Bajaj Pulsar 200NS is powered by a liquid cooled 200cc 4 valve engine producing 23ps of power at fairly higher RPMs. The engine is very similar to KTM Duke 200 apart from that fact that Bajaj DTS-i engine comes with extra 2 spark plugs and SOHC, compare to Duke, which is more refined and advance engine with DOHC.
Being SOHC, one common problem what we see riders with 200NS are facing is the tappet issue. Which, if not checked and rectified properly, may lead to valve damage and thus engine seizure.
What is Tappet / Valve Clearance ?
The engine comes with four valves. Two inlet and two exhaust. The inlet valves allow air and fuel mixture from carburetor to come into the engine combustion chamber and after the combustion, the exhaust valves allow the burnt gases to go out via the exhaust.
There is a specified gap, as you may see in the above illustration, which may needs to be adjusted over time, since the tension of the springs may increase of decrease. This happens with every engine but with Bajaj 200NS, due to too much power, single over head cam (SOHC) and quality issue, clearance may need to be checked often.
What happens with wrong settings ?
Over time of usage, due to wear and tear, the valve sprint may lose tension or the rocker arm may lose its edge, hence allowing the gap to unsettle. If the value drops below specified limit, you may find starting trouble in cold weather, but usually the gap increases, and when it does, you would face host of issues.
- Vibration from engine.
- Noise from engine..
- Power loss in high RPM
- Effects in fuel economy as the bike starts to give low mileage
With time, it would effect the valve and may cause valve damage and lead to engine seize !!
How often you may need to look into the issue ?
As per the service schedule, which you may find in your service book, it is recommended to check and adjust the tappet settings / valve clearance in every service.
We agree here, although in bikes like Yamaha FZ16 / Fazer, or Yamaha R15, one may hardly need to adjust, but in case of this bike with such high power output, its really necessary to look into this work at every single service, that’s every 5000kms.
How do one adjust the valve / tappet clearance ?
It’s always better to head down to a service center and ask for the work, but we advice you stand there with your bike and make sure they do it right. You may get it done from any experience mechanic also, but do supervise the process via this below guide on how to adjust the valve / tappet clearance of the engine.
Point’s to Remember
Always make sure, the engine is dead code. Since metal expands in heat, so if one carries out the process of adjusting in warm or hot engine, the setup values wont be correct, so make sure there is at-least a 2 hour rest given to the engine to cool down before the work is done in the valve clearance adjustment.
Valve / Tappet Clearance values
Following are the values for Valve clearance / Tappet Adjustment for Bajaj Pulsar 200NS
Intake -> 0.05 mm
Exhaust -> 0.08 mm
Removing the Fuel Tank and Cover
It’s not easy to access the tappet as in case of Pulsar 200 NS. Since to get to the engine head cover, first one has to remove the fuel tank plastic cover and then the fuel tank itself. There are many screws, so remove them one by one from every side.
The Air Filter Box
Next step would be removing the air filter and air filter housing cover.
Once the Air Filter housing cover is removed, one can now access the Engine Head Cover for the valve clearance or tappet adjustment.
Opening of the Cylinder (Engine) Head Cover
Four Screw of the cylinder head cover can be removed every easily to expose the head to access the valve / tappet clearance settings.
The head cover comes with a rubber gasket so be careful on not to damage it when pulling the cover out. If the gasket (seal) is torn or damaged, you may need to replace it. (Costs Rs. 55/-)
Adjusting the TDC
It’s once again an area where we are disappointed with Bajaj design, as the design of the bike makes it hard to follow the instructions as laid by the Bajaj technical documents. First let’s read what the repair manual has to say on adjusting the TDC for Bajaj Pulsar 200NS Engine,
Problem is, the cam sprocket stays hidden behind the frame (check the below image for reference) of the bike when viewed from the right hand side to check for TDC alignment. One has to snick from different angles and gaps to align the TDC before proceeding with the valve adjustment.
But you can’t help it since this step is very important as without proper TDC alignment, if you proceed with the valve adjustment, it may cause series damage to the engine hence be careful and make sure it is done properly, as said above.
Valve Clearance / Tappet Adjustment
Once the TDC is properly aligned, next and final step is the valve / tappet adjustment. By using a good / accurate filler gauge, adjust both the intake and exhaust valve clearance to the specified values.
When the valve adjustment is done, try to adjust both the valves at once. By both, we mean both intake and then separately both exhaust. Intake is 0.05 mm and Exhaust is 0.08 mm.
Once done, put everything carefully back together !!
Compare to other bikes, design wise the work is bit of an hassel in case of Bajaj. Irony is, other bikes may continue to clock more kms without the need of the work but with Bajaj, we felt in our long term riding experience, it is a must do work in every service (every 5000 kms). Depending on your location, it may cost your between Rs. 100 to Rs. 150 and the work can be done at Bajaj service station or from your trusted and experienced local mechanic. Don’t hesitate to invest this time and money, which will make sure long term benefit with a trouble free ride.
Let us know if you guys have any doubt or question by dropping us a comment.