Bike Engine Overhaul in Pakistan – Cost, Process & Maintenance Guide 2025

A bike engine overhaul in Pakistan is the process of restoring a worn motorcycle engine to good working condition by repairing or replacing internal parts. For popular commuter bikes such as Honda CD70, CG125, Yamaha YBR125, and Suzuki GS150, an overhaul typically includes piston and ring replacement, cylinder rebore, valve servicing, gasket changes, and oil seals.

Signs Your Bike Needs an Overhaul

Recognizing the early signs of engine wear can save money and prevent breakdowns. Common symptoms include:

• Weak pickup, low compression, or hard starting.
• Blue or white smoke with high oil consumption.
• Knocking or tapping noises from the engine.
• Overheating, excessive vibrations, or metallic flakes in the oil.
• Repeated ring-piston jobs that fail to solve the issue.

Parts Replaced During an Overhaul

A professional bike engine overhaul in Pakistan usually involves replacing or repairing the following components:

• Piston, piston rings, wrist pin, and circlips.
• Cylinder sleeve (rebore or new fitting).
• Timing chain and guides.
• Valve seals and valve seat re-facing.
• Complete gasket set and oil seals.
• Fresh engine oil and filter.
• In some cases, clutch plates or crankshaft bearings.

Using genuine parts ensures longer life and better performance, while aftermarket options reduce cost but vary in quality.

Bike Engine Overhaul Cost in Pakistan (2025)

The cost of a bike engine overhaul in Pakistan depends on the bike model, choice of parts (genuine vs aftermarket), and workshop labor charges.

• Honda CD70: Around Rs 11,000 (genuine piston & sleeve).
• Honda CG125: Around Rs 14,000 for genuine parts; aftermarket ranges between Rs 7,000–15,000.
• Suzuki GS150: Between Rs 18,000–25,000 depending on part quality.
• Timing Chain Kit: Rs 980–1,500.
• Full Overhaul: On average Rs 20,000–40,000+ for most commuter bikes in major cities.

Prices may be higher in Karachi, Lahore, and Islamabad due to higher labor and parts availability.

Step-by-Step Overhaul Process

A complete bike engine overhaul in Pakistan follows these key steps:

1. Diagnosis and compression test.
2. Engine removal and full teardown.
3. Measuring cylinder, piston, and valve wear.
4. Machining (rebore, honing, valve seat cutting).
5. Replacement of piston, rings, timing chain, seals, and gaskets.
6. Reassembly with proper torque settings.
7. Initial testing, leak checks, and tuning.
8. First oil change after 300–500 km.

Break-In and Maintenance After Overhaul

To extend engine life, follow a strict break-in procedure:

• Avoid high RPMs and heavy loads for the first 500–800 km.
• Change engine oil at 300–500 km, then again at 1,000 km.
• Recheck tappets, timing, and chain tension during the first service.
• Clean the air filter regularly and avoid dust intake.

Choosing the Right Workshop

When selecting a mechanic for a bike engine overhaul in Pakistan, keep these points in mind:

• Ask for a written estimate with part details.
• Ensure the mechanic uses genuine parts if you want durability.
• Request to see old parts after replacement.
• Look for workshops that use torque specs and provide short-term service warranties.

Genuine vs Aftermarket Parts

• Genuine parts: Higher cost but better performance, durability, and resale value.
• Aftermarket parts: Cheaper but quality may vary widely. Only buy from trusted shops or suppliers.

Conclusion

A bike engine overhaul in Pakistan is an essential process when your motorcycle shows signs of wear and performance loss. In 2025, overhaul costs range between Rs 20,000–40,000+ depending on the bike model and parts used. Choosing a reliable workshop, opting for genuine parts when possible, and following proper break-in procedures will ensure your engine runs smoothly for years to come.