Bajaj pulsar F250 2022 Service Station Manual
  1. Manuals
  2. Brands
  3. Bajaj Manuals
  4. Motorcycle
  5. pulsar F250 2022
  6. Service station manual

Bajaj pulsar F250 2022 Service Station Manual

Hide thumbs

Advertisement

Table of Contents

Service Station Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the pulsar F250 2022 and is the answer not in the manual?

Questions and answers

Related Manuals for Bajaj pulsar F250 2022

Summary of Contents for Bajaj pulsar F250 2022

  • Page 1 Service Station Manual...
  • 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 Sr. No Rev No Date Reason for change April 2022 Developed for new models Addition of Supplementary Service Station Manual-Pulsar 250 MAY 2022 Twin Channel ABS. Addition of Supplementary Service Station Manual-Pulsar N160 Single JUNE 2022 Channel ABS. Addition of Supplementary Service Station Manual-Pulsar N160 Twin JULY 2022 Channel ABS.

  • Page 4: Table Of Contents

    INDEX INDEX 1. Workshop Safety......................1 2 General Information..................... 4 3. Customer Information....................11 4. Technical Information....................16 5. I Read…….. I Learn....................18 Vehicle Identification.................. 19 Speedometer Information/ABS System............. 20 Control switches / Ignition switch /Headlight Information......29 Preventive Maintenance Chart..............32 PDI Checklist....................
  • Page 5 INDEX INDEX 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..................
  • Page 6 INDEX INDEX 12. Supplementary Service Station Manual-Pulsar N160 Twin Channel ABS..Specifications Information..................Revised Technical Specifications................Preventive Maintenance Chart................PDI check sheet..................... Part Identification....................Torque value & Service Limit................. Cable / Hose Routing..................... Wiring Harness Routing..................Electric Circuit Diagrams..................Service Support - M/C Service Station Manual...

  • Page 7: Workshop Safety

    Workshop Safety • Workshop Safety • General Information • Information For Customer • Technical Specifications...
  • Page 8 WORKSHOP SAFETY • 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 9 WORKSHOP SAFETY • Never use the blow gun to blow dust off your clothes and never point it at anyone. The air pressure can drive dust particles at high speed. These particles can penetrate the flesh or eyes. High pressure air hitting on open wound can force air into the blood stream. This can result in death. •...

  • Page 10: General Information

    GENERAL INFORMATION 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 11 Replace the parts if any damage has been found or if the part is beyond its service limit. 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.
  • Page 12 GENERAL INFORMATION 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 13 GENERAL INFORMATION 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 14 GENERAL INFORMATION 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 15 GENERAL INFORMATION 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 16 INFORMATION FOR CUSTOMER GENERAL INFORMATION 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. •...

  • Page 17: Customer Information

    INFORMATION FOR CUSTOMER What to Check Check for Fuel Enough fuel for the planned distance of operation, no leaks in the fuel lines. Oil Level Oil level between upper and lower marks in vehicle upright on a level surface position 1.
  • Page 18 INFORMATION FOR CUSTOMER Fuel Saving Tips A well-maintained vehicle and good driving can contribute a lot to the saving of petrol. Following are a few simple fuel saving tips. • Avoid harsh braking. • Change the gear judiciously according to the speed requirement. •...
  • Page 19 INFORMATION FOR CUSTOMER 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 20 • 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 21 • Always insist on Bajaj Genuine Spare Parts in case of replacement. • Always insist on Bajaj Genuine Oil for optimum engine performance & warranty benefits. • Do not repair front fork inner pipe for bend removal & rear suspension for oil leakages in local workshop.

  • Page 22: Technical Information

    Tyre Pressure Rear (Solo) 2 Kgf/cm² (28 PSI) Rear (Pillion) 2.25 Kgf/cm² (32 PSI) Fuel Tank Capacity Full 14 Litres Fork oil Grade Bajaj Genuine, SAE 10W20 Fork oil Quantity / leg 342 ml Service Support - M/C Service Station Manual...
  • Page 23 TECHNICAL SPECIFICATIONS Specification Pulsar F250 / N250 Parameter 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 24: I Read

    I Read ………. I Learn ……. • Vehicle Identification • Speedometer Information • Antilock Braking System (ABS) • Control Switches / Ignition Switch / Headlight /side Stand Information • Preventive Maintenance Chart • PDI Check Sheet • Skill Tips / Notes At Pdi Stage...

  • Page 25: Vehicle Identification

    VEHICLE IDENTIFICATION 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-Numeric - 11 Digits)

  • Page 26: Speedometer Information/Abs System

    SPEEDOMETER INFORMATION 14/15 Speedometer display will work when Ignition switch is in 'ON' position. 1. Tachometer Dial: It shows engine speed in RPM. 2. High Engine Oil Temp. Indicator ( ): It glows when engine Oil Temperature is more than 18 c. 3.
  • Page 27 SPEEDOMETER INFORMATION 14/15 17. Service Reminder ( ): 'Wrench' symbol glows when ODO following meter reading reaches to set Kms. It indicates vehicle is due for periodic service. This Icon will flash at 1st : 450 km -2nd : 4450 km, 3rd : 9450 km, 4th : 14450 km and subsequently at each 5000 kms.
  • Page 28 SPEEDOMETER INFORMATION Details - IFE & ODO Condition Ignition switch is ON & Set push button not pressed. Following display will be shown by digital speedometer. 1. IFE (Instantaneous Fuel economy): This will indicate 3. Fuel Level Indicator: Fuel level is shown by digital fuel economy in km/L.
  • Page 29 SPEEDOMETER INFORMATION DTE / TRIP DTE (Distance to empty): It indicates the estimated distance that the vehicle can travel under current fuel economy & fuel level condition. DTE calculation is independent of TRIP and based on AFE for distance covered for last 25 Kms.
  • Page 30 SPEEDOMETER INFORMATION Speedometer Setting / USB Charger Press mode & set ‘:’ stops blinking button together for Digits HH starts blinking. more than 3 sec. Charger Cap Press set button for HH value will be stored HH value will be stored 1 sec.
  • Page 31 SPEEDOMETER INFORMATION Service Reminder Reset : Note : 1. To reset the service reminder icon, vehicle speed & engine rpm should be zero. 2. Service reminder reset can be done in all modes ODO / TRIP 1 / TRIP 2. Step Result Press ‘MODE’...
  • Page 32 SPEEDOMETER INFORMATION 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 33 SPEEDOMETER INFORMATION Below information is for information only. Volume Fuel bar indication Warning Full 3.06 Litres Fuel icon in speedometer blinks 2.3 – 2.5 Litres Last bar blinking Fuel icon speedometer blinks fast Gear Indicator Icon : • Number of gears: 5 and Neutral •...
  • Page 34 ANTILOCK BRAKING SYSTEM (ABS) • Single Channel ABS System is fitted in these vehicles This means ABS is fitted on Front wheel Only. • Always maintain a safe distance between you and objects ahead. Vehicle speeds should always be reduced during extreme road conditions.

  • Page 35: Control Switches / Ignition Switch /Headlight Information

    CONTROL SWITCHES / IGNITION SWITCH / HEADLIGHT /SIDE STAND INFORMATION Control switch LH ‘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 Beam : Low beam B.
  • Page 36 CONTROL SWITCHES / IGNITION SWITCH / HEADLIGHT /SIDE STAND INFORMATION Condition 2 : Ignition ON, Kill switch ON, Engine ON Headlight Switch Effect on pressing Headlight Position Lamp Position Pass switch Low beam Low beam High beam High beam, High beam High beam No change Headlight...
  • Page 37 CONTROL SWITCHES / IGNITION SWITCH / HEADLIGHT /SIDE STAND INFORMATION Cranking ON & OFF Control “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.

  • Page 38: Preventive Maintenance Chart

    PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 39 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 40 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 41 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 42 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 43 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART PM SOP for added Point Recommended frequency -- Service interval & Kms 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th11th 12th13th14th15th 16th Activities / Check points 74.5 ~ Remarks 75 K Drain hole no blockage verification C,CL below starter motor Insert small size screwdriver as shown from RH side (below starter motor) Screwdriver can be seen from LH side as shown...
  • Page 44 PREVENTIVE MAINTENANCE CHART 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 Why Preventive Maintenance 1.
  • Page 45 PREVENTIVE MAINTENANCE CHART b. Customer side – • Display periodic parts replacement chart in customer interaction explaining adverse effects, if not done. 6. Preventive Maintenance effectiveness - Indicators to be monitor by WM at service station? a. Reduction in repeat complaint. b.

  • Page 46: Pdi Checklist

    PDI CHECK SHEET 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...
  • Page 47 PDI CHECK SHEET Recommendation / Workshop Tools , equipment Check Point What to check How to check Reference Observation & consumables required 1.Front & rear axle 8 to 10 Kgf-m Using dial torque Engine foundation - wrench Front bottom : 4 to 4.2 Kgf-m Dial torque Fasteners Torque 2.Engine foundation...
  • Page 48 SKILL TIPS / NOTES AT PDI STAGE Battery –ve terminal fitment. (For more details, Refer Battery replacement SOP) Battery terminal fitment Bracket latch seat removal Nut fitment direction 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.

This manual is also suitable for:

Pulsar n250 2022

Table of Contents

Save PDF