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INDEX

Service Support - M/C

Service Station Manual

9. Supplementary Service Station Manual

-Pulsar N250

......................................... 298

Technical Specifications............................................................................ 301

PDI Check Sheet....................................................................................... 301

Torque Value............................................................................................. 302

Service Limit ............................................................................................. 304

Important SOP .......................................................................................... 306

Part Identification ...................................................................................... 328

Cable / Hose Routing ................................................................................ 338

Wiring Harness Routing ............................................................................ 343

Cable Tie Matrix......................................................................................... 356

10. Supplementary Service Station Manual-Pulsar 250 Twin Channel ABS.............

298

Preventive Maintenance Chart................................................................... 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 Service Station Manual-Pulsar N160 Single Channel ABS.......

402

Technical Specifications .......................................................................... 403

Preventive Maintenance Chart ................................................................ 405

PDI Check Sheet ..................................................................................... 406

Special Tools ........................................................................................... 408

Changes in SOP for Pulsar N160 with respect to Pulsar N250................. 409

Part Identification....................................................................................... 410

Torque value & Service Limit ..................................................................... 455

Engine Oil Flow Path.................................................................................. 461

Cable / Hose Routing................................................................................. 465

Wiring Harness Routing............................................................................. 467

Circuit Diagram.......................................................................................... 480

Electrical Parts Value................................................................................. 483

INDEX

Содержание pulsar F250 2022

Страница 1: ...Service Station Manual...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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