Bajaj Pulsar F250 BS VI Guide

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Service Station Manual - Pulsar F250 & N250 BS VI
Product codes :
➢Pulsar F250 - JR05
➢Pulsar N250 –JR03

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All information contained in this service station manual is based on the latest product information at the time of publication.
BajajAuto 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. The right is reserved to make such changes at any time without prior notice.
Doc. No . :71120182 Rev. No . : 00 Nov’21

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Sr
No
Rev No Date (MM/YY) Reason for change
100 Nov / 2021
Developed for new models
Revision Matrix

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Sr No
Parameter
1
Workshop Safety
2
General Information
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Customer Information
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Technical Information
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I Read…….. I Learn
•Vehicle Identification
•Speedometer Information/ABS System
•Control switches / Ignition switch /Headlight
Information
•Preventive Maintenance Chart
•PDI Checklist
Index
Sr No
Parameter
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Engine Section
•Torque Value & Service Limit
•Special Tools
•Important SOP
•Engine Oil Flow path
•Part Identification
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Frame Section
•Torque Value & Service Limit
•Special Tools
•Hose/Cable Routing
•Important SOP
•Part Identification
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Electrical Section
•Important SOP
•Part Identification
•Wiring Harness Routing
•Circuit Diagrams
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Supplementary Service Station Manual
–Pulsar N250

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Workshop Safety

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• 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.
Precautions to be taken while handling Fire Extinguisher
-Install ‘ISI’ approved Fire extinguishers – CO2gas cylinders.
- Refill CO2before the gas expires.
- Install CO2gas cylinder at appropriate place so that there is
no obstruction / good accessibility.

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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. It regulates the outlet pressure to
@6.5 Kg/cm² . This avoids the risk of personal injury.
• 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.
• Never look into the air outlet of a pneumatic tool.
• Never blow-clean brake or clutch parts. This could put
asbestos dust particles into the air which are harmful to inhale.
(These particles are cancerous - can lead to Cancer).

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• 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.
• Waste Oil Disposal
- Sell used oil to Government approved re-cycle agencies.
- Collect used oil in oil disposer / barrel.
-Don’t throw oil into sewage line.
-Don’t spill oil on the floor.

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• 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.
• Safety Tips
- Do not lower the lifter bay table without unlocking the
mechanical lift lock.
- Do not keep your leg between the top and bottom frame while
lowering the lifter bay.
- Do not work with loose clothing while working on the lifter bay.
- Do not keep hydraulic joints loose.
-Do not stand on the lifter bay’s top, when it is being operated.
- Special care is to be adopted to avoid injuries if either leg or
hand is entangled between.
- Keep off direct fire near the power pack.
- Avoid oil spillage around the working area for safety reasons.
• Electrical Wiring
- Carry out periodic checks & repairs
- Electrical board & Main Switch must be located such that
they are easily accessible.

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General information

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Battery Ground
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.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from
possible sharp edges on the parts.
-ve Terminal
+ve Terminal

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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.

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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
Reuse of worn or damaged parts may lead to serious accident.
Visually inspect removed parts for corrosion, discoloration, or
other damage. Refer to the appropriate sections of this manual
for service limits on individual parts. Replace the parts if any
damage has been found or if the part is beyond its service limit.
Visual Inspection of Parts

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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.

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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. Conversely when loosening the bolts, nuts or
screws, first loosen all of them by about a quarter turn and
then remove them.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to
serious damage. Tighten fasteners to the specified torque using
a good quality torque wrench.

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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. Remove old
gaskets and clean the sealing surfaces thoroughly so that no
gasket material or other material remains. Install the new
gaskets and replace the used O-rings when re-assembling.

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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.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing
to prevent deformation.

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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. Replace with new ones whenever
removed. Press bearings with the manufacturer
and size marks facing out. Press the bearing into place by
putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the
inner and outer
race and result in bearing damage.
Press inner race - when bearing is to be fitted on shaft.
Press outer race - when bearing is to be fitted in the bore.

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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.
Lubrication
It is most important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation.Apply the
specific oil or grease as specified.

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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. Read the manufacturer's instructions thoroughly
before using the meter. Incorrect values may lead to improper
adjustments.