I am Ahmad from Egypt and i have pulsar 220 cc model 2010 and this problem is still remain and i will fixed it by myself thank you a very much you are a genius
Thanks a lot, am from Nicaragua, América, nice video you truly know about the pulsar, I got a 220 and I have to buy the complete scissor gear which cost to me 20 dollars of USA, thanks for do this amazing videos.
Thank you so much man. It's very important information to me. I have replaced timing chain and tentioner but still hear the rattling noise and now I Know why. IAM going to change the scissor gear and update here😊
I got the perfect information about working of scissor gear. You explain in detail with actual parts which added more comfort in getting understand. And also help me in how to repair the instead of replacing gear. Thanks again 🤗
Really appreciate bro! Very well explained..I am a heavy mechanic myself but never understood the theory of scissor gears in Pulsar..I do own a 220..great video..Thanks a lot👍👍👍
The spring load is in anti-clockwise for both nylon scissor gears. How to load? First take a reference of any tooth of first scissor gear, Align the tooth of scissor gear with the tooth of idler gear and make a mark with a marker. Now, hold the first scissor gear in gear holder/puller then you have to twist idler gear to two teeth in anti-clockwise direction in order to load the first scissor gear then slide the idler gear in gear puller. Next step is same, take reference on second scissor gear, align it with idler gear then turn it to two teeth in anti-clockwise direction then slide again. That's it. Note:- Handle the scissor gear carefully. The nylon gear teeth must not get damage in any condition! Even a damage to one gear tooth can make strange noises.
Hi.. i think you are the right person to understand my problem.. i have gear shifting problem in pulsar 150, gears become hard while down shifting.. gear is never smooth needs to put effort.. i replaced clutch plates and shaft on advice of showroom however the problem still exists.. kindly help.. model 2016
My first advice is to use recommended engine oil grade, i.e, 20W-50. And if you have good budget, then use semi-synthetic or full synthetic engine oil of grade 15W-50 or 20W-50(Motul 7100). Now as far as i know, it might be a worn out Gear position guide sprocket along with sprocket stopper (it must be replaced in pair). Inspect the part first before attempting to replace it. To inspect gear guide sprocket :- -drain oil -Open clutch cover -Remove clutch Springs (no need to remove whole clutch at this point) - Turn the tyre while changing the gear simultaneously (help needed). - Inspect the movement of position guide sprocket while changing gears. See if it is shifting hard or stops at some point or not. If it stops then before replacing the part, try to inspect the gear shifting drum. To inspect gear shifting drum:- -Remove gear lever -Remove gear shaft (now to remove gear shaft, you have to remove the whole clutch assembly) - After removing the gear shaft, remove the guide sprocket stopper. -turn the guide sprocket (gear drum) and try to change gears along with turning the rear tyre. Change gears back and forth from 1 to 5 and 5 to 1. -Inspect if the gears are shifting smoothly or you feel any STRONG resistance(mild resistance is normal) or hard resistance at a particular Gear position for example,3rd gear position. -after inspection, if the gears are shifting smoothly(without stopper) then there is no problem with the gearbox of your pulsar, It is that faulty/worn out GEAR GUIDE SPROCKET AND SPROCKET STOPPER. Replace it with genuine parts.(Congratulations! You are saved from major repairs. Haha.) But if you observe hard resistance while turning the guide sprocket(gear drum), then unfortunately, its the problem with gearbox and you have to live with it. I hope this info will sort out your problem. Btw, if you are going to service center again, then it is advisable that you must find a good mechanic who truly listen to your problem and solve it to the core. Else, I know that most of the mechanics don't like to get advice from other people as it hurts their ego. LOL
nope.. I kept the old one.. To put new bearings.. I had to replace the balancer assembly and disassemble the whole engine to get to the rear bearing to replace it. So, i kept the old one, no changes.
@@srk0034 you can replace the rear bearing of old balancer which is 6303 but you can't change the bearing built-in the balancer. it's 6303N and you can't replace it because of the interference fitting between the shaft and the gear of balancer. You have to buy the balancer itself.
Nice video and explanation. Thank you. A Question. The post Oct 2012 Pulsars have a different balancer bearing with inner dia of 20mm compared to 17mm inner dia on the older pulsars. Then how can the new improved bearing fit on the older pulsars since the inner dia is different?
As I have mentioned in video... You have to replace the whole balancer assembly.. And replace the rear bearing which supports the balancer(you need to open the whole engine).. Since the outer dia is same as the old one... There will be no problem in installing the new balancer assembly.. But its recommend to replace whole set...i.e, primary gear, clutch housing, scissor gear and balancer gear... It's a hassle to change all these parts as it is time consuming and heavy on pocket... But if you want to reduce the noise of scissor gear then go for it, else, there's no need to change it because bajaj's quality is sub par and it will wear out in a very short time and you will face the same problem again in future, so it's not worth the money!
I plan to make more videos. Viewers like you inspire me to make more tutorial videos and now I have plenty of time in this Lockdown period to make such videos.!
Good information, really helps a lot . 👍 If you include the engine noise before and after changing the scissor gear in this video, then It will be easy to hear the sound and compare with our bikes. Because my bike making some weird noise and vibration.
Balancer rotates to balance crank weight.. It has no relation to standard sized piston.. Although, if you install oversized piston, then, it will have an effect on overall balance of engine..
Brother if that teeth setting will 3 teeth what will be the problems? Avenger me gear change ki time me jo kat kat karke juttering noice ata hai, wo kya kharab sessor gear ki liye hota hai?
Generally jab scissor gear ghis jata hai tab uski setting 1 teeth aur ghuma dete hai.. Us se purana scissor gear aur chalaya ja sakta hai par pehle se zyada awaaz aane lag jayega.. Agar bike sirf 30,000-50,000km(normal riding conditions mei) tak hi chali hai aur awaaz karne lage.. Toh sirf nylon gear change karke hi awaaz normal ho jayegi... But agar rough riding hai and over 50,000+kms hai toh Bhai complete set [clutch housing+ primary gear+ scissor gear(complete) +balancer gear] change karne ke baad hi awaz normal hogi.. Aur yeh kaam bahut mehnga hai.. Approx. 3000 rupye.. Without labour changes.. Agar tera budget hai itna toh tumpe depend karta hai ki change karna hai ya nahi.. Nahi Toh, jesa chal raha hai wese hi chala lo.. 😁
@@sumesh_singh563 bhai mera avenger me clutch housing chainge kiya, sessor gear ko 3 teeth set kiya...ek batao usse bike ka picup bhi kam ho jata hai! Hai na? Aur gear change karne ke time me katar katar sound karta hai ?
@@gareebtravelleraniruddha nahi bhai.. Clutch dabaate wakt agar katar katar ki awaaz aati hai toh.. Clutch centre and clutch hub ghis gye hai.. Usey change karo... Scissor gear ka gear change karte waqt koi role nahi hai.. Reference ke liye ye picture dekhlo.. www.google.com/imgres?imgurl=https%3A%2F%2Fstatic6.industrybuying.com%2Fproducts_medium%2Fautomotive-maintenance-and-accessories%2Fmotorcycle-parts%2Fmotorcycle-transmission%2FAU.MO.MO3.516273_1.jpg&imgrefurl=https%3A%2F%2Fwww.industrybuying.com%2Fmotorcycle-transmission-gap-AU.MO.MO3.516273%2F&tbnid=yJ9GssSFNgt9oM&vet=1&docid=6cBXX4WR4rDYvM&w=300&h=138&source=sh%2Fx%2Fim
@@sumesh_singh563 bhai mei Pura clutch Housing, clutch plate steel plate, Pressure plate, centre,hub ka set change karwaya bilkul naya. Pata nahi qu ata hai.
Pulsar 180 2010 model. Bike is not climbing above 80kmpl speed at 6000 rpm. Changed clutch kit twice, mechanic said scissor gear is good, changed what was recomended by service center but no one is able to solve the problem. Plzz suggest.
It is the problem with carburetor, in Pulsars the carburetor vacuum piston is activated by vacuum created inside the carburetor. There are three possibilities of piston not lifting properly. 1st- sleeve of piston is dirty or it has accumulated corrosion on its surface, 2nd - The sleeve of piston is heavily scratched/worn out. 3rd- The diaphragm of sleeve has a small hole in it which is causing vacuum leak. Either of the problems will not let the piston to lift properly or will not lift to the max limit. Solution#1 - service the carburetor piston. Use a super fine sandpaper of grit#500 or #600 to sand off the dirt or corrosion on piston.. Use either petrol or machine oil to lubricate the surface while sanding, make sure not to scratch the surface of sleeve. Solution #2- use sandpaper of grit#280 and sand horizontally as the scratches are vertical. Sand until the scratches are smooth, Don't try to completely clean off the scratches, just make the surface smooth. Also, First try it on a small area and see if its causing deep scratches or not. If grit #280 is creating scratches, then use grit#500 sandpaper. Note- if the scratches are too deep, replace the piston, do not attempt to sand off the scratches as sanding too much will downsize the piston and it will not create vacuum anymore. Solution to vacuum leak - inspect for any hole and seal it with glue or clear type gasket maker. If the hole is more than one in diaphragm, then, you have to replace the vacuum piston. It costs Rs. 950+ , and about Rs. 100delivery charges. This part is available on www.99rpm.com. It takes about 2-3 weeks to deliver(depending on location) Note- while working on vacuum piston, make sure that you don't puncture the diaphragm.. So be careful. Terminologies- *Vacuum piston- the part on which needle is installed. *Sleeve- skirt/sides of vacuum piston. *Diaphragm- rubber part on the top of vacuum piston. Hope this will work for you.!
If the problem is same as I told you and the part needs to be replaced, then you may buy it from here. You can't get vacuum piston in market as majority of shops don't know about its availability. Here's the link below. www.99rpm.com/bajaj/carburettor-avenger-150-street.html
I you take out all of the three components.. Then, the Engine will vibrate a lot due to unbalanced forces.. Engine will not accelerate smoothly and trying to run at high speeds can make the Piston fail, connecting rod can break.. Engine failure for sure.
Bro kya body balancer khrab hone k wjha s bhi shrrr shrrrr sound krta hai..mene.cluth housing primary gear and sciccor gear sab chamged kr diya hai body balancer merko work shop mel.nhi rha...but sound m maja nhi aarha.... Pulsar 180 ug4 h
Amit Sharma body balancer ki wajah se hi hai problem... New Balancer mei 6204 bearing hai.. Jabki purane balancer mei 6303 bearing tha... 6204 ki load rating zyada hai 6303 se... Purana balancer khrabi hi karega.. Paise khrab karne ka fayda nahi hai.. Aise hi chala lo bhai.. ✌️
Bro my 220 engine heats up with dry engine noise after 2kms ride no one able to solve the sound I am ready to change anything any suggestion? I m using motul full synth even though it heats and making some zzzz noise
Noisy NIGHTS, well, that's the main problem in pulsars... If you've ridden your bike over 60,000+ kms, then, the noises are of bearings... do Change all the main bearings of the engine... I.e, Crank bearings, clutch shaft bearings, and drive shaft bearings.. Replace Camshaft bearings or just replace the camshaft.. Its only of Rs.330 MRP,.. i would prefer to buy SKF bearings, they're expensive but worth the price... And, if, the crank rod pin assembly needs to be replaced, then, do buy SRIRAM assembly(USHA). In short, the problem of noise after heating up is due to worn out engine bearings..
please enlighten me .......after changing the cylinder kit and all stuff my pulsar 180 is not getting its high speed ..the rpm needle hardly goes above 6000 rpm. i got tuned my carburettor but still milegae is giving good but power is still lacking and yes it also have scissor gear problem since very long many vibrations the engine vibrates a lot cant even hear the pure engine revivng sound while riding.. what shall i do? i want that 180 power back😑
First of all.. You shouldn't revv over 4000rpm till the break-in period.. You have to break-in the piston cylinder first and ride slowly for first 1000-1500kms.... And check out for the timing of the main Crank balancer... If its vibrating a lot.. Then, it's with the problem of timing ofcrank balancer.. And if, its not vibrating much but creating rough noise.. Then, it's the problem with scissor gear.. you should check for the timing of crank balancer first..
Sumesh Doal no no i completed the break in period gently as per the mech. not going above speed of 45. ..aftr checking the timing of crank balancer will it retain its power back??
Hamare Hindustan me rahne wale log hi hamare hindi bhashe ki koye ahmiyat nahi rakhte is baat ko aap hindi me bhi bol sakte ho bhai you are very good thinking but next time video loading with hindi language...
Bro are you rotating scissor gear in the wrong direction when loading it using a tool, balancer has torsion spring and its looks like you rotating it in the wrong direction. Great video by the way.
It is loaded in right direction, i.e, anti-clockwise direction.. In this manner, the scissor gear will make a load in anticlockwise direction, idle gear will have a metal to metal loaded contact with clutch gear and the nylon gear will only push the clutch gear.. No engine load except the spring load on nylon gear..... If you load scissor gear in anticlockwise direction, the nylon gear will have direct contact with clutch gear.. Also, it will have a stressed load from spring and this will make the nylon gear to wear out prematurely..!! I have done this experiment also.. You can try it by yourself to learn about it more!!
भाई इस वीडियो को आप हिंदी में बनाते तो बोहत अच्छा होता ये वीडियो बोहत हेल्प फुल होती अगर हिंदी में होती अगर हो सकता है तो आप इसको दुबारा हिंदी में अपलोड करे
Thanks for the detailed explanation. Much appreciated 👍🏻 Hope you can make a complete engine overhaul video for Pulsar 220F in the future when you feel like it.
Bhai mai Philippines mei rehta hu ab.. And southeast Asia and Europe ke kyi countries mei pulsar bahut zyada popular hai.. Isliye yeh mind mei rakh k video bnayi thi Maine.. ☺
Aditya maghwal.. Bhai.. Technical words toh English hi use honge.. Isliye maine English prefer kiya.. Maybe east asian countries ke log bhi dekhle.. 😂 😂
Ashish kumar suggestions k liye thanks bro.. Hindi mei nahi daal saka.. Isliye hindi subtitles add kari hai maine..options mei Captions/cc button dba k hindi subtitles select karlijiye.. ☺
