Pulsar f250 2022

Service Station Manual
SPECIFICATION INFORMATION
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. The right is reserved to make such changes at any time without prior notice.
Doc. No . :71120182 Rev. No . : 03 JULY 2022
Service Station Manual Service Support - M/C

REVISION MATRIX
Sr. No Rev No Date Reason for change
1 00 April 2022 Developed for new models
Addition of Supplementary Service Station Manual-Pulsar 250

2 01 MAY 2022
Twin Channel ABS.
Addition of Supplementary Service Station Manual-Pulsar N160 Single

3 02 JUNE 2022
Channel ABS.
Addition of Supplementary Service Station Manual-Pulsar N160 Twin

3 03 JULY 2022
Channel ABS.

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............................................................................................... 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. Frame ........................................................................................................................ 144
Torque Value............................................................................................. 145
Service Limit............................................................................................. 146
Special Tools............................................................................................. 147
Hose/Cable Routing.................................................................................. 150
Important SOP.......................................................................................... 156
Part Identification...................................................................................... 200
8. Electrical ....................................................................................................................235
Important SOP........................................................................................... 236
Checking Procedures................................................................................. 258
Wiring Harness Routing............................................................................. 269
Circuit Diagrams........................................................................................ 281

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......................................................................................... 356
10. Supplementary Service Station Manual-Pulsar 250 Twin Channel ABS............. 298
Preventive Maintenance Chart................................................................... 357
PDI Check Sheet....................................................................................... 357
Revised Torque Values............................................................................. 357
ABS Hose / Speed Sensor Routing........................................................... 367
DRL Information......................................................................................... 373
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
Torque value & Service Limit ..................................................................... 455
Engine Oil Flow Path.................................................................................. 461
Cable / Hose Routing................................................................................. 465
Circuit Diagram.......................................................................................... 480
Electrical Parts Value................................................................................. 483

INDEX
INDEX
12. Supplementary Service Station Manual-Pulsar 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 Limit................................................................................. 492
Cable / Hose Routing............................................................................................. 498
Wiring Harness Routing......................................................................................... 502
Electric Circuit Diagrams........................................................................................ 514

Workshop Safety
• Workshop Safety
• General Information
• Information For Customer
• Technical Specifications
1
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.
Precautions to be taken while handling Fire Extinguisher
- Install ‘ISI’ approved Fire extinguishers – 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 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.
Service Station Manual 2 Service Support - M/C

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.
• 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).
• 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.
• 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.

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.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible
sharp edges on the parts.
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.

GENERAL INFORMATION
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 Visual Inspection of Parts
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.
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.

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. 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.
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.

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.
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.
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.

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.
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.
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.

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.
• To avoid warpage of mating / sealing faces, mounting bolts should be tightened in a crisscross pattern.
• To avoid slippage of threads leading to components damage, do not over torque bolts, nuts or screws.
• Always install new gasket & O rings when reassembling.
• Always apply grease to the lip of seal before installing.
• Always replace circlips / cotter pins & radiator hose clamps with new ones.
• Take care not to excessively spread open circlips with tool during installing to prevent deformation.
• Always use appropriate special tool for opening & assembling parts to avoid damages.
• To avoid dust / muck entry inside the engine wash vehicle thoroughly before executing any repair work related to
engine or otherwise this may lead to early failure of parts.
• Always use lint free cloth while handling engine parts.
• Always apply few oil drops between two moving parts to avoid dry run.
• Always blow high pressure compressed air through oil passage holes in reverse direction of flow of oil & ensure that
the passages are clear.
• Always apply Loctite to bolts, screws or nuts wherever recommended to avoid loosening & subsequent break down.
• Confirm proper seating of circlips by rotating them to avoid it from coming out.
• Do not tap engine components by hammer in order to avoid damage. Engine components are precisely machined.
• Do not fit extra electrical accessories otherwise wiring would get short & battery would get discharged.

INFORMATION
GENERAL INFORMATION
FOR CUSTOMER
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.
• Do not overload your vehicle.
• Familiarize yourself well with starting, acceleration and braking of the vehicle.
• When applying the brakes, use both, the front and rear brakes. Applying only one brake
may cause the vehicle to lose control.
• During monsoon drive the vehicle more cautiously. Remember vehicles skid more easily during light showers.
• Always carry vehicle registration papers, insurance and a valid driving license with you.
MONSOON CARE : Fit & Finish Parts

• The appropriate surface preventive coat to be applied to avoid rusting on account of adverse atmospheric conditions.
• Clean & lubricate all the important parts as detailed in a periodic maintenance chart.
• Do not obstruct engine cooling by adding mud protection sheet from front.
• Vehicle cleaning to be done with soft & clean wet cloth to avoid scratches on painted parts.
• Do not apply direct water jet on painted, electrical / electronic parts.
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.
Failure to perform these checks every day before you ride may result in serious damage or severe accident.

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. Correct free play in the throttle cable (2 to 3 mm)

Throttle
2. Smooth operation and positive return of the throttle grip to the closed position. Steering Lock
Steering Lock Correct operation.
Brakes No dragging.
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. Smooth operation of lever.
Side Stand Return to their fully up position.
1. Correct pressure.
Tyres 2. Adequate tread depth.
3. No cracks or cuts.
Mirrors Correct view position.
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 following speed limits.
• Always keep the speed below the limits mentioned in the table.
• Do not race the engine excessively.
• Do not start moving or race the engine immediately after starting. Run the engine for a minute at idle speed to give the
oil a chance to work up into the engine.
Kms 1 st 2 nd 3 rd 4 th 5 th
0 - 1000 10 20 30 40 50
1000 - 2000 20 30 40 50 60

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.
• Don’t overload the vehicle above the specified payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for more than two minutes.
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) & Disable for 2 sec.
- 2nd Crank ON (5 sec) & Disable for 2 sec.
- 3rd Crank ON (5 sec) & Disable for 10 sec. After a gap of 10 sec cranking cycle continues.
Recommended speeds for down shifting

From 5th to 4th Gear 45 Km / h
From 4th to 3rd Gear 35 Km / h
From 3rd to 2 nd Gear 25 Km / h
From 2nd to 1st Gear 15 Km / h
Warning :
• When shifting down to lower gears, do not shift at such high speed that engine rpm jumps excessively. This may cause
engine damage & rear wheel may skid. Downshifting should be done at recommended speed as shown in table above.
• Always ensure side stand is up while starting. Starter will be disabled if side stand down. With side stand down
condition & vehicle in gear, engine cranking is disable through ECU & side stand down indication will be displayed in
speedometer.

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.
• Clean the entire vehicle thoroughly.
• Empty the fuel from the fuel tank (if fuel is left in for a longer time, the fuel will break, and gummy substance could clog
the throttle body).
• Remove the spark plug and put several drops of engine oil into the cylinder. Self start the engine a few times to coat the
cylinder wall with oil and install back the spark plug.
• Set the vehicle on a box or a stand so that both the wheels are raised off the ground.
• Ensure vehicle cleanliness & apply antirust oil ( Parco Lubricant PL 101 of M/s Hankle) on fasteners & completely cover
the vehicle (It is mandatory to cover the vehicle after application of anti rust oil).
• Cover the entire vehicle neatly. Ensure that the storage area is well ventilated & free from any source of flames or
spark.
• Fill 10% excess air pressure in both wheels.
** For Battery:
a. Remove battery and keep it on wooden plank, in properly ventilated area.
b. Before taking the vehicle for use.
• Get the battery recharged from the Authorized Service Center / Battery Dealer.
• Apply petroleum jelly on terminals.
Preparation for regular use after storage :

• Clean the vehicle
• Make sure the spark plugs are tightly fitted.
• Fill the fuel tank with fuel.
• Change the engine oil.
• Check all the points listed in the Daily Safety Checks section.
• Check and inflate tyres to the proper tyre pressure

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.
• Use both brakes simultaneously while braking.
• Do not ignore brake & engine oil leakage.
• Do not ignore worn out / cut tyre condition, if found replace immediately.
• Do not ignore fuel leakage.
• Ensure specified brake free play.
• Ensure minimum 3 Liters fuel is available in fuel tank, otherwise it may result into hesitation issue above 40 Kmph
speed.
2) Vehicle usage :
• During running in period, do not exceed speed limits mentioned in owner's manual. It may lead to failure of engine
components.
• Do not drive vehicle above its rated payload.
• Do not drive vehicle with brake pedal / lever partially pressed.
• Do not drive vehicle with clutch lever half pressed.
• Avoid harsh braking & do not drive the vehicle by keeping brake pedal pressed.
• Always ensure tyres are inflated to specified air pressure.
• Do not add extra electrical accessories e.g remote, horn, buzzer etc.
• 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.
3) Vehicle maintenance (PM schedule / service at authorized locations) :

• During periodic service replace mandatory periodic parts as per PM schedule given in owners manual.
• 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.

• 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.
• Always fill petrol from reputed petrol pumps. Use petrol of Octane number 91.
• Do not add additives in engine oil / petrol.
• Drive chain cleaning & lubrication by OKS spray at every 500 Kms. This spray is available with BAL dealer for sale.
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
• Do not replace fuse with higher capacity fuse.
• Never bypass fuse.
• Do not cut wiring conduit / wires midway.
• Never remove conduit from wiring harness.
• Do not repair wiring harness instead replace for safety.
• Do not ground any wire for checking current-spark.
• Wiring harness failure due any one of the reason mentioned above is not covered under warranty replacement.
• Do not fit splash guard in front of the engine.
• Do not fit accessories to carry extra load.
5) BAL warranty policy - (Fuel adulteration / local accessories fitment & vehicle maintenance as
per PM schedule) : For detailed warranty policy, refer the Owner’s Manual.

TECHNICAL SPECIFICATIONS
Parameter Specification Pulsar F250 / N250
Engine
Type 2 Valve, Single cylinder, oil cooled
Bore 72 mm
Stroke 61.17 mm
Displacement 249.07 cc
Idling speed 1500 ± 100 rpm
Max.Net Power 24.5 PS @ 8750 rpm
Max. Net Torque 21.5 N.m @ 6500 rpm
Ignition system DC, Fuel Injection
Spark plugs Qty 2 Nos
Spark plug gap 0.8 - 0.9 mm
Lubrication Wet Sump Forced Lubrication
Transmission 5 Speed, Constant 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
Frame Tubular frame
Front Front : Telescopic suspension

Suspension
Rear Rear : Mono suspension, without canister
Single channel ABS,

Front
Brakes Disc Ø 300 mm
Rear Disc Ø 230 mm
Front 100/80-17, 52P, Tubeless

Tyres
Rear 130/70-17, 62P, Tubeless
Front 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
Fork oil Grade Bajaj Genuine, SAE 10W20
Fork oil Quantity / leg 342 ml

TECHNICAL SPECIFICATIONS
Parameter Specification 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 – F250
Vehicle Gross Weight
312 Kg – N250
Electrical
System 12V DC
Battery 12V 8Ah VRLA
Head Lamp LED
Position Lamp LED, Integrated in headlamp - F250

LED, Separate - N250
Tail / Stop Lamp LED
Side Indicator Lamp LED
Neutral Indicator LED
Hi Beam Indicator LED
Turn Signal Indicator LED
Speedometer back light LCD
Fuel Level Indicator LCD Bar
Low Oil Pressure Indicator LED

Malfunction Indicator LED
High Engine oil Temperature Indicator LED
Low Battery Indicator LED
REV Indicator LED
Service Reminder LCD
Side Stand Indicator LED
ABS Indicator LED
Rear Number Plate Lamp 12V,5W
Horn 12v, DC
NOTE • All dimensions are under UNLADEN Condition. • Above information is subject to change without any notice.• This vehicle complies to BS VI standards • AHO is government regulation.
Always maintain minimum 3 litres fuel in fuel tank for smooth functioning of vehicle.

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
18
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)

SPEEDOMETER INFORMATION
1
2 11
3 12
4
13
5
14/15
6
16
7
17
8
18
9 19
20
10
21
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 180c.
3. High Beam Indicator: It glows when Headlight is ON & High beam is selected with engine running.
4. Turn Signal Indicator (LH & RH): When Turn signal switch is pushed to Left or Right, Turn Signal Indicator - LH or RH will flash.
5. Side Stand Indicator: It glows when side stand is down Under condition-side stand down & vehicle is in gear, self start will be disabled.
6. Malfunction Indicator ( ): It glows whenever any abnormality is noticed in functioning of Fl system related components.
7. Low Battery Indicator: It indicates battery needs charging.
8. Low Oil Pressure Indicator ( ): It glows when engine oil pressure is low.
9. Mode Button: Mode button used for 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
and clock setting.
11. Engine Rev Indicator: It glows when engine RPM exceed 9000 RPM. It indicates customer "Not to REV up engine beyond
safe engine operating RPM.
12. ABS Indicator ( ): With Ignition switch ON the ABS indicator glows. When vehicle speed is more than 5 Km/h the ABS
indicator goes off, if this indicator glows while vehicle is running, it means there is problem in ABS
13. Neutral Indicator: When the transmission is in Neutral, Neutral indicator will glow.
14. Odometer: The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to 'Zero'.
15. Trip Meter: Selected Trip meter shows the distance traveled since it was last reset to zero. Both trip meters can
be reset to zero by pressing the Set button. After completion of max value of 999.9 Km, selected trip display will
get freezed and will not get set automatically to zero.
16. Fuel Level Indicator: It shows available fuel in fuel tank.

1
2 11
3 12
4
13
5
14/15
6
16
7
17
8
18
9 19
20
10
21
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. Icon will continue to glow till it is reset. This icon is to be reset after service
is carried out. Service reminder reset is to be done at zero vehicle speed & zero engine speed.
18. Low Fuel Level Indicator: It 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 display gear position from 1 to 5 It will display 0 when vehicle is in neutral position.
Note :
After switching 'ON' the ignition switch, the indications will remain 'ON' till engine is started.
• High Engine Oil Temperature Indicator
• Low Battery Indicator
• Low Oil Pressure
• Malfunction Indicator
Instructions
Incase high engine oil temperature indicator, Low battery indicator, Low oil pressure indicator, Malfunction indicator,
ABS indicator gets ON during vehicle running, bring the vehicle to nearest BAL authorised workshop for inspection/ repair.

Details - IFE & ODO
1 2 3
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. at any given time. Value will be LCD bars with (E) empty, (F) full & ( ) fuel tank LCD
displayed only when vehicle speed & Engine RPM is symbol.
more than zero. Low fuel level icon blinks if number of bars on the fuel
If vehicle speed is zero then IFE will be displayed gauge are less than 2 bars.
“--km/L” Note:
2. ODO: The Odometer shows the total distance that IFE (Instantaneous fuel economy)/AFE (Average fuel
the vehicle has travelled. economy)/DTE (Distance to empty) readings are indicative
& may vary due to driving and road conditions.
Details - AFE 1, TRIP 1 / AFE 2, TRIP 2
1 2 3 4
Procedure to set AFE1 & TRIP1: Procedure to set AFE2 & TRIP2:
Ignition switch is ON & Set push button pressed for Ignition switch is ON & Set push button pressed for
less than 1 sec. - TRIP1 mode gets selected & less than 1 sec. - TRIP2 mode gets selected &
following display will be shown by digital speedometer following display will be shown by digital speedometer
1. AFE1 (Average Fuel economy1): This will indicate 3. AFE2 (Average Fuel economy2): This will indicate
the average fuel economy in km/L in TRIP1 mode. the average fuel economy in km/L. in TRIP2 mode.
2. TRIP1: The Trip meter shows the total distance 4. TRIP2: The Trip meter shows the total distance that
that the vehicle has travelled in TRIP1 mode. If the vehicle has travelled in TRIP2 mode. If TRIP2 is
TRIP1 is reset, average fuel economy (AFE1) will reset, average fuel economy (AFE2) will reset.
reset.
Note: AFE will be updated every 60 sec. AFE will be reset if corresponding TRIP1 or TRIP 2 is reset or battery disconnected.

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.
Max count of DTE is 990 Km. speedometer will display values in multiple of 10.
TRIP Setting:
If Set button is pressed more than 3 sec.in TRIP1 or TRIP 2 mode, then respective AFE & trip distance will reset to Zero
while DTE will continue to show earlier value.
Note:
After completion of max value of 999.9 Km, selected trip display will get freezed and will not get set automatically to
zero.
However speedometer will continue to calculate and display AFE value.
Note:
If vehicle is driven by ignoring fuel level display & Tank symbol ( ) blinking after reaching fuel unutilized level DTE will be
shown as ‘--’ Km.
During Petrol Refilling:
If petrol filled is more than 1 Litre then DTE will be calculated based on the revised fuel volume.
If petrol filled less than 1 litre then there will be no change in DTE value.
Speedometer Setting
Service Reminder
Mode
Trip 1/2
/ Distance to next service’.
1 / Distance
to next service’.
3 sec.
For entering clock setting mode - press mode & set

button together for 3 sec.

Speedometer Setting / USB Charger

Press mode & set
‘:’ stops blinking
button together for
Digits HH starts blinking.
more than 3 sec.
Press set button for HH value will be stored Charger Cap

1 sec. while MM starts blinking.
Press mode button for Minute digits will

1 sec. increase.
Charging Socket
Press set button for HH and MM value will be
1 sec. stored & AM starts blinking
• The mobile charger will supply output voltage only in
engine running condition.
• Customer to use suitable USB cable for mobile charging.
Caution:
Do not use mobile phone while driving. Momentary
lapse in concentration might result in an accident.
Mobile Charger
• Mobile charging socket has been provided 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 charger socket is not in use.

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’ push button &

Turn ON ignition switch, Hold
‘MODE’ push button for more Service reminder icon will start blinking.
than 10 sec.
Release mode push button &

Service reminder icon will get reset (Service reminder
within the 10 seconds, press
SET button for more than 5 sec. symbol turn off).
ODO / TRIP 1/ TRIP 2 (text) will turn OFF Next service

schedule in Km. is displayed on ODO digit 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 resetting @ more than 14000 kms & less than 14450 kms, next service schedule shall display as
19450 km.
Prior Service Reminder Reset :

Prior Service reset of service reminder is allowed only if DISTANCE TO SERVICE is less than
450 kms.
(DISTANCE TO SERVICE = NEXT SERVICE SCHEDULE IN KMS – PRESENT ODO) Service reminder icon resetting
procedure remains same as mentioned in “Normal Service Reminder Reset procedure”.
If DISTANCE TO SERVICE is more than 450 kms then Service reminder icon reset is disallowed.
Example -
• If you are resetting before 4000 kms i.e. more than 450 kms from 2nd service schedule icon i.e. 4450 kms, you can’t reset
for next service.

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.
• Dial, LCD and pointer illuminations should be turned ON : Time – Complete power on cycle.
• After the power on cycle, fuel gauge bars to be updated instantaneously as per the fuel input.
• All micro controller based tell tales should be ON during power on cycle : Time – Complete power on cycle
• Post power on cycle, all tell tales and LCD segments should follow respective inputs.
ODO Module :
• Type: 6 Digits & indicates 0 to 999999 km.
• Roll over Condition: Rolls over to zero & starts recounting after 9, 99,999km.
TRIP 1 & TRIP 2 :

• Indication :
- 0 to 999.9 Km
- Max value for display : 999.9 Km.
• Roll over condition: After completion of max value, speedometer should continue display max value and should not roll
over to Zero.
• Mode push button for selecting ODO / TRIP 1/ TRIP 2.
• Set push button for resetting ODO / TRIP 1/ TRIP 2.
Step Result
Press MODE push button Mode changes from ODO / TRIP 1 /TRIP 2
for less than 2 sec
Press SET push button for Selected TRIP 1 / TRIP 2 will reset.
more than 5 sec Other TRIP mode will continue updating.
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.

Volume Fuel bar indication Warning
Full 9
3.06 Litres 1 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
• Gear Display segments should show “0” when in neutral.
• If neither Neutral nor Gear input is present, then Speedometer shall not show any Gear position and “GEAR” icon shall
blink and “-“ shall be shown on gear display segments.
• Presence of more than 1 input (Short Circuit): “GEAR” will blink and the lowest value among the inputs will be
displayed.
Example: If Gear 1 and Gear 2 are active low at the same time, then Dashboard shall display Gear 1 with “GEAR” icon
blinking to indicate short circuit condition.
Between “Neutral” and other gear input, Neutral shall be given priority.
Condition 1 : Ignition ON, Kill switch OFF :

• 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
• Side stand icon & Neutral (N) icon appears for some time & then disappears
Condition 2 : Ignition ON, Kill switch ON :

In addition to above,
• ODO
• Gear indication
• Speed (in Km/h)

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. The braking distance for motorcycle equipped with an anti-lock braking system may be
longer than for those without it on rough road conditions. During these conditions the vehicle should be driven at
reduced speeds
• When you apply Front brake / Rear brake by pressing Front brake lever/Rear brake pedal under conditions which may
lock the wheels, you feel a corresponding sensation (pulsation) in Front brake lever/Rear brake pedal. (as applicable
to model) This is normal and it means ABS is active.
• Also it is recommended to use both front Er rear brakes simultaneously.
• Always slow down when cornering. The anti-lock brake system cannot prevent accidents resulting from excessive
speeds.
• Never drive by disconnecting wheel speedometer cable.

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. Turn Signal Switch: When the turn signal knob is
turned to Left ( ) or Right ( ) respective
indicator will start blinking, to stop blinking push
the knob in & release.
C. Horn Button ( ): Press button for sounding horn.
Control switch RH
Headlight
Condition 1 : Ignition ON, Kill switch ON/OFF, Engine OFF
Headlight Switch Effect on pressing

Headlight Position Lamp
Position Pass switch
Low beam OFF ON High beam
High beam,
High beam OFF ON
No change

Condition 2 : Ignition ON, Kill switch ON, Engine ON
Headlight Switch Effect on pressing

Headlight Position Lamp
Position Pass switch
Low beam Low beam ON High beam
High beam,
High beam High beam ON
No change
Headlight
LED 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 temperature difference. A thin film of fog can
form on the inside surface of the headlamp lens. The thin fog will clear and exit through the vents during normal
operating condition. Condensation & fogging of headlamp lens may happen during rain or after washing. Moisture
condensation inside the headlamp lens will disappear gradually by switching ON the headlamp in high beam and
driving the vehicle at 30 to 40 Kmph speed for about 15 minutes. Time for evaporation will vary depending on the
humidity of the ambient air.
Side Stand
Side stand condition Side stand Indication in speedometer Gear position Remark
Vehicle gets started after

Yes Neutral
pressing self start button
Down Gear is applied in vehicle
Yes start condition by pressing Vehicle gets OFF
clutch lever
Self starter is disabled,
Down Yes Gear
vehicle will not start
Steering cum Ignition switch

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.
• Cranking on-off duration control feature to avoid battery discharge-

- 1st Crank ON (5 sec) & Disable for 2 sec.
- 2nd Crank ON (5 sec) & Disable for 2 sec.
- 3rd Crank ON (5 sec) & Disable for 10 sec.
After a gap of 10 sec cranking cycle continues.
Fuel Tank Cap

• This practice needs to be followed to maintain the shine
of color on petrol tank.
Glossy Finish Painted Parts Cleaning

Do’s:
· Use Colin or caustic free detergent solution for
cleaning.(1 spoon in ½ bucket)
Remove foreign substances like insect remains, road
debris using a soft brush.
· Use microfiber cleaning cloths Ex.- Muslin cloth for
painted parts cleaning.
· Use recommended 3M polish.
Don’ts:
· Do not use products that are even mildly abrasive, such
as polishes, glazes, or rubbing compounds.
· Do not use mechanical cleaners/polishers.
· Do not use terrycloth or paper towels or shine
enhancement products.
· Do not rub the finish vigorously, this will burnish the
SOP to prevent fuel stains on petrol tank
paint finish, causing a permanent shiny spot. Shiny
• After petrol refilling & before shutting the cap wipe the spots cannot be removed.
spilled petrol from the painted areas around the cap by soft
dry cotton cloth.
• Shut and lock the cap fully.

Recommended frequency -- Service interval & Kms
Sr. 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th
Activities / Check points
No. 500 4.5 9.5 44.5 74.5
~ ~ 5 ~ 10 ~ 45 ~ 75 Remarks
750 K K K K K K K K K K K K K K K
Protect to prevent water entry in Petrol

1 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-
2 R R R R R R R R Oil level window cleaning at every 10000
oil) up up up up up up up up
kms by petrol spray & nylon brush
Oil strainer cleaning at the time of oil
3 Oil strainer CL CL CL CL CL CL CL CL
change.
4 Engine oil filter R R R R R R R R Replace oil filter during every oil change
Air cleaner element** with ‘O’ Replace Viscous air filter at every 20,000
R R R
ring. kms.
5
Replace Air filter cover ‘O’ ring along with
Drain tube cleaning. CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL
PREVENTIVE MAINTENANCE CHART
air filter
32
Fuel Pump Nylon hoses with
6 C,R C,R C,R Replace if required
quick connector
CL, CL, CL, CL, CL,
7 Spark plug clean & check gap R R Replace at every 30000 kms
A A A A A
8 Valve tappet clearance C,A C,A C,A
Replace if required. Need to remove RH

Engine breather tube for
9 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 Side cover. Breather Tube is visible with
cracks.
this cover removed.
Service Support - M/C

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th
Sr. Activities / Check
No. points 500 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
~ ~ 15 ~ 20 ~ 25 ~ 30 ~ 35 ~ 40 ~ 45 ~ 50 ~ 55 ~ 60 ~ 65 ~ 70 ~ 75 Remarks
5 K 10 K
750 K K K K K K K K K K K K K
EVAP system

Drain EVAP "Y" connection drain tube.
10 Hoses- check for C,R C,R C,R
Replace if found cut / damaged
cracks
Engine oil cooler

11 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 If found damaged, replace it.
fins
Silencer drain hole
12 CL CL CL CL CL CL CL CL CL CL CL CL CL CL
cleaning
Wiring harness
connections, Damaged conduit / PVC sleeves protection by
C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A,
13 routine & Conduit / C,A,T applying electrical tape film & ensure tie bands
T T T T T T T T T T T T T T T
PVC sleeve / Tie to specific location.
band inspection.
Apply petroleum jelly on battery terminals.

Battery connections
Use Midtronics battery tester.
33
& health by load C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A,L
14 In case of Battery removal
tester. +ve terminal L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T L,T ,T
1.Battery negative terminal to be disconnected
cap fitment.
2.Latch seat bkt to be removed
Ignition switch
15 CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L Use recommended WD40 spray
contacts cleaning
HT coil connections
16 (Primary and C,T C,T C,T
Secondary)
Starter motor &
17 starter relay C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T
connections

Sr.
Activities / Check points 500 4.5 9.5
No. 74.5 ~
~ ~5 Remarks
75 K
750 K K K K K K K K K K K K K K
Icon should disappear post engine ON.

Oil pressure indicator check on
18 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 After 4000 rpm, no icon should be
console post ignition ON.
displayed.
Check fault code, Clear fault
19 history, Update latest hex file if C C C C C C C C C C C C C C C C
applicable
During 1st free service use OKS spray
for chain cleaning without removing
chain from vehicle.
During other services clean chain with
Sealed Drive chain wear** – Clean,
CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, CL, Diesel+ SAE 90 oil ration of 50:50 &
20 lubricate & adjust. Replace if CL,L,A
L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A L,A lubricate by SAE 90 oil.
required
(Customer to use OKS chain lube
spray at every 500 kms
Setting of chain play/slackness (20 -30

mm in 1G/both wheels on ground)
34
CL, CL, CL, Use recommended AP grease. Main
21 Main stand & Side stand pivot pin
L L L stand will be supplied as an accessory.
22 Steering play C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A
Steering stem bearing & Cap C,C C,C C,C C,C C,C C,C C,C Replace if required. Use Limaplex
23
steering bearing (Plastic)** L,L L,L L,L L,L L,L L,L L,L HTX3 grease for lubrication
Replace oil and oil seal +Dust seal in

24 Front fork oil & seals C,R C,R C,R C,R C,R C,R R C,R C,R C,R C,R C,R R C,R C,R C,R
pair at every 30000kms
Lubricate NRB at every 40,000 kms
25 Swing arm NRB for more play L
Use AP grease.

Sr.
No. 74.5 ~
~ ~5 Remarks
75 K

Front & Rear Brake pads for wear
26 C,R C,R C,R R C,R C,R R C,R C,R R C,R C,R R C,R C,R R Replace at every 15000 Kms
limit.
1.Check source of leakages if any Check & Top up DOT4 brake oil in
in the brake system. every service.
2.Check Front & rear brake hose C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, C,A, Replace DOT 4 brake oil & Master /
27 R R C,A,R
condition. R R R R R R R R R R R R R Caliper seals at every 30000kms
3.Check Brake fluid level and top
up, if needed.
Rear sprocket fasteners for
28 C,T C,T C,T C,T C,T C,T C,T C,T Torque-3.5 - 3.8 Kgf-m
looseness.
Rear wheel rubber shock dampers Replace rear wheel rubber shock
29 C,R C,R C,R C,R C,R C,R C,R
for excess play. damper if required
35
Clutch & Throttle cable free play
30 C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A Replace cables if operation found hard.
adjustment
31 Head light focus adjustment C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A
Check & confirm all lights / LEDs / Contact type switches if found sticky
32 C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A
Switches / Horn working. then use recommended WD40 spray
General lubrication –
33 C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L C,L Use recommended AP grease.
Rear brake pedal
Front - 1.75 Kgf/cm² (25 PSI)
34 Tyre air pressure. C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A Rear (Solo) - 2 Kgf/cm² (28 PSI)
Rear (Pillion)-2.25 Kgf/cm² (32 PSI)
35 Mirror position & joint firmness. C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A

Sr.
No. 74.5 ~
~ ~5 Remarks
75 K
All fasteners tightness, few are Recommended Torque values
1.Front & rear axle Front & rear axle : 8 to 10 Kgf -m

2.Swing arm axle Swing arm axle- 13 to 15 Kgf-m
Engine foundation-
Top : 2.2 to 2.4 Kgf -m
36 C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T
3.Engine foundation Front top : 2.8 to 3 Kgf -m
Front bottom : 4 to 4.2 Kgf -m
Rear : 4 to 4.2 Kgf -m
4.Rider/Pillion foot rest holder Rider/Pillion foot rest holder - 1.8 to 2.2
(Stay) Kgf-m
Charging OK to be checked at Engine
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
start condition using LED USB light
Drain hole no blockage verification C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C
38 C,CL
below starter motor L L L L L L L L L L L L L L
Fuel tank water drain no blockage C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C
39 C,CL
36
verification L L L L L L L L L L L L L L
Added points for Pulsar F250 / N250
CAUTION:
It is most important to adhere to recommended grade & frequency of oil change for long life of critical engine components.
Do not reuse drained oil. Dispose drained engine oil in a manner which is environment friendly.
It is important to charge the VRLA Battery initially with recommended electrolyte only.

PM SOP for added Point

Recommended frequency-- Service interval & Kms
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th11th 12th13th14th15th 16th
Sr.
No. 74.5 ~
~ ~5 Remarks
75 K
Drain hole no blockage verification C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C C,C
38 C,CL
below starter motor L L L L L L L L L L L L L L
Insert small size screwdriver as shown from RH side (below starter motor) Screwdriver can be seen from 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

Recommended frequency-- Service interval & Kms
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th11th 12th13th14th15th 16th
Sr.
No. 74.5 ~
~ ~5 Remarks
75 K
Charging OK to be checked at Engine
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
start condition using LED USB light
LED USB Light – For checking USB Charger (Socket charger)
Checking of USB Charger (Socket charger)

• Lift USB charger (Socket charger) cap & fit LED USB Light in it.
• Put ON ignition switch & Start the engine.
• LED light glows (as shown in photograph) indicates USB charger (Socket
charger) is OK.

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. 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. Why Preventive Maintenance ?
Preventive Maintenance is predetermined work to –
• Ensure safe functioning of product with intended reliability.
b. Reduce cost of repairs & replacement.
c. Protect assets & prolong the useful life of component / product.
3. How to perform ?
• Clean / Inspect / Lubricate / Adjust / Replace as per the PM chart & encyclopedia guidelines.
b. To correct deficiencies found through testing & inspection.
4. How to ensure execution & competency ?
• Training programs, encourage & appreciates for abnormality identification & prevention.
b. Audit & review to assure quality performance.
c. For better understanding show “Periodic Service DVD” to technicians at suitable interval.
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. Monitor consumption of Periodic parts vis a vis vehicle serviced month wise.

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. Parts, components performing to intended life.
c. Reduction in brake down.
d. Increase in service volume through AMC engagement.
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.
Engine oil filter replacement
Smooth functioning of engine parts.
Oil strainer cleaning.
Spark plug cleaning. Better drive ability.
Air filter element replacement consistency in mileage.
Petroleum jelly application on battery terminals.
Battery terminals connection tightening.
Easy & smooth functioning of DC system.
Battery charge / condition checking by battery tester.
Charging of battery on BAL recommended battery charger.
Clutch free play setting
Smooth gear shifting, effective braking
Accelerator free play setting
Drive chain lubrication on vehicle
No chain noise issues.
Drive chain overhaul
Optimum performance of drive chain.
Drive chain slackness checking & adjustment
Wiring harness checking
Ignition switch contacts checking & cleaning Smooth functioning of electrical controls.
LH & RH Control Switch contacts cleaning
General lubrication / greasing. No noise / wear & tear of parts.
Fasteners tightening by torque wrench. No vibration related issues.

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 consumables
required
Vehicle to be parked on 1. Engine cold condition --

center stand. (Vehicle Oil level should be above
1. Engine oil
1. Engine oil level. without center stand - Oil lower mark & just below the
filling funnel.
Engine Oil level to be checked at top window quadrant point of
2. BGO
vehicle upright position, both oil level window.
2. Oil leakages, if any. wheel resting on plain 2. Check this point after test
20W50,BS6
surface) ride on road.
Compatible
Fuel Pipe 1.Pipe & Circlip fitting Visual _

2.Fuel leakage
Mirror 1.Fitment. Mirror adjustment as per Clear rear view setting on
2.Adjustment. user's requirement. vehicle.
Leg & Saree guard Ease of fitment _ Hardware fully tightened.
1. Level in Front & Rear 1. Brake fluid level above DOT 4 brake
reservoir. fluid.
Brake Fluid Visual MIN mark, top up if required.
2. Brake Fluid leakage if 2. Check this point after test Syphon pump
any. for air bleeding.
ride on road.
Smooth operation of Insert vehicle key in lock &

Lock Operation Steering cum Ignition lock, By using vehicle key.
Seat lock, Petrol Tank cap check operation of
lock respective lock.
Green LED-Battery fully
charged. Yellow LED -Battery
Battery charge condition As per SOP partially discharged. Red
LED-Battery deep
discharged.
1. Midtronics
battery tester,
2. Battery
Battery * Ensure firm connection of chargers (
VRLA)
+ve & -ve terminals, apply 3. Petroleum
Battery terminals tightness Carry out cable petroleum jelly & ensure jelly
& Petroleum jelly connections. protection cap fitment on
application. +ve terminal
1.Check air pressure in both Front - 1.75 Kgf/cm² (25 PSI)

tyres using tyre pressure
Air pressure in Front & gauge. Rear solo - 2 Kgf/cm² (28 PSI) Tyre pressure
Tyre Pressure Rear with pillion - 2.25 gauge.
Rear tyre 2.Refill air using by Kgf/cm² (32 PSI)
Pneumatic connection /
Good quality foot pump.
Clutch Lever / Throttle Free play of Clutch lever Use free play Free play 2 - 3 mm
Free play
& Throttle. gauge. gauge
Use chain Brake pedal

Drive Chain Slackness slackness Slackness 20 - 30 mm
play /chain
checking gauge slackness
checking gauge

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 wrench 20 Kgf-m
values
3.Rider (bottom bolt

only)/Pillion foot rest holder 1.8 to 2.2 Kgf-m
(Stay)
2. Check Points during / after starting the vehicle

RH & LH control switch, Check for smooth
Switch Operation ignition switch, clutch switch operation & _
& brake switches functioning
Coupler connection,Horn
Horn By hearing _
sound.
Head lamp Tail / stop lamp,
All Bulbs Working Side indicators, Speedo Check functioning. _
bulb, No. plate lamp
Working of speedometer, Fuel gauge-By Speedometer, Odo meter & trip Funnel for filling
Odometer, Trip meter, Fuel filling fuel. meter working to be checked petrol &
gauge , Clock. Gear Clock-Set clock if during / after test ride measuring jar
indicator, AFE, DTE required as per
SOP.
Speedometer Working of all signal

indicators icons (N, Turn
By observing ABS icon will turn off if vehicle
signal, Side stand, High
speedo Indications speed is more than 5 Kmph
beam, oil pressure, Engine Fi icon will glow if there is any
after switching ON
Temp, Low battery, MIL, malfunction in FI system.
ignition switch.
ABS, Service reminder & B
Logo)
Head light
As per head light Refer head light focus values
Head light Low beam focus Focus display
Headlamp focus checking chart. Focus to be checked with
checking rider & from a distance of 5 chart with 5m
SOP.
meters. mark.
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 & Rear gauge,Multimet
attended in workshop.
er.
Engine noise No abnormal noise
4. Visual inspection for dent, scratches, rust etc.
5. Clean the vehicle thoroughly before delivery to customer.
Note -
Vehicle FIFO system required with monitoring system.
Vehicles to be dispatched to network only after carrying out PDI activity at Dealership.

SKILL TIPS / NOTES AT PDI STAGE
Battery –ve terminal fitment. (For more details, Refer Battery replacement SOP)
Bracket latch seat removal Nut fitment direction Battery terminal fitment
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” 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 only.
Sequence seen from outer side:

Nut Leg guard Washer
Leg
Importance of washer : guard
Washer-KDAB0816
To avoid leg guard fitment on vehicle in stressed condition, this washer is to to be fitted
on LH Bottom
be fitted. mounting Nut
Torque value
Leg guard mounting Top bolt : 2 – 2.2 Kgf-m
Leg guard mounting bottom nut : 2 – 2.2 Kgf-m
Clutch cable routing while Leg guard Fitment

Route the clutch cable as shown in photograph. Clutch is to be routed
above leg guard.

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Service Station Manual

Doc. No . :71120182 Rev. No . : 03 JULY 2022

Service Station Manual Service Support - M/C

Sr. No Rev No Date Reason for change

1 00 April 2022 Developed for new models

Addition of Supplementary Service Station Manual-Pulsar 250

Addition of Supplementary Service Station Manual-Pulsar N160 Single

Addition of Supplementary Service Station Manual-Pulsar N160 Twin

Service Station Manual Service Support - M/C

Service Station Manual Service Support - M/C

Service Station Manual Service Support - M/C

Service Station Manual Service Support - M/C

• Information For Customer

• Technicians must use Personnel Protective Equipment (PPE) like –

• Wear Nitrile Rubber Hand Gloves while handling

Precautions to be taken while handling Fire Extinguisher

- Install ‘ISI’ approved Fire extinguishers – CO2 gas cylinders.

Safety Precautions while Operating Air Tools

Service Station Manual 2 Service Support - M/C

• Never look into the air outlet of a pneumatic tool.

• Calibration of Workshop Equipment

• Avoid direct body contact with Petrol, Kerosene.

• Waste Oil Disposal

• Precautions to be taken while handling Hydro-Electric Lift

Service Station Manual 3 Service Support - M/C

Battery Ground +ve Terminal -ve Terminal

Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

Service Station Manual 4 Service Support - M/C

Storage of Removed Parts

Service Station Manual 5 Service Support - M/C

Service Station Manual 6 Service Support - M/C

Liquid Gasket, Non-permanent Locking Agent

Circlips, Cotter Pins

Ball Bearing and Needle Bearing

Service Station Manual 7 Service Support - M/C

Oil Seal, Grease Seal

Apply specified grease to the lip of seal before installing the

Direction of Engine Rotation

Service Station Manual 8 Service Support - M/C

Service Station Manual 9 Service Support - M/C

Safe Riding Tips

MONSOON CARE : Fit & Finish Parts

Daily Safety Checks

Service Station Manual 10 Service Support - M/C

What to Check Check for

1. Correct free play in the throttle cable (2 to 3 mm)

Steering Lock Correct operation.

1. Proper slack (20 ~ 30 mm)

Lighting Operation of all lights.

Horn Correct functions.

Side Stand Return to their fully up position.

Mirrors Correct view position.

Service Station Manual 11 Service Support - M/C

Fuel Saving Tips

• Avoid harsh braking.

Information on Bike handling :

Recommended speeds for down shifting