt good there.
Idling is still a problem issue.

now the major area of concern is this.
at idle, to get the bike moving, i have the delay the clutch release to say about 2500 - 3000 rpm, and basically slipping the clutch for
longer time. needless to say, clutch wear.

the clutch side has to be opened again, but any idea what could be the reason for this? and what should i be looking for?

in the mean time, i have started on some other issue, primarily, cone set and suspension.
Got coneset and fork oil from Bajaj ASC, Grease was included in the packet, that's a thumbs up for Bajaj.

What ever is being opened is thoroughly cleaned and put aside for final assembly. will also get some can paint tomorrow
for attending some rusty and scratched parts.

here are some pics of work in progress

Re: Pulsar 200 DTS-i

^ The bajaj ASC have a particular tool for fitting the cone set. It is basically a large threaded screw with tapered nuts that can rotate on it, to tighten the ball races within the head. I hope your mechanic also used that tool, because I got it done once from an independent mechanic (without that tool) and that cone set did not last very long.


Meanwhile there was this kat-kat sound coming from my chain, I opened up the drive sprocket cover to see a broken tooth among other bent teeth:



Thankfully a front sprocket is available separately. Got one for 90 bucks and also got two link-lock sets for backup.

Re: Pulsar 200 DTS-i

@ tanay - well, all the work is being done by yours truly at home, used an old broad nut and hammer to put the cone set patiently in place , its an old technique it learned and have previously implemented on my 180 aswell, but my fingers are crossed for now.

Re: Pulsar 200 DTS-i

ok, so for updates, bike has been run in, engine oil change done, and running smoothly or was running smoothly till new problem propped up.

the bike has gone through 3 cdi changes in past 2 days, the new one just keeps getting fried. after changing it starts and runs fine
but as soon as i stop and shut off the bike, kaput, it doesnt start, so put the new cdi in and its up and running again.

i have even changed the coil, but no relief.

any ideas?

Pulsar 200 DTS-i

Hey Guys,

does any one know or help me or can advise me where can i find this kinda headlight !!





Sent from my Inspiron 7520 using Tapatalk

Re: Pulsar 200 DTS-i

Work is in progress, will post a detailed report by Sunday,

Some issues are still persisting. Like delayed clutch release in 1st gear. It has to be revved to 4k rpm for smooth operation. Could it be clutch shudder?

And has anyone experimented with 220 carb? The stock jet on 200 is 110 / 17.5. Even bs 29 on 180 now has 117.5/ 17.5.

@ tanay: braided brake line costs 1100. And brybre master cylinder whole assembly with brake switch and lever at rs. 950.

Re: Pulsar 200 DTS-i


Which ASC can you get these parts from? The Karol Bagh one? Or perhaps Okhla?

Re: Pulsar 200 DTS-i

From Karol bagh.
Part number for braided hose is DV111005. price without tax is 985.78. (Bought 3-4 parts that day so can't calculate exact price but tax should be around 110 to 130 )
Bybre master cylinder part no dj191056 price 973 with tax. 864.89 without tax.


P.s I have pm their number to you as well. Cheers

Re: Pulsar 200 DTS-i

Good to see some owners still active on the thread for the P200! I think I'm one of the last few to still own this beauty of a tourer.. still remember all the issues & suggestions that were shared with a big bunch of owners on this thread!

I was curious to know for all those who made the change... what have people upgraded to?? KTM's? or the CBR250?

Re: Pulsar 200 DTS-i

What bike to upgrade to? 250s are a small increment.
After that first dose of mind-blowing quality and refinement from Bajaj, never buying another.
The solution is a big bike that takes big money