Why did you have to replace piston, etc?
Which oil has been poured in?
Check air/fuel mixture. Lean mixture causes overheating.
The engine just shuts off after riding for 10minutes eh?

just 2 days before the replacement my bike .ie on Sunday my bike just ran dead at arnd 115kmph twice after that I just reduced the speed and bike came back to life. after that I reduced the speed but the knocking sound began,as soon as i got an off-day on wenesday i was in garage to change the parts which needed attention.
right now its running on SERVO 900ml oil, and I m not satisfied with , will change the oil this Sunday.

Update:--
visited the mechanic today , he said that pls complete the run-in religiously , and I agreed to him. I can understand that the bike has gone through an heart replacement, guys will hav to fly low arnd 40kmph.
took the bike for much needed bike wash and got the battery recharged as it was drainned out of electricity by the heated engine when the bike stalled after over heating.

But yes the world is totally diff now as biking at 40 kmph is so much slow...ha ha even an 100cc can overtake take me even if the whole family is onboard. !!!

@rpmboy: Dude, that's some bad job they've done. You should have got it done at some place with newer digital equipment. I had to have my 150 DTSi (UG1-2004) rebored, with new piston and rings. I got it done at this place in KINFRA park at Trivandrum, Kerala that does aerospace parts. The machining was so exact, the bike was smoother than it was when I first got from the dealer. I went on a 200 km trip the next day, and rode at 80-100 the whole time. Covered almost 3000 km since then, and still running smooth. It cost me around 3K, all inclusive. But it was completely worth it.

u c , delhi has a very limited place to take ur bike. But yes I think there has been some problem and I m looking for an maintence work in couple of nxt days

Wow, and I thought that a metro like Delhi would have a lot of opportunities for bike enthusiasts. Guess it's all about cars, eh? I guess it's not surprise then that most of the bike racing scene in India is down south.

Anyway, I'm not sure what exactly the workshop guy did to make it run so good, but it's running butter-smooth since the piston/rings and the re-boring. Hope everything works out for you too. If all fails there's always the option to get a new cylinder kit from the ASC. It's not that expensive for a Pulsar.

OK, I have a question. I've got a P150 DTSi with a K&N R-1060 running a P180 main jet (117.5). Ordered the P180 main jet kit from BAL, it includes a 117.5 size main jet + holder. The bike revs up real quick, and is strong after 4000rpm, but the throttle response is still a bit below par. I mean, it takes a while for the bike to pick up its skirts and start sprinting, after I've twisted the throttle. I can make up for it to some extent by blipping with half-clutch, but I'd like a more permanent solution.

Here's what I want to know. If you have ever owned/tuned a P150 DTSi with K&N, please help.

1. Should I go for a bigger jet? If so, which bike's jet would be a direct fit on the BS26 carb? A list of jet sizes for various bikes would be most useful.

2. Could anyone familiar with carbs give some tips on tuning, with novice-level instructions (as in, not just 'tighten the air screw 1/4 turn' but start with where the air screw is, and so on)

3. The bike leaks fuel like crazy if I leave the fuel cock in the ON or RESERVE position. The leak is through the overflow tube that comes out from under the carb. What could be causing the problem? I took the bike to the ASC and my mechanic, but the problem recurs after a few days. Anyone encounter this before, and if so, what is the solution?

4. Can the problems be solved by fitting a complete carb from a P180, P200 or Karizma? Cuz I could get one from the guys who strip crashed bikes.

How many kms has your bike clocked?

my bike has clocked arnd 48000kms . A bit early , as I think.

Someone please help me pick a good/recommended set of tyres for my P150 UG2 18 inch spoke wheels.Presently i have 2.75 in the front and 3 in the back. I want nothing but the best without compromising on bikes performance like if a 3/18 gives me good handling in the front i can live with a few kms drop in topend, and a few kms drop in mileage. So, basically suggest me a good/recommended set of tyres!

Let us know how the bike behaves with the replacements after run-in (difference in mileage, top speed, etc..).

u can go for 100x90x18 , I think MRF ZAPPER Q will be the best combination for ur bike as i m using the same in the bike. very gd rubber for normal use.
keep the front config as stock i.e 2.75x18 is gd.

ya during the run-in period bike is returing an mileage of 55-59kmpl as I was riding at 40-55kmph constant. not checked with the Top speed yet, but yes 60kmph comes like anything and sounds with a roaring sound from the engine.

Loosen up the fuel screw (that is not the air screw!) to about 4-5 turns from closed position and see, should help with the initial pick up.

Your float pin is leaking fuel. Check the float pin, replace if needed.

p150 need help..

hello friends..
this is my first entry in this discussion.
and i m having some problems with my 2005 model dtsi p150.
arnd 22000kms done..
recently changed its clutch plates n chain set.
and front disc pads.
and front shockers were not straight thats why some pressing also done.
and now after a vey short ride generallt the handle becomes very hard n sometimes it feels like bike is going in some other direction.
it is going very heavy day by day infact i cant turn it sometimes.
..also its pick up and average arent also doing well.
everything messed up like.
so plz help what should i do
thanx

For handle problem, i think it needs cone set replacement.
for pick up and average- get carburator cleaned and tune it properly.