Engine teardown at 30.000km mileage
Hello everyone, today we have very interesting topic and I want to introduce a couple of guys.
Alex, come here please.
Alex is the owner of this bike.
What is the model name?
It is called Bajaj Pulsar 200NS
200 cubic centimeters, 23,5 horse powers
very popular model in Ukraine
Carburator version? Yes, carburator.
I want to tell you why we have gathered here today
but before that I want to introduce Vladimir Baranov - we are at his workshop
This person is bike pilot and mechanic. Many people know him in our bike society.
So welcome - Vladimir Baranov
We have met here today with Alex and Vova to give this yellow Alex's bike which has the mileage of ...
What is the mileage?
30.000 kilometers 30.000 and 100 kilometers, right? Yep
So we've met here with Vova and asked him to find some time to teardown the engine and to find out what happened to this engine on thirty thousands, measure it and to compare to japanese and italian brands
I wanted to add
Yes, as an owner tell us do you like this bike?
I wanted to start that this bike is manufactured at the same factory in India which makes KTM bikes with small displacement engines and some Kawasaki models by the way.
So we can call it a younger brother of KTM Duke 200
There are some interchangeable parts but there are many differences in parts as well.
Many people ask what are the differences with KTM
how good is the quality and is it better than chineese bikes?
As a result, we've decided to make this video at 30.000 mileage
and with hundred percent working motorcycle in which we would teardown the engine
No problems with bike now?
No, no problems. Just to change drive chain and sprockets that passed twenty four thousands kilometers and change tires
Why do you say 24.000 if this bike has 30.000 of mileage?
Because I've changed drive chain and sprockets at six thousands. I bought this bike with 6.000 mileage
And you've changed chain and sprockets right away? It has total mileage of 30.000?
Yes
Ok, understood, thank you Alex. Let's start our teardown. Follow our video, we think it should be interesting. Thank you
Vova thank you as well Let's begin and best wishes to everyone
Our clutch. Assembled. Clutch cover is not removed yet
This small clutch hub nut which holds our clutch in place has left hand thread.
For those who would try to remove it - don't forget that we have to unscrew it clockwise, not the opposite.
Such nuts are hard to find in local shops.
Right hand nuts are available, but not this one. Just keep it in mind.
Couple of words about clutch.
Our mechanic examined it and tells us that my clutch is almost new and seems that I didn't use it.
24.000 kilometers and it is like a new part.
Finally, our engine is removed.
Part 2: engine teardown
Camshaft chain is dead. It is moving on the sprocket. If you try to pull it - it has a free play over sprocket...
What is going on?
Removing camshaft chain tensioner.
Yep, chain is dead.
In order to remove camshaft chain on this engine - we would have to remove spark plug sleeve
It just has rubber o-ring
You can see here that chain link jams
Sport bikes have another system - we had a problem that clutch cover is fixed by the chain and we couldn't remove it.
On a sport bike you would remove this sleeve, move cover to side and take it out.
And here, this sleeve cannot be taken out.
This is definitely better than any chineese engine
I know that Bajaj engine is more or less technologically advanced
Yep, I like it. Some minor cheap parts among electrical connections, but still good.
This free play is very bad.
Free play of rocker bearing. This bearing is not feeling well and we can see that it slipped over camshaft.
Was not rotating but slipping. It might have even jammed sometimes.
I can't see any wear on rocker shafts but I don't like its color.
The surface should be either rubbed or shiny and here we can see that it is rubbed and shiny at the same time. But we would measure it. Measured: ok
This rocker bearing has smaller free play
Those rockers have no bearing joints with shafts right?
Yes, no bearings on shafts. It is called sliding bearing.
No additional friction parts inside.
And we also see that camshaft surface has slipping marks as a result of bad rocker bearings.
Here is our cylinder head cover
Pretty.
With a small amount of scorching.
You mean small amount for this mileage?
I mean that oil has a good cleaning potential
Everything burns and nothing stays - it is very good and a result of using three spark plugs.
We would disassemble it in a while.
By the way - this cylinder has cast iron sleeve which was pressed in.
Even honing is still present.
And is still good.
We can see some minor marks from piston rings at the top spot but either honing was deep or we almost have no wear here.
no scratches?
no scratches at all. No dirt and no mechanical damage.
And even teflon layer is at good condition.
It stayed good because this special spot is carrying the most friction.
This is how piston looks after 30.000 kilometers mileage.
Just some barely visible friction marks.
really looks great. Almost no scorching.
Our cylinder definitely has no wear.
wear in hundreds...
... you want to say that it is perfect after such mileage?
Yes, but you should understand that this cylinder has cast iron sleeve which wearproof in its nature.
We have here the new cylinder, piston, holder and rings.
And new gasket.
But truthfully speaking, concerning condition of old parts - my bike would probably survive two more seasons without the replacement of those parts.
But our mechanic says that if we have new parts and we already opened engine - it is better to replace everything we can.
Also concerning its low total cost - cylinder, piston, rings and gusket - I think that this is reasonable to replace everything and be sure that the engine is good for another thirty thousands and more.
Stock drive chain and sprockets have a mileage of twenty four thousands kilometers.
Stock chain with o-rings and I've treated it properly each five hundred kilometers.
Here is the shaft for drive sprocket and here you can see all dirt that appeared here
for the 700 kilometers from the last treatment.
Finally, we have managed to open our engine and disassemble it completely.
We wanted to inspect the wear of transmission gears. Inspection showed no critical wear.
All bearings and shafts are ok. we can now put everything back together.
Our engine. Ok. Starting to assemble everything back with a new gasket and move further.
This engine can be replaced in a field...
Seems that my new tire is not compatible...
Part 3: summary
Vova, you have just finished this bike's engine teardown, which has passed 30.000 kilometers
you also have your own opinion about it now - can you tell us what you think about the quality and the whole process.
Let's start with removing engine first.
My first impression is a score of four Out of five? .
Yes. Accessible, comfortable, everything can be easily removed, nothing to brake here
This is important point
And it is also easily assembled back after teardown.
the quality is ok, four out of five
And overall parts wear also kept in standard measures of any good single cylinder bike.
30.000 kilometers is not very small mileage for a bike. Have anything negatively impressed you when you've inspected the wear in engine?
Everything that we've inspected and measured was fine or typical for this mileage.
No more than that.
What about if to compare this engine to any other of the same type of different japaneese or italian brands?
Are there much of a difference in wear over the same mileage or in the process of teardown and servicing?
everything is typical. Some minor differences in engine construction but nothing very new. As well as nothing bad.
Good quality of all parts. Everything is accessible and good wearproof of different parts. Especially cylinder block.
Could you tell us more about the engine teardown? Which parts had wear and which parts had to be replaced?
And should those parts have been replaced at this mileage? And should we have disassembled it in overall or could this bike survive two more seasons at least?
From what I've found - camshaft chain had to be replaced which is very typical for such bikes because the chain is thin and small.
Another thing is rocker arm. Arms are used to forward kinetic force from camshaft to valves and the bearing that touch camshaft were almost dead.
Those bearings are non-removable and we've decided to replace both rocker arms.
Concerning cylinder block - we've found that there were almost no wear, no friction damage and no mechanical problems.
engine geometry is good and coaxial. Oil supply is perfect.
But we still replaced those parts just because we had them and because we already opened our engine. It was better to replace.
So, at 30.000 cylinder kit was totally good?
it was
But other parts like camshaft chain was definitely dead - this is one
Second is rocker arms.
Third - cylinder block was replaced just because the engine was opened.
So, two mandatory replacements and one non-mandatory?
Yes.
Cylinder head was inspected as well. We've found that valve oil seals are at good conditions, have no leakage and no signs of scorching on valves.
No valve free play and no any other valve wear... Everything was fine.
when you disassembled engine there was nothing strange?
No. I didn't like that sometimes I had to apply some excessive force
To remove it?
to open the engine. Sometimes I had to use heatgun, sometimes I had to use additional tools. But as I've already said - my mark is four out of five.
If we would have all the necessary special tools to work with this engine
by the way we already made one special tool to remove magneto because it also had specific left-hand thread
and if we would keep those tools in a box - it would be much easier to work with this engine next time
One more question that interests me and other people - I've heard that there are KTM logos on engine parts in this bike because some parts are directly deposited from KTM
or at least manufactured on the same factory. Have you seen KTM logos inside?
Yes, I've seen it.
I've seen it on covers, Not on the parts itself. This engine definitely from KTM family or reminds about it.
Yes, you are familiar with KTM engines cause you service dirtbikes
Yep, the most of the difference is in cylinder head. It is less advanced here.
Ok. Than this bike can be called KTM's younger brother?
Yes. To some extent.
hank you Vova for servicing this bike. It was a pleasure to work with you.
I am sure that we would cooperate in future, Thank you!
sunscribe to our channel and thank you
PS from bike owner
As the very last summary of this bike engine teardown - this is Bajaj Pulsar 200NS - with total mileage of 30.000, year 2013, and 24.000 of which I made on this bike for the last one and a half seasons:
About the engine removal - everything went fine and easy, Our mechanic even told us that this engine can be easily replaced in the field.
There were no problems whatsoever removing it. He has also added that the whole frame construction received his high score because everything is well placed together especially if to compare with some chineese bikes, and looks good if not similar to most of more advanced european or japaneese brands.
About the engine itself: After we have disassembled and inspected it there were some negative points: camshaft chain was not feeling well on this mileage
it had some free play and we had to replace it. you have to watch after it. And we also didn't like rocker arms. Their bearing that touch camshaft were almost dead.
At the same time rocker shafts were ok and the wear was typical for this mileage.
Positive points are numerous: there were no wear whatsoever on cylinder block parts. We have measured cylinder itself, inspected piston and rings - no wear, no mechanical damage, no scratches.
Even honing layer looks perfect.
I've actually wouldn't replace those parts but I had new parts from our Motomania company - our local Bajaj representative in Ukraine - so I've decided to replace it.
I was using this set of drive chain and sprockets for the last 24.000 kilometers and it was time to replace it as well. I would like to say that such mileage is significant and many people tend not to believe it but if you treat it right - it would run this long.
And the last part is the tires which are completely flat by now. I've replaced front with hundred twenty by seventy tyre and back with hundred fifty by seventy. Stock back was hundred thirty by seventy. I had doubts that it would fit, and it actually didn't. I would have to change back to 130
That's all. All other parts were inspected carefully and had no significant wear. Cylinder head was fine, nothing strange there, no scorching. All valves are very good, no leakage and no problems. everything else is ok.
I can tell that this bike has a very good condition at 30.000 kilometers of total mileage. Frame, plastics, suspension and other parts have no problems either.
Therefore, the only two parts to watch after - camshaft chain and rocker arms.
That is all. Thank you very much for watching. I would like to thanks everyone who participated in making this video and inspecting bike:
RSmoto team, Vladimir Baranov and his workshop, and Motomania company which is the official distributor of Bajaj brand in Ukraine.
Thank you everyone. This bike would continue to serve me well and I hope that for a long time.
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