Need advice: My 2003 Bajaj Pulsar's engine dies every 5 km

It would run for 5 - 6 km and then stop. I need to rest it for few mins and then it will run for another 2 - 3 km and stop again.

BHPian shrinz.vivek recently shared this with other enthusiasts.

I have a 2003 model Pulsar 150cc. It gave me a trouble free ride until 2 months back. However, 2 months back its kick shaft broke and it took the local mechanic a long time to fetch some internal part to make it work again.

Since the time I have got it back, I am facing peculiar problem with the bike.

It would run for 5 - 6 km and then stop. I need to rest it for few mins and then it will run for another 2 - 3 km and stop again. And the process repeats.

It stops as if it has run out of fuel.

My first suspect was the air vent of the tank may be blocked. Got it cleaned, but didn't resolve the issue. Tried running the bike with fuel cap half opened, but still the issue persisted.

Next got the carburettor and fuel tank cleaned suspecting it may be water in the tank, but still the issue persisted.

Then I suspected the fuel tap. Though I could see the fuel flowing, I thought may be amount of fuel flowing is low so that might be the issue. I replaced the fuel tap with OEM one but still no good.

I am at complete loss of what might be causing the problem. Any help debugging the issue?

Here's what BHPian iamgyan had to say on the matter:

Since some work on engine was done, check if the crankcase ventilation port is blocked and if there is a tube connected to it, check if it is pinched or the outlet of the pipe itself is blocked.

Also, maybe it's time to retire the bike.

Here's what BHPian Indian2003 had to say on the matter:

I figure you have a CDI ignition. Have that checked. You can also try to replace the spark plug to see if it helps.

Here's what BHPian shancz had to say on the matter:

Since you've already checked the fuelling, I have some guesses:

• Since its raining, check if pushing the key to the ignition position makes it start when it shuts down, spray in some WD40 in the key cylinder and the switches(engine kill, lights etc.) anyway.
• Ignition and Electricals: could happen if the bike was left outside in the workshop, water could've seeped-in some electricals? Ask them to dismantle what they had earlier and then check out the electricals especially relays.

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