Go Back   Team-BHP > BHP India > Motorbikes


Reply
 
Thread Tools Search this Thread
Old 26th March 2015, 21:57   #31
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by TorqueyTechie View Post
Should I go with the old type or with the gas filled shocks? Does this provide a better ride quality?
Go for the Gas loaded shocks. They are way better than normal ones.
PS: I'm using them on my RX as well.
Mr.Boss is offline   (1) Thanks Reply With Quote
Old 26th March 2015, 22:03   #32
BHPian
 
TorqueyTechie's Avatar
 
Join Date: Apr 2014
Location: Bengaluru
Posts: 713
Thanked: 1,024 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by Mr.Boss View Post
Go for the Gas loaded shocks. They are way better than normal ones.
PS: I'm using them on my RX as well.
Thank you sir. I will get them changed as well.
TorqueyTechie is offline   (1) Thanks Reply With Quote
Old 10th April 2015, 10:03   #33
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

At last we had some spare time to proceed further.

Tank, Shields & seat removed
Bajaj Pulsar 150 Classic - Restoration & Modification-img_0884.jpg

Oil leak in Head cover
Bajaj Pulsar 150 Classic - Restoration & Modification-img_0886.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_0887.jpg

Head & Cylinder removed
Bajaj Pulsar 150 Classic - Restoration & Modification-img_0888.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_0893.jpg

Complete block removed from the bike
Bajaj Pulsar 150 Classic - Restoration & Modification-img_0897.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_0898.jpg

Initial observation:
- Scoring mark in cylinder (vehicle front direction)
- Excess play in connecting Rod (Approx 2mm at piston end)
- Clutch needs replacement
- Inner sprocket oil seal damaged
Mr.Boss is offline   Reply With Quote
Old 10th April 2015, 10:45   #34
Senior - BHPian
 
arnabchak's Avatar
 
Join Date: Sep 2009
Location: MH-04
Posts: 1,319
Thanked: 1,084 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by Mr.Boss View Post
Below is the list of work done
- Given a neat wash
- Flushed the fuel tank
- Cleaned the carburetor
- Spark plug replaced
- Battery replaced
- Ignition lock set replaced
- Brake shoes and pads changed


Items to be painted
- Frame
- Engine
- Tank & Shield (Not debided yet)
Dear Boss

I will be restoring my 2004 Fiero F2 next month.
However, I will be doing in from my trusted mechanic and close friend.

Request if you could share the indicative costs for the same as it will give me a rough estimate of my expenses.
My restoration will also be on the same lines of the work mentioned by you, give or take a few more.
arnabchak is offline   Reply With Quote
Old 10th April 2015, 14:27   #35
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by arnabchak View Post
Request if you could share the indicative costs for the same as it will give me a rough estimate of my expenses.
Here is the rough estimate dude,
Painting - 7~10k (If completely dismantled and painted. There are cheaper solutions available as well)
Engine + Transmission - 5~10k (depending on the parts usage)
Others - 2~4k (brakes, cables, harness, fork oil seals, etc)

A proper restoration will take you over 20k. You may refer my RX restoration threads for detailed job & cost break-up
http://www.team-bhp.com/forum/motorb...amaha-rxg.html (Restoration - 1997 Yamaha RXG)
http://www.team-bhp.com/forum/motorb...storation.html
Mr.Boss is offline   (1) Thanks Reply With Quote
Old 16th April 2015, 14:28   #36
BHPian
 
TorqueyTechie's Avatar
 
Join Date: Apr 2014
Location: Bengaluru
Posts: 713
Thanked: 1,024 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Mr. Boss, Apologies for hijacking this thread!

I got my bike restored after 3 weeks at the mechanic garage. Both of us had spent considerable amount of time on discussing on the various options but finally decided to keep the bike stock.

Out of the things I had originally intended, I didnt change the air filter yet (this will be done by next month) and the lights (the HID didnt fit) and also didnt get the engine block painted. The shocks were good enough and didnt warrant any change.

Have changed the handle, all the cables, brake pads, oil seals and rings. Total Cost came upto 11 K.

Attaching the end result.
Attached Thumbnails
Bajaj Pulsar 150 Classic - Restoration & Modification-image1.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image2.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image3.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image4.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image5.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image6.jpeg  

Bajaj Pulsar 150 Classic - Restoration & Modification-image7.jpeg  

TorqueyTechie is offline   (1) Thanks Reply With Quote
Old 16th April 2015, 14:40   #37
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by TorqueyTechie View Post
Have changed the handle, all the cables, brake pads, oil seals and rings. Total Cost came upto 11 K.
11k for the mentioned job only? Looks little expensive.

BTW your bike looks neat and well maintained. Congrats buddy.
Are you running with 16" wheel at the rear?
Mr.Boss is offline   Reply With Quote
Old 16th April 2015, 15:56   #38
BHPian
 
TorqueyTechie's Avatar
 
Join Date: Apr 2014
Location: Bengaluru
Posts: 713
Thanked: 1,024 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by Mr.Boss View Post
11k for the mentioned job only? Looks little expensive.

BTW your bike looks neat and well maintained. Congrats buddy.
Are you running with 16" wheel at the rear?
I had to get the engine reboring done and add the labour charges which came upto 5000 itself. Thats the problem of giving it to a mechanic . No matter how good and known he may be, but there will be something extra he would charge. But no qualms as the bike is running like new and I am enjoying the ride. Whatever it is the joy of riding is something which is unparalled!

Yeah I am running on 16" at the rear. This I felt gives me better grip. Thanks for the comment on the bike. Yeah trying to maintain it in a better shape but finding time to do for one bike itself is a challenge! I wonder how you are managing time to do all the restorations!
TorqueyTechie is offline   (1) Thanks Reply With Quote
Old 16th April 2015, 23:35   #39
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by TorqueyTechie View Post
Yeah I am running on 16" at the rear. This I felt gives me better grip.
Try increasing the wheelbase with UG2 swing arm, that should improve the handling and enhance the overall look
Quote:
Originally Posted by TorqueyTechie View Post
I wonder how you are managing time to do all the restorations!
Little (???) difficult, but manageable
Mr.Boss is offline   Reply With Quote
Old 17th April 2015, 10:28   #40
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Minor update on the cracked HL reflector. Changed them last night
Amby reflector --> TATA Ace reflector (the later one has more curvature on the surface)

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1227.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1228.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1229.jpg
Mr.Boss is offline   Reply With Quote
Old 20th April 2015, 10:04   #41
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Quote:
Originally Posted by Mr.Boss View Post
Minor update on the cracked HL reflector. Changed them last night
Amby reflector --> TATA Ace reflector (the later one has more curvature on the surface)
Final outcome

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1289.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1291.jpg
Mr.Boss is offline   Reply With Quote
Old 11th May 2015, 11:05   #42
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Lazy painter did his job well. Got those parts back and assembled the engine with New bearings, clutch plate, clutch springs, kicker spring, etc. Engine rebored to 1OS piston (from Goetze), new valves and valve guide. Saturday late night we managed to fire the engine

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1989.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1990.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1991.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1992.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_1993.jpg

Bajaj Pulsar 150 Classic - Restoration & Modification-img_2009.jpg
Mr.Boss is offline   Reply With Quote
Old 11th May 2015, 16:02   #43
Senior - BHPian
 
Mr.Boss's Avatar
 
Join Date: Mar 2011
Location: Chennai
Posts: 1,943
Thanked: 2,398 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Here is the final outcome
Bajaj Pulsar 150 Classic - Restoration & Modification-img_2044.jpg
Mr.Boss is offline   (2) Thanks Reply With Quote
Old 11th May 2015, 16:27   #44
Senior - BHPian
 
svsantosh's Avatar
 
Join Date: Mar 2008
Location: Hosur
Posts: 3,309
Thanked: 1,389 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Brilliant effort... As a past owner of a 150Dtsi and a 220Dtsi-carb I loved it.

There are a few sore points sticking out. It is a small effort but will gel with overall effort.

1) rear grab handle
2) side stand and center stand
3) front fork top yoke and Key switch plate
4) a speedometer rebuild specialist can dismantle the 3-dials, 4 LED dial glasses and polish her like new

One nice powder coat of these will make the bike stand out. PS - guessing the age of the bike, do take the effort to get the FC done and give her a fresh lease of life.
svsantosh is offline   (1) Thanks Reply With Quote
Old 11th May 2015, 19:08   #45
BHPian
 
jayakumarkp's Avatar
 
Join Date: Aug 2008
Location: Pune
Posts: 147
Thanked: 18 Times
Default Re: Bajaj Pulsar 150 Classic - Restoration & Modification

Dear Mr. Boss,
How was the cleaning of the aluminum parts - ie the cylinder head, cylinder, clutch casing cover etc?
Looks amazingly clean.
jayakumarkp is online now   (1) Thanks Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search


Similar Threads
Thread Thread Starter Forum Replies Last Post
Restoration and The Untold story of Our Prized Possession "The 1974 Bajaj 150". sushil_n79 Post-War 292 16th November 2016 17:59
Bajaj Pulsar 150 DTSi Series 2- Test Drive islero Motorbikes 17 22nd July 2016 10:02
Headlight Upgrade for Bajaj Pulsar 150 DTSi ankushmulay Motorbikes 73 6th March 2013 21:32
Bajaj Pulsar 150/180 - Technical Specifications & Feature List bluevolt Motorbikes 1 4th October 2011 17:22
Fully Loaded BAJAJ Pulsar 150 DTS-i version 2.2 (2004) for sale pranaviitkgp Shifting gears 0 20th August 2007 22:36


All times are GMT +5.5. The time now is 12:45.

Copyright 2000 - 2017, Team-BHP.com
Proudly powered by E2E Networks