Related Manuals for Bajaj Pulsar F250 BS VI
Summary of Contents for Bajaj Pulsar F250 BS VI
- Page 1 Service Station Manual - Pulsar F250 & N250 BS VI Product codes : ➢ Pulsar F250 - JR05 ➢ Pulsar N250 – JR03...
- Page 2 All information contained in this service station manual is based on the latest product information at the 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 possible. All procedures and specifications subject to change without prior notice.
- Page 3 Revision Matrix Rev No Date (MM/YY) Reason for change Nov / 2021 Developed for new models...
- Page 4 Index Sr No Parameter Sr No Parameter Engine Section Workshop Safety • Torque Value & Service Limit • Special Tools • Important SOP • Engine Oil Flow path General Information • Part Identification Frame Section Customer Information • Torque Value & Service Limit •...
- Page 5 Workshop Safety...
- Page 6 • Technicians must put on shoes & dressing should not be very loose. • Technicians must use Personnel Protective Equipment (PPE) like – - Hand Gloves - Mask - Safety Goggle - Ear Plug • Wear Nitrile Rubber Hand Gloves while handling petrochemicals like petrol, Oil, Kerosene etc.
- Page 7 Safety Precautions while Operating Air Tools Air tools operate on compressed air supplied by the shop air system (Compressor & Air supply system). Observe the following safety related precautions when using an air tool. • It is advisable to fit a pressure regulator (FRL:- Filter Regulator Lubricator) in the pneumatic line which supplies air pressure to the air tool.
- Page 8 • Hand Tools - Do not use worn out hand tools. • Calibration of Workshop Equipment - Calibrate all Workshop and M & T Equipment once in a year. • Avoid direct body contact with Petrol, Kerosene. Caution : Prolonged contact of used oil may cause cancer. •...
- Page 9 • Precautions to be taken while handling Hydro-Electric Lift - While raising / lowering the lifter bay ensure that vehicle is firmly hold on the lifter bay to avoid accident. - After raising the lifter bay, lock the lift. - Don’t put leg/hand in between while raising / lowering the lifter Bay.
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Page 10: General Information
General information... - Page 11 Battery Ground +ve Terminal -ve Terminal Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (-) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (-) cable to the negative terminal.
- Page 12 Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. Arrangement and Cleaning of Removed Parts Use engine parts handling trays for storage of engine parts.
- Page 13 Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before reassembly. Inspection Visual Inspection of Parts Reuse of worn or damaged parts may lead to serious accident.
- Page 14 Replacement Parts Replacement parts must be BAJAJ genuine or recommended by BAJAJ. Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter pins must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
- Page 15 Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction.
- Page 16 Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non-permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance.
- Page 17 Liquid Gasket, Non-permanent Locking Agent For applications that require liquid gasket or a non-permanent locking agent, clean the surfaces so that so oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
- Page 18 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 alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
- Page 19 Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing the seal.
- Page 20 Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from clutch cover side). Instrument Use a meter that has enough accuracy for an accurate measurement.
- Page 21 General Precautions : • To avoid damage to head of fasteners do not use over size or worn-out tools. • To avoid damage to painted parts, prevent spillage of battery acid & brake fluid. • To avoid damage of machined face & color of the components store the parts in a clean plastic bin having compartments to avoid components touching to each other.
- Page 22 Information for Customer...
- Page 23 Safe Riding Tips • Always wear ISI mark helmets while driving or riding. • Read thoroughly the instructions in this manual and follow them carefully. • Avoid unnecessary accessories for the safety of both rider and other motorists. • Get familiar and follow traffic rules and regulations in your states as well as general traffic signs.
- Page 24 Daily Safety Checks Before riding the motorcycle be sure to check the following items. If any irregularities are found during these checks, refer to the Maintenance chapter and see your dealer for the action required to return the motorcycle to a safe operating condition.
- Page 25 What to Check Check for 1. Proper slack (20 ~ 30 mm) Drive chain 2. Adequate lubrication. Lighting Operation of all lights. Horn Correct functions. 1. Smoothness. Steering 2. No restriction of movement. 3. Loose or Tight. 1. Correct lever play. (2 to 3 mm). Clutch 2.
- Page 26 Running In Proper running-in is important for the better life and trouble-free performance of the vehicle. • During first 2000 kms running-in period do not exceed 0 – following speed limits. 1000 • Always keep the speed below the limits mentioned in the table.
- Page 27 Information on Bike handling : “Cranking ON and OFF duration” control: • During Engine crank cycle cranking is allowed only for fixed duration and in between successive cranks (in case engine does not start) here is a cooling off period. Cranking ON-OFF duration control feature to avoid battery discharge- - 1st Crank ON (5 sec) &...
- Page 28 Non - Use Maintenance Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from such other non-operational damages like fire hazards.
- Page 29 Costumer Awareness Points : Customer awareness to be developed on following points for trouble free performance of vehicle : 1) Regular Checks : • Always ensure tyres are inflated to specified air pressure. • Keep vehicle clean regularly. • Ensure engine oil level between MAX. - MIN. mark. •...
- Page 30 • Disconnect battery terminals, if vehicle is not being used for long time (more than 2 weeks) • To take help of BAJAJ authorized workshop, bring vehicle to the workshop for repair if coolant leakage is noticed through coolant system & “ABS” icon gets ON continuously.
- Page 31 • Follow periodic service schedule strictly for optimum engine & vehicle performance. • Carry out any service/repairs at Bajaj authorized service centers only for quality service & genuine parts. • Always insist on Bajaj Genuine Spare Parts in case of replacement.
- Page 32 4) Accessories : • Do not fit extra electrical accessories, otherwise wiring would get short & battery would get discharged. Few e.g. – - Remote / central locking system. - Extra & bigger size horns. - Musical brake light. - Buzzer. - Higher wattage Headlamp bulb - Flasher operating all 4 side indicators simultaneously •...
- Page 33 5) BAL warranty policy - (Fuel adulteration / local accessories fitment & vehicle maintenance as per PM schedule) : For detailed warranty policy, refer the Owner’s Manual.
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Page 34: Technical Specifications
Technical Specifications... - Page 35 Wet Sump Forced Lubrication Transmission 5 Speed, Constant mesh Gear shifting pattern 1 Down, 4 Up BAJAJ DTSi 10000 BS6 Compliant Grade- Engine oil Grade SAE 20W50 JASO MA2 API SN Engine oil Drain & Refill quantity 1300 ml Overhaul quantity...
- Page 36 1.75 Kgf/cm² (25 PSI) Tyre Pressure Rear (Solo) 2 Kgf/cm² (28 PSI) Rear (Pillion) 2.25 Kgf/cm² (32 PSI) Fuel Tank Capacity Full 14 Litres, No Reserve Fork oil Grade Bajaj Genuine, SAE 10W20 Fork oil Quantity / leg 342 ml...
- Page 37 Frame Specification Parameter Pulsar F250 / N250 Length 1989 mm Width 743 mm 1143 mm – F250 Height 1050 mm – N250 Wheelbase 1351 mm Ground Clearance 165 mm 164 Kg – F250 Vehicle Kerb Weight 162 Kg – N250 314 Kg –...
- Page 38 Electrical Specification Parameters Pulsar F250 / N250 System 12V DC Battery 12V 8Ah VRLA Head Lamp LED, Integrated in headlamp – F250 Position Lamp LED, Separate – N250 Tail / Stop Lamp Side Indicator Lamp Neutral Indicator Hi Beam Indicator Turn Signal Indicator Speedometer back light Fuel Level Indicator...
- Page 39 I Read ………. I Learn …….
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Page 40: Vehicle Identification
Vehicle Identification... - Page 41 The Frame and Engine serial numbers are used to register the motorcycle. 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) Engine Number Location On LH Side Crankcase Near oil cooler pipe fitment (Alpha-...
- Page 42 Speedometer Information / ABS System...
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Page 43: Speedometer Details
Speedometer Details... - Page 44 Speedometer Details...
- Page 45 Speedometer Details...
- Page 46 Speedometer Details Details – IFE & ODO...
- Page 47 Speedometer Details Details – AFE 1 , TRIP 1 / AFE 2, TRIP 2...
- Page 48 Speedometer Details DTE / TRIP...
- Page 49 Speedometer Details Speedometer Setting...
- Page 50 Speedometer Details Speedometer Setting / USB Charger...
- Page 51 Speedometer Details Service Reminder Reset :- Example - ●If you are resetting @ more than 9450 kms & less Note :- than14000 kms, next service schedule shall display as 1. To reset the service reminder icon, vehicle speed & 14450 km. engine rpm should be zero.
- Page 52 Speedometer Details Power ON Cycle (Time Duration: 5.5 sec) • All LCD segments, icons & fuel gauge bars should be turned ON: Time – Complete power on cycle. • Tachometer pointer indication should increase from 0 to 12,000 & return back to 0 within 5.5 sec. •...
- Page 53 Speedometer Details Fuel Level indication: • Type : Variable resistance TFR type with Digital bar graph indication. • Number of bars/segments for indication: 8 bars. • Indication: Letters 'E' at lower end indicate the Tank empty & 'F' at upper end indicates Tank full conditions. Below information is for information only.
- Page 54 Speedometer Details Condition 1 : Ignition ON, Kill switch OFF : • DRL / Position lamp ON • Tail lamp ON • Control switches illumination • Speedometer illumination • Low Battery icon, engine oil pressure icon, engine temperature icon, MIL & ABS displayed in speedometer •...
- Page 55 Control switches / Ignition switch / Headlight /Side stand information...
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Page 56: Control Switch Lh
Control switch LH... -
Page 57: Control Switch Rh
Control switch RH... - Page 58 Headlight Condition 1 : Ignition ON, Kill switch ON/OFF, Engine OFF Headlight Switch Effect on pressing Headlight Position Pass switch Low beam High beam High beam, High beam No change Condition 2 : Ignition ON, Kill switch ON , Engine Headlight Switch Effect on pressing Headlight...
- Page 59 Headlight...
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Page 60: Side Stand
Side Stand Side stand Indication in Side stand condition Gear position Remark speedometer Vehicle gets started after Neutral pressing self start button Down Gear is applied in vehicle start condition by Vehicle gets OFF pressing clutch lever Self starter is disabled, Down Gear vehicle will not start... - Page 61 Steering cum Ignition switch...
- Page 62 Cranking ON & OFF Control...
- Page 63 Fuel Tank Cap...
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Page 64: Preventive Maintenance Chart
Preventive Maintenance Chart... - Page 65 √ √ √ √ √ Servicing with water wash tank, Silencer & electrical parts. Use caustic free detergent for washing. Use BGO 20W50 BS6 compliant. Engine oil (Bajaj DTSI 10000 Top- Top- Top- Top- Top- Top- Top- Top- Oil level window cleaning at every 10000 oil) kms by petrol spray &...
- Page 66 PM Schedule Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5 69.5 74.5 points 4.5 ~...
- Page 67 PM Schedule Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check points 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5 69.5 74.5 ~ ~ 10...
- Page 68 PM Schedule Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check points 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5 69.5 74.5 ~ ~ 10...
- Page 69 PM Schedule Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check points 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5 69.5 74.5 ~ ~ 10...
- Page 70 PM SOP for added point Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check points 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5...
- Page 71 PM SOP for added point Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th Activities / Check points 14.5 19.5 24.5 29.5 34.5 39.5 44.5 49.5 54.5 59.5 64.5...
- Page 72 Note about engine oil level : AT MAX OIL LEVEL – OIL LEVEL SHOULD BE JUST BELOW THE TOP WINDOW QADRENET POINT AS MARKED … Only lower position of the marking shall be present in the cover Clutch...
- Page 73 Why Preventive Maintenance 1. What is Preventive Maintenance ? Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to upkeep health of product through out it's life. 2.
- Page 74 Why Preventive Maintenance 5. How to promote compliance to PM schedule ? a. Workshop side – 1. Ensure adherence to S.O.P. while carrying out repairs through stage wise, service wise check sheet deployment. 2. Monitor effectiveness of technicians through final inspection. 3.
- Page 75 Importance of PM schedule Execution Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to upkeep health of product through out it's life. PM Activity Benefits Engine oil replacement / top up. Better lubrication of engine components.
- Page 76 PDI Check sheet...
- Page 77 PDI Check sheet Dealer's Name Dealer's code: Model City Frame No. Date of PDI Engine No. PDI done by 1. Check Points before starting the vehicle Tools , Recommendation / Workshop equipment & Check Point What to check How to check Reference Observation consumables...
- Page 78 Tools , Recommendation / Workshop equipment & Check Point What to check How to check Reference Observation consumables required Smooth operation of Insert vehicle key in lock & Steering cum Ignition lock, Lock Operation By using vehicle key. check operation of Seat lock, Petrol Tank cap respective lock.
- Page 79 Tools , Workshop equipment & Check Point What to check How to check Recommendation / Reference Observation consumables required Free play of Clutch lever & Use free play Free play Clutch Lever / Throttle Free play 2- 3 mm Throttle. gauge.
- Page 80 Tools , Workshop equipment & Check Point What to check How to check Recommendation / Reference Observation consumables required 2. Check Points during / after starting the vehicle RH & LH control switch, Check for smooth Switch Operation ignition switch, clutch switch operation &...
- Page 81 Tools , Recommendation / Workshop equipment & Check Point What to check How to check Reference Observation consumables required 3. Check Points during Test Ride Gear shifting Smooth operation A.P.Grease,Fe In case of any issue during Throttle response, Brakes eler Driveability test ride, vehicle to be effectiveness- Front &...
- Page 82 Note : Mirror fitment for Pulsar F250 during PDI : • Apply limaplex(HTX 3) grease(Refer spare parts catalogue for part number) as shown in photograph before mirror fitment on vehicle. For Mirror fitment SOP, refer “Headlamp / Speedometer / Harness speedometer / Flap speedometer / Structure speedometer / Windshield / Fairing structure Replacement”...
- Page 83 Clutch cable routing while leg guard fitment Route the clutch cable as shown in photograph. Clutch is to be routed above leg guard.