[Mr.Boss]

The new (current) avatar

[Mr.Boss]

I need some suggestion here.
Earlier we had the plan to upgrade the coil from Avenger 180 so that we can go for 12V 60/55W HL bulb. I got few suggestions to switch to DC set up. Now with the current set up (35W bulb in Ambassador reflector) is very much satisfactory and further upgrade is optional.
- What are the advantages of full DC set up?
- Is it worth upgrading to full DC? (Bike is running with 2.5A battery, I should upgrade the battery as well)

[ashis89]

Originally Posted by Mr.Boss

I need some suggestion here.
Earlier we had the plan to upgrade the coil from Avenger 180 so that we can go for 12V 60/55W HL bulb. I got few suggestions to switch to DC set up. Now with the current set up (35W bulb in Ambassador reflector) is very much satisfactory and further upgrade is optional.
- What are the advantages of full DC set up?
- Is it worth upgrading to full DC? (Bike is running with 2.5A battery, I should upgrade the battery as well)

I own the current gen P180 and the only advantage I find of the full DC set up is better (or rather constant) headlamp intensity at all engine revs (I am using a 60/55W Osram NB which is miles ahead of the stock 35/35W stock setup). But this was not a problem in my 2nd gen P150 (round lamp DTSi with stock bulb). Even when I slowed down, a little throttle input was enough to light up the road in front of me. The only reason I see is, to be able to get the full benefit of 60/55W HL (or a projector) bulb if you upgrade in future. IMO, since you are working on the bike you might do all possible future upgrades too. Once the bike is running fine, I would have hesitated to get down to perform another upgrade, lazy me .

And yes, you will need to upgrade the battery as well to a higher capacity one.

[Mr.Boss]

^^^ thanks ashis, I'm leaving the DC conversion as a future upgrade.

Guys, I have another query regarding the painting scheme. I have something in mind, please suggest
1) Shiny Black (OE) - Body (Tank / Shield / mud guard)
2) Matte Black - Front Fork, Rear swing arm, chain guard, engine cylinder & head, kicker
3) Silver (OE) - Crank case, foot peg bracket, T-stem top

Regarding the Silver, which one should I go for? Regular silver that came with this bike or the latest one (little golden shade) in UG4.5?
Also the engine cylinder and the head, should I go for Solver or Black?

[ashis89]

Originally Posted by Mr.Boss

^^^ thanks ashis, I'm leaving the DC conversion as a future upgrade.

Guys, I have another query regarding the painting scheme. I have something in mind, please suggest
1) Shiny Black (OE) - Body (Tank / Shield / mud guard)
2) Matte Black - Front Fork, Rear swing arm, chain guard, engine cylinder & head, kicker
3) Silver (OE) - Crank case, foot peg bracket, T-stem top

Regarding the Silver, which one should I go for? Regular silver that came with this bike or the latest one (little golden shade) in UG4.5?
Also the engine cylinder and the head, should I go for Solver or Black?

Some suggestions to your points:

1) How about changing the color? Latest trend of metallic white (Karizma/UG5/Ninja/Apache) or the Plasma blue of UG4.5 or the blue used in the Yam Gladiator SS? Though White will be prone to scratches.
I agree the Pulsar Black theme will give it ageless look.

2) Swing-arm and chain guard used to have dull black without clear-coat (not matt) in OE paint scheme. Matt might be easier to maintain in those areas.

3) The new silver (UG4.5) looks much better. Cylinder, head and gearbox again look best in black but the color is known to peel off due to heat if not painted properly.

Apart from this, I have a couple of more suggestions.
1) Try to look around for a used P200/P220 exhaust pipe (new ones used to cost around 7k). It would further improve the looks and performance. The "Exhaustec" technology was introduced UG3 onwards which improved the low-end performance significantly. I replaced my UG2's rusted silencer with a new UG4 black silencer (Rs3.5K) and the low-end performance was addictive.

2) I hope you have thoroughly cleaned the fuel tank and checked for corrosion. Pulsar fuel tanks are notoriously known to be the hiding place of water which corrodes it badly, sometimes irreparably. I learnt this the hard way when I flushed my old P150's tank after 5 years and was surprised to find almost 1 litre of water at bottom, below the petrol layer . That along with almost a fistful of muck/rust and a leaking tank made me . The bike was running like a dream and gave no signs of danger.

3) Get the clutch and accelerator wires (with sheath) replaced as a preventive. Also replaced the front brake disc hose with that of a P220(one of the best available in the market).

[Mr.Boss]

Thanks for the suggestions Ashis.
Regarding the base color (Black) we aren't looking to deviate.

Originally Posted by ashis89

1) Try to look around for a used P200/P220 exhaust pipe
Let me put this in 'wish list' for future upgrade (may be Phase 4)
2) I hope you have thoroughly cleaned the fuel tank and checked for corrosion.
Not done yet. Now added to the checklist during painting.
3) Get the clutch and accelerator wires (with sheath) replaced as a preventive. Also replaced the front brake disc hose with that of a P220(one of the best available in the market).
All 3 cables will be replaced with brand new ones. Brake hose was already replaced, is there a drastic difference between P220 hose and the others?

[ashis89]

Originally Posted by Mr.Boss

Thanks for the suggestions Ashis.

Regarding the base color (Black) we aren't looking to deviate.

P220 has steel braided brake hose which improve the brake performance very significantly.

[toothless]

Wow... And here I was thinking that I am the only fool still in love with his college time P150. Wonderful progress on your bike!
I have just started collecting all the parts I require for my bike, starting with the fuel tank and instrument cluster. Bookmarking your thread for inspiration.

[Mr.Boss]

Can someone share the P180 UG4.5 (or the old P200) wiring diagram? Since I'm using the foot pegs and brake pedal from P180 UG4.5 old brake light switch cannot be used. Old (regular) brake light switch has 2 wires but the new one came with 3 wires. I suppose 2 wires should be the +ve & -ve input to the switch and the 3rd one is +ve output.

Originally Posted by toothless

Wow... And here I was thinking that I am the only fool still in love with his college time P150. Wonderful progress on your bike!
I have just started collecting all the parts I require for my bike, starting with the fuel tank and instrument cluster. Bookmarking your thread for inspiration.

Thanks for the kind words and all the very best for your restoration. Drop a PM once you start the job / thread.

[Mr.Boss]

Originally Posted by Mr.Boss

Can someone share the P180 UG4.5 (or the old P200) wiring diagram? Since I'm using the foot pegs and brake pedal from P180 UG4.5 old brake light switch cannot be used. Old (regular) brake light switch has 2 wires but the new one came with 3 wires. I suppose 2 wires should be the +ve & -ve input to the switch and the 3rd one is +ve output.

Finally managed to figure out the circuit, but now the other roadblock came in. Latest (magnetic) type switch is capable of operating LED lamps and conventional bulbs less than 5W. Regular brake lamp doesn't work with it. Any help / suggestion?

[TorqueyTechie]

Did you get a chance to complete the restoration. I have some free time tomorrow and planning to start the restoration of my bike.

Here are some mods/cleaning that I am planning to make.
1. Change the spark plug with NGK Iridium spark plug.
2. Change battery.
3. Clean the fuel tank.
4. Put K&N filter.
5. FFE
6. Change tires. (need to know good ones for better grip during rain)
7. Change lights
8. Oil filter.

Also, if there is more rust I am planning to paint the engine.

Any suggestions?

[Mr.Boss]

Originally Posted by TorqueyTechie

Did you get a chance to complete the restoration

No dear. Hell lot of year end commitments kept me away from this bike. I hope I could make it happen after a couple of weeks.

Originally Posted by TorqueyTechie

I have some free time tomorrow and planning to start the restoration of my bike.

2. Change battery.
5. FFE
6. Change tires. (need to know good ones for better grip during rain)
7. Change lights

Any suggestions?

All the very best dude.

a) Lighting:
Since you are changing the battery and lights (not sure if it only the bulbs or the complete unit) are you going for DC setup? I got this suggestion from so many people to upgrade the HL to DC.

b) FFE:
Any specific reason to go for FFE? For performance or sound?

c) Tires:
I'm yet to confirm the wet grip performance of Ceat Zoom series. As of now it is so good and I got similar feedback from other users as well (known & reliable sources)

Apart from these items, give a look at all cables and change them if required.

[TorqueyTechie]

Originally Posted by Mr.Boss

All the very best dude.



a) Lighting:

Since you are changing the battery and lights (not sure if it only the bulbs or the complete unit) are you going for DC setup? I got this suggestion from so many people to upgrade the HL to DC.



b) FFE:

Any specific reason to go for FFE? For performance or sound?



c) Tires:

I'm yet to confirm the wet grip performance of Ceat Zoom series. As of now it is so good and I got similar feedback from other users as well (known & reliable sources)



Apart from these items, give a look at all cables and change them if required.

Thanks Boss! I am not planning to change the lighting to a dl setup just an upgrade and probably will go for a hid.

With regards to ffe i wanted both performance and sound but i may not go for this now.

I went to look at tires today and bought the michelins 2.7 x 17. Costed me 1600 for the same. The rear tires have good tread grip amd will check the performance before changing. Bought the spark plug as well.

I am also going to change all the cables and get a clean up of the engine and carburettor.

Will post the pics soon. But i wouldnt be doing it myself but working along with my trusted mechanic.

[Mr.Boss]

Originally Posted by TorqueyTechie

probably will go for a hid.

Is it only HID or with projector as well?

[TorqueyTechie]

Originally Posted by Mr.Boss

Is it only HID or with projector as well?

Its only HID. I am not going with projector at least for now.

I am planning to go change the suspension. Should I go with the old type or with the gas filled shocks? Does this provide a better ride quality?