[download2live]

When threads on Pulsar 150 restoration start coming up, it means I am an Old man.

The bike brings back lot of memories. Golden warm memories. Of Hyderabad and Bangalore. Bachelor life was incomplete without a Pulsar. No Unicorn, No Karizma. Had to be a Pulsar. Miss those days.
And the bike never failed me. Ever.

[Mr.Boss]

Originally Posted by svsantosh

Brilliant effort... As a past owner of a 150Dtsi and a 220Dtsi-carb I loved it.
One nice powder coat of these will make the bike stand out.

Thanks Santosh. All points added to the list for upcoming weekends.

Originally Posted by jayakumarkp

How was the cleaning of the aluminum parts - ie the cylinder head, cylinder, clutch casing cover etc?
Looks amazingly clean.

They were painted

Originally Posted by download2live

Bachelor life was incomplete without a Pulsar.

+100

[The Pain]

Originally Posted by Mr.Boss

Here is the final outcome
Attachment 1369444

A 4 page thread and only 1 pic of the final outcome. Seems unfair plz post more pics!

[Mr.Boss]

Originally Posted by The Pain

A 4 page thread and only 1 pic of the final outcome. Seems unfair plz post more pics!

Proper photo-shoot will happen this weekend

[ashis89]

Can we have some more pictures of the restored beauty (or should I call it a definitely male beast)?

[Mr.Boss]

Originally Posted by ashis89

Can we have some more pictures of the restored beauty (or should I call it a definitely male beast)?

Bike is with my friend and hopping to get back within a couple of weeks. Let me share more snaps as soon as I get the bike

[TorqueyTechie]

Reviving this old thread.

I am facing a weird issue with my '02 pulsar. Whenever I slow down or change gears (upshift/downshift) I see a sudden loss of power and the engine note will be harsh. I have to revv a little and slowly engine comes back to normal. When I went to my local mechanic he checked and said clutch plates are gone and needs to be replaced which I agreed to. Also got the bike completely serviced (replaced all oils as well). But after a month the issue persists. Any idea on what the issue might be?

[Mr.Boss]

Originally Posted by TorqueyTechie

Whenever I slow down or change gears (upshift/downshift) I see a sudden loss of power and the engine note will be harsh. I have to revv a little and slowly engine comes back to normal.

Did you feel the clutch slipping? or is it only a drop in power like clogging or insufficient fuel supply?

[TorqueyTechie]

Originally Posted by Mr.Boss

Did you feel the clutch slipping? or is it only a drop in power like clogging or insufficient fuel supply?

There is no clutch slipping. Its drop in power and harsh engine note. Have to revv hard and then slowly the power builds up.

[samybravo]

Mod's note: Numerous grammatical and punctuation errors fixed. Moving forward, please take time to review quality of post before submitting


Dear Friends

Help me to modify my Pulsar 150cc 2006 model.

I have been inactive for a very long time since i was not able to login and now its been resolved. (thank you admin).

So coming back to business friends, I am planing to do some modifications to gain some advantage of low end torque. Recently I had a chance to ride a 1990 model Bullet for a month almost and I found that the bike had lots of low end torque and can shift to top gear under 25kmph and if needed, with a twist of the throttle, had a decent pick up to cruise 45 to 55 Kmph easily.

So here is the idea of my modifications.

Low RPM good torque and should cruise at low speeds.

1. Convert 150cc to 180cc or 200cc
2. Change 4th and 5th gear ratios from stock setting to reduce RPM speed.
3. Change sprockets both front (up size) and Rear (down size) to gain mid range speed with low revs.
4. Change 17" wheels to 18" as it gives more revs at lower RPM range

Finally with the above modifications we can get low end torque and lower RPM speeds so the bike can cruise effortlessly.

Please help me with these modifications, technical gurus and torque experts.

[abhishek46]

In short, NO.

The old school Bullet 350 manages the 'chugging' you experienced, thanks to it's long stroke heavy crank design, with a large capacity single.

Boring out a 150 into a 200, and changing the gearing will not yield same results.
What you need is longer 'stroke', and not a large 'bore'.

[ashwinprakas]

Two ways you can get what you want.

1. Engine swap with a P220's engine, use the P180's chain and sprockets. You'll have a scarily fast machine.

2. Rebuild your current motor with P220 internals,crank, cylinder kit and head, not as expensive as you might expect it to be and with a P180's chain and sprockets would still scare you silly.

In both cases you'd need to use a BS32 from the Avenger 220 or UCAL 33 from the BS4 P220 to keep the fueling right.

A friend of mine went with option 1, sourced an old beaten up P180, a P220 engine, P220 swing-arm, some other parts and built his own motorcycle.

[desideep]

I am a MOD it all types person.

But in your case i would suggest that get rid of the current pulsar and just go for the 220, i am sure ample good examples in the market.

I am suggesting this because the ride quality is very different when it comes to a 150 - 180 - 200 - 220.

I always found that 220 was way more connected and comfortable to ride as compared to a 180. There is a massive difference in the bikes.

[timuseravan]

Originally Posted by samybravo

Help me to modify my Pulsar 150cc 2006 model.

Is there any specific reason for modifying the bike instead of buying a new one?
If you are happy with a bullet, you should be able to get a good used bullet 350 for less than 1 lakh. No amount of modification of pulsar 150 can give you the kind of low end torque which a bullet has.

[ashwinprakas]

Here's some critical information regarding conversion of a P150 DTSi to P220.

i thank you all for your valuable inputs.. my bike is done now... the technical specifications are as follows:

1. P220 piston+bore
2. P200 cylinder head
3. P220 gear box(yes, my gears have been changed from all down to 1down, 4 up)
4. P200 intake manifold
5. P220 crank
6. wet clutch plates( machine work done on them, not a straight fit)
7. P220 cylinder head cover
8. switched back to the original airfilter box for the run in period(500kms) would be switching to the R1060 after the run in
9. BS29mm P200 Carbuerator
10. avenger 200 rear sprocket(need to check the front sprocket)
11. Yuasa AGM maintainance free battery(cool huh..!!!, the yamaha r1 battery...!! )
12. electrical system changed according to the P220.
13. custom made secondary oil supply to the piston to reduce the heat.
14. NGK iridium spark plugs
15. 20W50 engine oil.
16. retuned free flow exhaust for mid rande(5-8k rpm)
17. replaced cone set
18. removed the kicker(practically, it cannot be installed, very high compression)
19. front suspensions tuned to be a bit more hard
20. no alterations have been done to the frame or the swingarm

this is it.. and its jus amazing to drive this thing.! the exhaust note is awesome and u can jus feel the power surge in after 5k rpm... it literally shoots... "crotch rocket". now have to control the throttle until the run in is over...

anyway... i once again thank u all for helping me in this....

the total cost came to
engine components(cylinder head + gearbox + piston + bore + spark plugs) = Rs.11,000/-
P200 carbs + manifold = Rs. 4,200/-
engine oil = complementary..
battery = complementary again!
labour(includes: mounting the engine ofcourse, front fork bend removal, and other petty things) = Rs. 3,000/-
retuning the exhaust = complementary( got the free flow custom made from him only)
wet clutch plates = Rs. 2,500/-(this was the last minute expense i incurred... but money well spent... till now, 120kms completed on the run in and not even one false gear or a gear slip...!!!)
so overall it came just around 21k...

The mod was done by an enthusiast who goes by the handle 'undefineme3' circa 2009.