Bajaj Pulsar 150 Classic Restoration & Modification

[Mr.Boss]

old handle bars which is more relaible and last than clip ons. They only bent will not broke. I had seen the new apache & pulsars with one side broken clip ons after falling down.

This is something worth thinking. Let me put the clip-ons as tentative

 

[RVSB]

Please have a look at this, it may help you:
http://www.bcmtouring.com/imp/Pulsar_DTSi_Workshop_Manual.pdf

 

[Mr.Boss]

Please have a look at this, it may help you:
http://www.bcmtouring.com/imp/Pulsar_DTSi_Workshop_Manual.pdf

I have them already (along with RX service manuals)
thanks anyways.

 

[RVSB]

Then see this:
https://mega.co.nz/#F!ghVxiZwa!cq6zyApX-IxXOFJVDSfWHg

 

[Mr.Boss]

Got a set of used alloy wheels from a known and reliable source. Let me post the snaps tomorrow. Parts to be procured (to fix alloys in the bike)
- Rear swing arm
- Chain guard
- Sprocket set
- Brake shoe
- Shock absorbers
- FR & RR tires

 

[Mr.Boss]

Got the HL reflector changed from OE --> Ambassador. This gives an advantage in using 12V 60/55W H4 bulb once when we upgrade the coil (very soon)

OE Reflector & HL socket


Reflector removed from the outer ring


Autopal 178mm reflector (for Amby)


Costed me 150 INR


This is how it looks


Found the reflector is cracked. It was perfect when I bought it.


After fixing this reflector to the OE outer ring, my poor mind went to super excited mode to test the out put and forgot to take the snaps Let me post the final outcome and beam spread snaps tonight.

This made my pocket lighter by 300 INR
Reflector - 150
HL Bulb - 80 (12V 35/35W Osram)
HL Holder - 70 (Ceramic holder)

 

[Mr.Boss]

Final outcome

 

[Releesh]

This is good. But original one came with clearlens type and in the photos it doesnt look it has any issues.

 

[Mr.Boss]

This is good. But original one came with clearlens type and in the photos it doesnt look it has any issues.

I'm not satisfied with the OE reflector beam spread (especially the Low Beam) May be I got used to the Amby reflector (which I'm using in my RX as well)

 

[Ilangop]

Would advice you to go for Pulsar 200/220 exhaust setup. They are made of stainless steel and hence don't rust for life time. New one costs close to Rs8000/- while in olx may find good ones at half the price. Many people go for performance exhausts in 220, that's why.
And let the classic looks remain intact. There is also a clear lens reflector available for Ambassadors, still this once looks nice and gels with the current looks. If you are pulling down the engine and if the alternator coils are outside, then its time to go for DC setup. Quite simple only. You can also upgrade your bike with bcm & illuminated switch setup if interested, still retaining the classic looks. This bullet has pulsar bcm and illuminated switches, http://www.theautomotiveindia.com/f...-350-electra-2008-restoration-upgrades-5.html

 

[Mr.Boss]

Thanks for the suggestions Ilango.

Would advice you to go for Pulsar 200/220 exhaust setup.

Doesn't it affect the back pressure? If there is no issues with the performance, let me put it in wish-list and proceed based on the budget availability.

There is also a clear lens reflector available for Ambassadors, still this once looks nice and gels with the current looks

You mean this reflector?




I have them already, but that doesn't house the ordinary H4 bulb (this one uses some round basket like structure & the pins same as H4. Finding 12V 35/35W bulb for this holder is bit difficult, if I postpone the idea of coil upgrade)

its time to go for DC setup
....
bcm & illuminated switch

You are tempting me man. OK, added to the wishlist

 

[Mr.Boss]

Few updates for this week.
Settled for CEAT Zoom series tires. Though there is a mixed review for these tires, I have a very good experience with them on my friend's Pulsar.
Front : 2.75 x 17 Tube type (Jan 2015 Manufactured)
Rear : 100/90 x 17 Tubless (Dec 2014 manufactured)

 

[Akash1886]

Few updates for this week.
Settled for CEAT Zoom series tires. Front : 2.75 x 17 Tube type (Jan 2015 Manufactured)
Rear : 100/90 x 17 Tubless (Dec 2014 manufactured)

Satish, the project is really going to be an awesome one! Really love the amount of efforts put in and of-course immense R&D (My favorite) put in it. How will be the ride of the bike if it has one tube and one tubeless tyre? Is there any significant difference having 2 different type of Tyre(s)?

Regards

Akash

 

[Mr.Boss]

Thanks Akash.

How will be the ride of the bike if it has one tube and one tubeless tyre? Is there any significant difference having 2 different type of Tyre(s)?

For 2 wheelers this shouldn't make any change in performance. Anyways, I bought the tube for rear as well. Since I settled for used alloy wheels, I don't wish to take the risk with tubeless scheme. Rear assembly is already fitted to the bike last night (late night) and the snaps are yet to be downloaded form my phone.

 

[Ilangop]

Doesn't it affect the back pressure? If there is no issues with the performance, let me put it in wish-list and proceed based on the budget availability.

Would affect back pressure very marginally, but not much. Because this is a 4 stroke bike and not a 2 stroke where the exhaust system design is very very critical.

You mean this reflector?
View attachment 161049
I have them already, but that doesn't house the ordinary H4 bulb (this one uses some round basket like structure & the pins same as H4. Finding 12V 35/35W bulb for this holder is bit difficult, if I postpone the idea of coil upgrade)
You are tempting me man. OK, added to the wishlist

Yes, you are right. This type of bulb is called H4 P45 type. The other one with 3 tiny protrusions is called H4 P43 type. P43 type transparent reflectors are also available in market. Check at a truck part store. Should cost you under Rs200/- for a local made stuff.