Got the motorcycle engine overhauled

On Saturday I finally got my motorcycle’s engine overhauled. It’s been a long time since I first felt the need to get it done, however due to financial and other constraints I had been unable to do so till last Saturday.

Initially I wanted to get it done in the official service center of Bajaj Auto, however their main mechanic who happens to be the person who has serviced my motorcycle for the majority of the time, wanted to make a quick buck. So out went the idea of getting the bike overhauled in the Bajaj Service Center and in came the prospect of getting it fixed at the road side.

This decision was made due to the fact that the service center I normally take my motorcycle to, had stopped fixing Bajaj Pulsar 180’s due to a directive from Bajaj Auto who thought it would be wise to limit the service centers for their premium bikes to a chosen few. They were willing to fix my motorcycle despite that; however they didn’t have any parts for the 180. And since I wasn’t willing to get her serviced from any other service center, due to the fact that Bagga Link had screwed her engine once.

All of the above circumstances dictated profit for the regular mechanic and while I wasn’t that willing, thinking at least my bike will be fixed properly I agreed.

So on the sunny Saturday morning I went to the place where the mechanics fixes motorcycles when he isn’t in the service center. He had already gotten most of the parts and thus began operation overhaul.

Slowly but steadily the engine bits came off:

Taking off the head

Lifting the cylinder block

Old piston attached to the crank



Clutch cover opened and piston detached

After the piston was detached my doubts were cleared, my bikes engine had seized twice in June 2005 while I was coming back from Rohru. This might have happened due to the fact it was in the middle of the afternoon in the hot month of June and the fact that I was continuously ridding at over 110kmph and also the fact that one of rocker arms had some issue.

Here are couple of photos of the seized piston:

In the end we ended up changing more parts then we had thought initially, here is a list of the parts that were changed.

1. Piston and rings

2. Cylinder block

3. Timing chain

4. Timing Guide

5. Clutch Plates

6. Pressure Plates

7. Clutch hub

8. Wheel Clutch

9. Valves

10. Rocker Arms

11. Air filter

12. Spark plug

13. Engine oil

14. Head decarbed

And lots of seals and packings and few small parts and rest of the bike was serviced. Total bill came to be Rs. 4020 (roughly US $ 92), Rs. 3720 for the parts and Rs. 300 as labor. I guess the whole job did end up costing a little cheaper than what it would have been had I got it done from the service center, not to mention the mechanic would have been the same and wouldn’t have been that happier servicing my motorcycle.

Now the bike is feeling peppy and rev happy, although I haven’t yet started ripping her. Right now I am trying to keep the speed at 50kmph – 65kmph (3000-4500rpm) in the fifth gear. And will do so until the trip in May.


  1. Sir I am brought secondend Bajaj pulsar 150cc 2006 modal but it produces more sound and sudden low acceleration during running even after changing the engine oil the sound is coming. . What can I do for that..

Leave a Reply