Bajaj pulsar F250 2022 Service Station Manual Download

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Service Station Manual

Summary of Contents for pulsar F250 2022

Page 1: ...Service Station Manual...

Page 2: ...time of publication Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as po...

Page 3: ...022 Developed for new models 2 01 MAY 2022 Addition of Supplementary Service Station Manual Pulsar 250 Twin Channel ABS 3 02 JUNE 2022 Addition of Supplementary Service Station Manual Pulsar N160 Sing...

Page 4: ...dlight Information 29 Preventive Maintenance Chart 32 PDI Checklist 40 6 Engine 43 Torque Value 44 Service Limit 46 Special Tools 48 Important SOP 52 Engine Oil Flow path 105 Part Identification 110 7...

Page 5: ...rt 357 PDI Check Sheet 357 Revised Torque Values 357 Part Identification 358 ABS Hose Speed Sensor Routing 367 DRL Information 373 Wiring Harness Routing 374 Circuit Diagrams 398 11 Supplementary Serv...

Page 6: ...sar N160 Twin Channel ABS 402 Specifications Information 485 Revised Technical Specifications 485 Preventive Maintenance Chart 485 PDI check sheet 486 Part Identification 487 Torque value Service Limi...

Page 7: ...1 Workshop Safety Workshop Safety General Information Information For Customer Technical Specifications...

Page 8: ...tinguishers CO2 gas cylinders Refill CO2 before the gas expires Install CO2 gas cylinder at appropriate place so that there is no obstruction good accessibility Safety Precautions while Operating Air...

Page 9: ...Collect used oil in oil disposer barrel Don t throw oil into sewage line Don t spill oil on the floor WORKSHOP SAFETY Precautions to be taken while handling Hydro Electric Lift While raising lowering...

Page 10: ...the positive terminal of the battery then the negative cable to the negative terminal ve Terminal ve Terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible s...

Page 11: ...rder In most cases assembly order is the reverse of disassembly however if assembly order is provided in this Service Manual follow the procedures given ReplacementParts Replacement parts must be BAJA...

Page 12: ...crewmayleadtoseriousdamage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or ha...

Page 13: ...gtopreventdeformation Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the contact area Be sure to maintain proper alignmentandusesmoothmoveme...

Page 14: ...portant to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Apply the specific oil or grease as specified Direction of Engine Rotation When rotating the cr...

Page 15: ...lyspreadopencirclipswithtoolduringinstallingtopreventdeformation Alwaysuseappropriatespecialtoolforopening assemblingpartstoavoiddamages To avoid dust muck entry inside the engine wash vehicle thoroug...

Page 16: ...carryvehicleregistrationpapers insuranceandavaliddrivinglicensewithyou MONSOONCARE Fit FinishParts Theappropriatesurfacepreventivecoattobeappliedtoavoidrustingonaccountofadverseatmosphericconditions C...

Page 17: ...ns Steering 1 Smoothness 2 No restriction of movement 3 Loose or Tight Clutch 1 Correct lever play 2 to 3 mm 2 Smooth operation of lever Side Stand Return to their fully up position Tyres 1 Correct pr...

Page 18: ...gON OFFdurationcontrolfeaturetoavoidbatterydischarge 1stCrankON 5sec Disablefor2sec 2ndCrankON 5sec Disablefor2sec 3rdCrankON 5sec Disablefor10sec Afteragapof10seccrankingcyclecontinues Recommended sp...

Page 19: ...plug Setthevehicleonaboxorastandsothatboththewheelsareraisedofftheground Ensurevehiclecleanliness applyantirustoil ParcoLubricantPL101ofM sHankle onfasteners completelycover thevehicle Itismandatoryto...

Page 20: ...re of engine components Donotdrivevehicleaboveitsratedpayload Donotdrivevehiclewithbrakepedal leverpartiallypressed Donotdrivevehiclewithclutchleverhalfpressed Avoidharshbraking donotdrivethevehicleby...

Page 21: ...batterywouldgetdischarged Fewe g Remote centrallockingsystem Extra biggersizehorns Musicalbrakelight Buzzer HigherwattageHeadlampbulb Flasheroperatingall4sideindicatorssimultaneously Donotreplacefusew...

Page 22: ...mesh Gear shifting pattern 1 Down 4 Up Engine oil Grade SAE 20W50 JASO MA2 API SN Engine oil Drain Refill quantity 1300 ml Overhaul quantity 1700 ml Frame Tubular frame Suspension Front Front Telesco...

Page 23: ...r Low Oil Pressure Indicator Malfunction Indicator High Engine oil Temperature Indicator Low Battery Indicator REV Indicator Service Reminder Side Stand Indicator ABS Indicator Rear Number Plate Lamp...

Page 24: ...Vehicle Identification Speedometer Information Antilock Braking System ABS Control Switches Ignition Switch Headlight side Stand Information Preventive Maintenance Chart PDI Check Sheet Skill Tips No...

Page 25: ...cle They are the unique alpha numeric codes to identify your particular vehicle from others of the same model and type Frame Number Location On RH side of steering column Alpha Numeric 17 Digits Engin...

Page 26: ...r toggling between different modes e g ODO Tripl Trip2 DTE and clock setting 10 Set Button Set button used for toggling between ODO to IFE Trip1 to AFE1 Trip2 to AFE2 DTE to distance to next service a...

Page 27: ...blinks incase of low fuel level 1 bar or less 19 Digital Clock It indicates time in HR MM AM PM 20 Speedometer Vehicle speed will be displayed in digital form in Km h 21 Gear Indication It will displ...

Page 28: ...Procedure to set AFE1 TRIP1 Ignition switch is ON Set push button pressed for less than 1 sec TRIP1 mode gets selected following display will be shown by digital speedometer Procedure to set AFE2 TRIP...

Page 29: ...ondition DTE calculation is independent of TRIP and based on AFE for distance covered for last 25 Kms Max count of DTE is 990 Km speedometer will display values in multiple of 10 TRIP Setting If Set b...

Page 30: ...on fuel tank cover The charger socket has been provided with cap to protect charger socket from dust water entry during washing during rain Always ensure charger cap is firmly fitted on socket when c...

Page 31: ...it for 5 sec After 5 sec text will reappear with respective Km reading Example If you are resetting more than 9450 kms less than14000 kms next service schedule shall display as 14450 km If you are res...

Page 32: ...rCondition Rollsovertozero startsrecountingafter9 99 999km TRIP1 TRIP2 Indication 0to999 9Km Maxvaluefordisplay 999 9Km Roll over condition After completion of max value speedometer should continue di...

Page 33: ...ay Gear 1 with GEAR icon blinkingtoindicateshortcircuitcondition Between Neutral andothergearinput Neutralshallbegivenpriority Below information is for information only Volume Fuel bar indication Warn...

Page 34: ...ditions During these conditions the vehicle should be driven at reducedspeeds When you apply Front brake Rear brake by pressing Front brake lever Rear brake pedal under conditions which may lock the w...

Page 35: ...change ON A High Low Beam Switch When headlight is ON High or Low beam can be selected with this switch Hi beam indicator light located on Speedo console will light up when high beam is selected High...

Page 36: ...Headlamp Condensation Condensation inside headlamp is a natural phenomenon Condensation occurs when atmospheric air containing water vapor or humidity enters the headlamp through the vents due to temp...

Page 37: ...ound the cap by soft dry cotton cloth Shut and lock the cap fully This practice needs to be followed to maintain the shine of color on petrol tank Glossy Finish Painted Parts Cleaning Do s Use Colin o...

Page 38: ...petrol spray nylon brush 3 Oil strainer CL CL CL CL CL CL CL CL Oil strainer cleaning at the time of oil change 4 Engine oil filter R R R R R R R R Replace oil filter during every oil change 5 Air cle...

Page 39: ...eeve Tie band inspection C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T C A T Damaged conduit PVC sleeves protection by applying electrical tape film ensure...

Page 40: ...L A CL L A CL L A During 1st free service use OKS spray for chain cleaning without removing chain from vehicle During other services clean chain with Diesel SAE 90 oil ration of 50 50 lubricate by SA...

Page 41: ...C T Torque 3 5 3 8 Kgf m 29 Rear wheel rubber shock dampers for excess play C R C R C R C R C R C R C R Replace rear wheel rubber shock damper if required 30 Clutch Throttle cable free play adjustment...

Page 42: ...Stay Rider Pillion foot rest holder 1 8 to 2 2 Kgf m 37 Mobile USB port C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R Charging OK to be checked at Engine start condition using LED U...

Page 43: ...m LH side as shown in photograph Note Take out gear position sensor harness as shown by Blue color to avoid damage of wire due to screwdriver PM SOP for added Point Sr No Activities Check points Recom...

Page 44: ...b Reducecostofrepairs replacement c Protectassets prolongtheusefullifeofcomponent product 3 Howtoperform Clean Inspect Lubricate Adjust ReplaceasperthePMchart encyclopediaguidelines b Tocorrectdefici...

Page 45: ...components Smooth functioning of engine parts Spark plug cleaning Air filter element replacement Better drive ability consistency in mileage Petroleum jelly application on battery terminals Battery t...

Page 46: ...for air bleeding Lock Operation Smooth operation of Steering cum Ignition lock Seat lock Petrol Tank cap lock By using vehicle key Insert vehicle key in lock check operation of respective lock Battery...

Page 47: ...cked during after test ride Funnel for filling petrol measuring jar Working of all signal indicators icons N Turn signal Side stand High beam oil pressure Engine Temp Low battery MIL ABS Service remin...

Page 48: ...Fairing structure Replacement SOP given in electrical section of Pulsar F250 Service station manual available on E SSM Leg Guard fitment during PDI Washer to be fitted on LH Leg guard bottom mounting...

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Bajaj pulsar F250 2022, Service Station Manual

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