OM KARIZMA ZMR-1.cdr - Hero MotoCorp

PREFACE

Your Authorised Hero MotoCorp dealer will be glad to provide further information or assistance and is equipped to handle your future service needs.

This booklet is your guide to the basic operation and maintenance of your new Hero MotoCorp Karizma ZMR. Please take time to read it carefully. As with any fine machine, proper care and maintenance are essential for trouble-free operation and optimum performance.

We at Hero MotoCorp, are committed to demonstrate excellence in our environment performance on a continual basis, as an intrinsic element of our corporate philosophy. To achieve this we commit ourselves to continue product innovations to improve environment compatibility, comply with all applicable legislation including environment legislation and strengthen the green supply chain.

Let us make this world a safer, healthier and more environment friendly place.

Your motorcycle is conforming to latest (Bharat stage-III norms) regulation for emission, safety & noise levels. We are also using non asbestos brake shoes/pads and engine gaskets which are environment friendly in nature.

Thank you for selecting a Hero MotoCorp Karizma ZMR. We wish you many miles of continued riding pleasure in the years ahead.

ALL INFORMATION, ILLUSTRATION, PHOTOGRAPH, DIRECTIONS, SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS OWNER'S MANUAL ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF ITS PRINTING APPROVAL, AND THE ACCURACY OR CORRECTNESS OF THE SAME IS NOT UNDERTAKEN OR GUARANTEED. Hero MotoCorp Ltd RESERVES THE RIGHT TO MAKE CHANGES IN ITS CONTENTS AT ANY TIME WITHOUT NOTICE AND/OR INCURRING ANY OBLIGATION, WHATSOEVER. NO ONE IS ALLOWED TO REPRODUCE ANY PART OF THIS PUBLICATION WITHOUT OBTAINING PRIOR WRITTEN PERMISSION FROM Hero MotoCorp Ltd.

NOTE

Pg. No. Pg. No.

CONTENTS

MOTORCYCLE IDENTIFICATION 1PRODUCT SPECIFICATION 2SAFE RIDING TIPS 4ACCESSORIES & MODIFICATIONS 5ANTI-THEFT TIPS 5TIPS FOR HEALTHY ENVIRONMENT 6MOTORCYCLE VIEWS 7PARTS FUNCTION 12

PRE-RIDE INSPECTION 27

• Real Time Mileage Indicator (RTMI) 20

• Digital Clock 16

RIDING 29STARTING THE ENGINE 28

• Steering Lock/Seat lock/Seat removal 22

• Odometer/Tripmeter 17

BRAKING 30

• Instruments & Indicators 12

• Left/Right Handlebar Controls 21

• Seat Installation/Helmet hanger 23• Fuel Tank 26

• Fuel Gauge 20

• Ignition Switch 14

• Scroll Message 17

TYRES 26

PARKING/TOOL KIT/FIRST AID KIT 31MAINTENANCE 32• Safety Precautions 33• Maintenance Schedule 34

• Brakes 46

• Headlamp Adjustment 51

• Side Stand/Side Stand Switch/Suspension 52

• Air Cleaner 39

• Drive Chain Slider 45• Clutch/Drive Chain 42• Throttle Operation/Valve Clearance 41

• Brake Pad Wear 47• Battery 48

• Centrifugal Oil Filter 37

ENGINE OIL/ENGINE OIL TOP UP PROCESS 36ENGINE OIL REPLACEMENT PROCESS 36

• Oil Cooler/Spark Plug 38

• Fuse Replacement 50

• Stop Lamp Switch 51

• Washing The Motorcycle 55• Catalytic Converter 56

WARRANTY DETAILSINSTALLATIONHERO GEUINE PARTS

• Front Wheel 53

ZONAL/REGIONAL/AREA OFFICES

BASIC TROUBLESHOOTING 57

• Rear Wheel 54

ROAD SIGNS 59

2. For dealing with legal & insurance departments.

VIN and Engine No. may be required:1. During registration of the motorcycle.

Location: Stamped on the right side of the steering head tube.VIN: MBLXXXXEJYZXYYYYY

Location: Stamped on the lower side of the left crankcase.

MOTORCYCLE IDENTIFICATION

Engine No.: XXXXEGYZXYYYYY

Model: Karizma ZMRVIN EngineVariants

XXXXEG Y Z X YYYYYEngine

DescriptionYear of

Manufacturing Assembly Plant Month of Manufacturing Serial Number

MBL XXXXEJ Y Z X YYYYYManufacturer

codeVehicle

DescriptionYear of

Manufacturing Assembly Plant Month of Manufacturing Serial Number

Vehicle Identification Number (VIN) Engine No.

Electric start/Front disc/Rear disc/Cast wheel EJ EG

1

MBLX

XXXE

JYZX

YYYY

Y

XXXXEGYZXYYYYY

SPECIFICATIONSITEMDimensionsOverall lengthOverall widthOverall heightWheelbaseSaddle heightGround clearance

Kerb weight

2100 mm805 mm1190 mm1360 mm810 mm145 mm

157kgWeight

Engine oilFuel tankHydraulic brake fluidFront fork oil disassembly

Maximum powerMaximum torqueBore and strokeCompression ratioDisplacement

1.35 litres at disassembly and 1.10 litre at draining15.3 litres (Minimum)Castrol Q stop-DoT 3 or DoT 4171±2.5 ml

14.9 kW (20BHP) @ 8000 r/min19.7 N-m @ 6500 r/min65.5 x66.2 mm9.6:1223 cc

Capacities

Engine

Spark plug gapValve clearance (cold)Idle speed

Front SuspensionRear Suspension

0.8-0.9 mm0.10 mm 0.10 mm1400±100 r/min

Telescopic hydraulic shock absorbersRectangular swingarm with 5 step adjustable iGRSsystem

Intake (cold)Exhaust (cold)

Chassis and suspension

Fuel meteringSpark plug

FI (Fuel Injection)NGK-DPR 8 EA 9, BOSCH-XR5DE

PRODUCT SPECIFICATION

2

Caster 26°

3

PRODUCT SPECIFICATIONSPECIFICATIONSITEM

Trail length 94 mmTyre size 80/100x18-47P (Tubeless tyre)

120/80x18-62P (Tubeless tyre)FrontRear

Brakes Dia. 276 mmDia. 240 mm

Front (Disc type)Rear (Disc type)

Primary reductionFinal reduction

stGear ratio, 1rd3th4

3.0909 (68/22)3.0769 (40/13)2.769 (36/13)1.722 (31/18)1.263 (24/19)1.000 (22/22)

Transmission

Cast wheel Cast wheel

Front wheelRear wheel

nd2

Battery 12V-6Ah, *MF BatteryElectricals

*MF stands for Maintenance Free**MFR stands for Multi-Focal Reflector

12V-0.2W/2.1W LED

AlternatorStarting systemHeadlamp (High/Low)Tail/Stop lampTurn signal lampMeter illuminationNeutral indicatorTurn signal indicator

Position lampLicence plate lampProgrammed FI Malfunction Indicator (MIL)Fuse

232W @ 5000 r/minElectric start

20A, 15A, 7.5 A

12V-35/35W Halogen Bulb (Dual headlamp)

L.E.D.12V-5W12V 1.0W LED (Lamp guide x 2)

L.E.D12V-1.14WL.E.D.12V-10Wx4 nos.-**MFR

th5 0.815 (22/27)

Hi beam indicator L.E.D

î During night time, dip headlamps of your motorcycle for oncoming traffic, or when following another vehicle.

î Always conduct simple pre-ride inspection (page 27).

î Always wear a helmet (ISI marked) with chin strap securely fastened and insist on a helmet for your pillion rider.

î While riding, sit in a comfortable position with your legs close to fuel tank.

î Ride defensively and at a steady speed (between 40-50 km/hr).

î To make yourself more visible, wear bright reflective clothing that fits well.

î Take care of loose/hanging clothes while solo/pillion riding.

î For stopping motorcycle, use both brakes simultaneously, keeping throttle in the close position.

î Give way to others on the road and signal before you make a turn.

î Get your motorcycle serviced regularly by the Authorised Hero MotoCorp workshop.

î Respect road signs and obey traffic rules for your own safety and that of others on the road (page 59).

î Avoid sudden acceleration, braking and turning of your motorcycle.

î Never ride under the influence of alcohol or drugs.

î Concentrate on the road and avoid talking to the pillion rider or others on the road.

î Do not litter the road.

î Never touch any part of the hot exhaust system like muffler.

î Never take your hands off the steering handle while riding.

î Never use cell phone while riding the motorcycle.

î Do not cross the continuous white/ yellow line in the center of the road, while overtaking.

î Do not attach large or heavy items to the handlebars, front forks, or fenders.

î Never shift gears without disengaging the clutch and closing the throttle.

SAFE RIDING TIPSDo's: Don't:

4

î Do not pull a trailer or sidecar with your motorcycle. This motorcycle was not designed for these attachments, and their use can seriously impair your motorcycle's handling.

î Be sure electrical equipment does not exceed the motorcycle's electrical system capacity (page 3). A blown fuse can cause a loss of lights.

î Make sure that the accessory does not obscure any lamps, reduce ground clearance, limit suspension travel or steering travel, affect your riding position or interfere with operating any controls.

Modifying your motorcycle or using non-Hero MotoCorp accessories can make your motorcycle unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following information.

ACCESSORIES & MODIFICATIONS ModificationsWe strongly advise you not to remove any or ig ina l equipment or modi fy your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycle's handling, stability and braking, making it unsafe to ride. Removing or modifying your lamps, mufflers, emission control system or other equipment can also make your motorcycle illegal.

î Follow all instructions in this owner's manual regarding accessories and modifications.

î Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.

WARNING

_____________________________________________________________________________________________________________________________________________________________________

NAME: _____________________________________________

PHONE NO : _____________________________________

ADDRESS: _______________________________________

î Many times stolen motorcycles are identified by information in the Owner's Manuals that are still with them.

î Put your name, address and phone number in this Owner's Manual and keep it in your motorcycle at all times.

î Use an additional anti-theft device of good quality.

î Park your motorcycle in a locked garage whenever possible.

ANTI-THEFT TIPSî Always lock the steering and never leave the

key in the ignition switch .

Accessories

5

î Genuine spares: Always insist on Hero MotoCorp genuine parts as spurious or incompatible spares and accessories can upset or deteriorate your motorcycle’s running condition.

î Genuine engine oil: Hero 4T Plus SAE 10W 30 SL grade (JASO MA2) engine oil recommended by Hero MotoCorp and make sure you change it every 6000 km (with top up every 3000 kilometres) to keep the engine fit and environment healthy.

The following tips shall ensure a healthy motorcycle, healthy environment, and a healthy you.

î Noise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or defective mufflers, excessive noise will cause headaches and discomfort.

î Healthy engine: The engine is the lifeline of every vehicle. To keep it healthy, it should be tuned regularly, which will also help reduce pollution and improve vehicle performance & fuel efficiency.

î Regular servicing: Get your motorcycle serviced at an Authorised Hero MotoCorp workshop, as per the service schedule, for an optimum performance and keep the emission level under check.

î Emission pollution: Get emission of your motorcycle checked by Authorised agencies atleast once every 3 months or as notified by the government from time to time.

î Fuel saving & reduce pollution: Switch "OFF" the engine while waiting at traffic signal points to save fuel and reduce pollution, if the waiting period is long.

SOME TIPS FOR HEALTHY ENVIRONMENT

6

5. Headlamp (Lo-beam)

1. Front fender2. Right position lamp guide3. Front right turn signal lamp4. Front visor

63

8

1

2

4

7

6. Front left turn signal lamp7. Left position lamp guide8. Headlamp (Hi-beam)9. Oil cooler

5

9

*Accessories and features shown may not be part of standard fitment.

FRONT VIEWMOTORCYCLE VIEWS

7

1. Left rear turn signal lamp2. Tail/stop lamp 4. Licence plate lamp

3. Right rear turn signal lamp

1 3

2

4


REAR VIEWMOTORCYCLE VIEWS

8

6. Rear view mirror

1. Horn switch2. Turn signal lamp switch3. Clutch lever 4. Passing switch 5. Dimmer switch

7. Combination meter console

8. Ignition switch with steering lock 9. Front brake lever

11. Throttle grip

14. Fuel tank cap

10. Dynamic handlebar damper

13. Headlamp switch 12. Electric starter switch

13

3

1

5

4

6

7

11

9

10

14

2


FRONT VIEWMOTORCYCLE VIEWS

9

12

8

2

6. Side stand

9. Saree guard with women pillion step

8. Seat/helmet hanger 7. Pillion foot rest

10. Rear grip 11. Document & tool kit compartment 12. Fuel pump13. Fuel injector

1. Starter motor 2. Gearshift pedal

5. Rider foot rest 4. Main stand3. Side stand switch

1

5 97 8

11

6

1213

10

LEFT SIDE VIEWMOTORCYCLE VIEWS


3 4

10

9. Front disc 10. Front master cylinder

7. Throttle body 8. Caliper assembly

11. Battery main fuse

12. Battery compartment

14. Fuse box15. Rear shock absorber

13. Rear brake fluid reservoir

16. Rear hugger fender4. Rider foot rest 5. Brake pedal

1. Rear disc

3. Rear master cylinder

6. Oil level dipstick

2. Pillion foot rest

5 7 81

RIGHT SIDE VIEWMOTORCYCLE VIEWS

11


11

10

13 1214

16

2 3 4 6 9

15

Instruments and IndicatorsPARTS FUNCTION

The indicators are in the combination meter console. Their functions are described in the tables on the followings pages.

Sl. No. (1) Position Lamp Indicator

(2) Selection Button

(3) Fuel gauge

12

1234

5 6 7

89

101112

1415 13

î To adjust time (page 16) in the digital clock when pressed along with the reset button for more than 2 seconds.

î To register user name (page 16) in the scrolling display.î To save mode selection.î To select Trip-A, Trip-B on tripmeter or odometer.

Use this button for the following purposes :

Light glows when the headlamp switch is shifted to “ ”. Position lamp, Tail lamp and Licence plate lamp are functional.

Indicates approximate quantity of fuel available in the form of digital segments. The fuel gauge digital segments will swing to the maximum scale on the fuel gauge LCD panel once when the ignition switch is turned "ON". The approximate amount of fuel is indicated by the number of segments displayed (pages 20).

FunctionDescription

(5) Digital clock (4) Digital speedometer Indicates driving speed.

Indicates hour and minute (pages 16).

(9) Tripmeter Shows the distance traveled during a trip (page 17).(10) Odometer Shows accumulated mileage

(11) Reset button

(12) Turn signal indicator Flashes when turn signal switch is operated (13) High beam indiactor Light glows when headlamp is in “Hi” Beam(14) Neutral indicator Light glows when vehicle is in neutral position

(15)Programmed-FI

lamp (MIL) malfunction indicator

13

(6) Tachometer

(8) Scroll message display/

message side stand “ON”

(7) Real time mileage indicator (RTMI)

Shows engine revolutions per minute. The tachometer digital segments will swing to the maximum scale on the tachometer LCD panel once when the ignition switch is turned ''ON".Indicates the current mileage of the motorcycle in (Km). The indication will change once in every 10 seconds depending upon the riding condition (page 20).

Displays a scrolling message as “SIDE STAND IS ON”. When the side stand is down to alert the customer to lift it up before riding.

Displays a scrolling Welcome Message when the ignition switch is turned "ON" (if the side stand is up) and Sign-Off message when the ignition switch is turned "OFF".

When the ignition switch is turned “ON” the Programmed-FI MIL glows for few seconds and then should go “OFF”. It indicates that Programmed FI system is “OK”. If it “flashes”, or remains “ON” there is an abnormality in the Programmed FI system, it is recommended to reduce the speed and drive it to Authorised Hero MotoCorp workshop for check up.

Use this button for the following purposes :

î To register user name (page 17) in the scrolling display.î To select mode selection.î To reset Trip-A and Trip-B on tripmeter.

î To adjust time (page 19) in the digital clock when pressed along with the select button for more than 2 seconds.

Key Position Function Key Removal

Key cannot be removed“ON”

(3) Steering lock (1) Ignition key (2) Ignition switch

î Programmed-FI Malfunction Indicator lamp illuminates for few seconds and goes “OFF”.

î “SIDE STAND IS ON” scroll message will be displayed if the stand is down.

î Turn signal lamps, Horns, Tail/Stop lamp, Passlamp, Headlamp & Neutral indicator will be functional.

î The engine can be started. î The combination meter console LCD panel

illuminates & initial display of multifunction digital segments are displayed.

Engine cannot be started and no electrical system will be functional. Key can be removed

Key can be removed“LOCK”

“OFF”

Steering can be locked.

“OFF” Position/Lock Open

“LOCK” Position

“ON” Position

Ignition switch

1

2

3

14

When the ignition switch is turned "ON" the combination meter console (1) LCD will display the following digital segments so that you can be sure the LCD display is functioning properly.1. Combination meter console

4. Real Time Mileage Indicator (RTMI)

2. Digital clock 3. Tachometer

5. Scroll message8. Fuel gauge 7. Odometer or6. Tripmeter

9. SpeedometerNOTE : Digital clock (2) has to be reset if the battery is disconnected.

}(depending on last selection)

3

1

2

4

56789

15

Digital clock

î Turn the ignition switch "ON".î Press and hold Select Button (2) and Reset

Button (3) simultaneously for more than 2 seconds. The clock will be set in the adjust mode with the display blinking.

Digital Clock (1) shows hours and minutes. To adjust the time, proceed as follows : · The time is advanced by 1 hour each time

the button is pressed.

î To set the hour, press Reset Button (3) until the desired hour is displayed.

î Press the Select Button (2). The minute display starts blinking.

· The time advances fast when the button is pressed and held.

SEL RESET

km/h

AMPM

TOTAL TRIP

km/lAv

01

23

4 5 6 78

910

x1000r/minx1000r/min

1

2 3

SEL RESET

km/h

AMPM

TOTAL TRIP

km/lAv

01

23

4 5 6 78

910


3

SEL RESET

km/h

AMPM

TOTAL TRIP

km/lAv

01

23

4 5 6 78

910


2

SEL RESET

km/h

AMPM

TOTAL TRIP

km/lAv

01

23

4 5 6 78

910


3

16

Odometer/TripmeterThe odometer (1) shows accumulated distance traveled.The Tripmeter shows distance traveled per trip. There are 2 tripmeters, Tripmeter-A (2) and Tripmeter-B (3).Push Select button (4) to select the Odometer, Tripmeter-A or Tripmeter-B. Tripmeter-A can be displayed from ''9999.9'' Km. Tripmeter-B can be displayed upto "9999.9" Km. If the Tripmeter-A or B exceeds "9999.9" Km. it will return to "0" automatically.The Odometer can be displayed from "0 to 999999" Km.

î To set the minute press Reset Button (3) until the desired minute. The minute display will return to " " when " " is reached without affecting the hour display.· The time advances by 1 minute, each

time the button is pressed.· The time advances fast when the button is

pressed and held.î To end the adjustment press Select Button

(2) or turn the ignition switch "OFF". The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 30 seconds.

The clock will reset " " if the battery is disconnected.

NOTEAM :

km.

TOTAL

km.

A

km.

B

SEL RESET

N

km/h

AMPM

TOTAL

km.

km/lAv

01

23

4 5 6 78

910


1

2

3

4

The scroll (1) displays a message whenever the ignition is either turned "ON" (Welcome Message) (if side stand is up) or "OFF" (Sign-Off Message).

Scroll message

SEL RESET

km/h

AMPM

TOTAL TRIP

km/lAv

01

23

4 5 6 78

910


1

î Welcome message: After the ignition is turned "ON" Welcome Message will be displayed.

17

î Sign-Off message: After the ignition is turned "OFF" the Sign-Off Message will be displayed.

î Side stand “ON” message: When the ignition is turned "ON" and side stand is down, “SIDE STAND IS ON” Message will be displayed.

User name registration

The “Welcome” and “Sign-Off” messages are displayed in two forms;

î User name display: The user can register a 6 character alphanumeric value in the message.

î Fixed Display: This is a fixed type of message and no changes can be made.

î Press the "SEL" button (2) and turn the ignition switch to "ON", 5 under bars (3) stout of 6will be displayed with the 1 under bar blinking.

SEL RESET

01

23

4 5 6 78

910


2

3

î Press "Reset" button (4) to select value of st1 character. (The value will increase every

.25 seconds if the button is pressed continuously) There are "6" characters and the value is alphanumerical.

SEL RESET

01

23

4 5 6 78

910


4

SEL RESET

01

23

4 5 6 78

910


î Press "SEL" button (2) to move to the next character, the cursor scrolls by one character and displays a blinking under bar at the blank display.

2

18

thî After selecting the 6 character, finally press the "SEL" button to "SAVE" the "User Name" in the memory and "END" the user name registration .

The scroll message can be displayed in four different modes;

Display mode

Mode Welcome Message

Sign-Off Message

A-Mode B-ModeC-Mode D-Mode

Fixed Type User Name Fixed Type User Name

î If the button is not operated for more than 30 seconds, the selected mode will become invalid.

î If the ignition switch is turned to "OFF" the selected value will become invalid.

NOTE

Fixed Type Fixed Type User Name User Name

Mode selection î Press the "RESET" button (4) and turn the

ignition switch to "ON" (mode display will be flashed)

î Press "SEL" button (2) to "SAVE" the selected "MODE" and "END".

î Press "RESET" button to select mode.

SEL RESET

01

23

4 5 6 78

910


4

SEL RESET

01

23

4 5 6 78

910


2

î If button is not operated for more than 30 seconds, the selected mode will become invalid.

î If the ignition switch is turned to "OFF" the selected value will become invalid.

NOTE

19

Fuel gaugeThe fuel gauge (1) is of a Liquid Crystal Display (LCD) type.The approximate amount of fuel quantity available in the fuel tank is indicated by the number of segments in the display. If all the segments (2) are displayed it means fuel quantity in the fuel tank is litres . 15.3 (minimum)

(1) Fuel gauge (2) Segments

1 2

If only one segment (3) is displayed and blinks, this indicates that the fuel quantity is low and the fuel tank should be refilled as soon as possible.REAL TIME MILEAGE INDICATOR (RTMI)The Real Time Mileage Indicator (1) shows the current mileage of the motorcycle in km/litre and is refreshed after every 10 seconds.When the ignition switch is turned ON, the Real Time Mileage Indicator will temporarily show the digit " " which indicates that all the digital LCD segments are working. The display range is from km/litre).

(3) Segment

3

1

The fuel consumption shall be displayed when the speed of the vehicle is more than 5 km/hr. If the speed is less than 5 km/hr only “- - - - km/l ” shall be displayed.The RTMI shows a minimum value of Km/litre and maximum value of Km/litre. During coasting with throttle fully closed, the fuel consumption is very minimal and hence the display can go up to Km /litre.

20

“ ” for high beam and downwards to“ ” for low beam.

Press the dimmer switch (2) upwards to

5. Clutch switch

Shift the turn signal lamp switch (3) sideways for Right/Left indications and leave it to come back to its normal position on its own.

4. Horn switch

There is a clutch switch provided for the safety of the rider. The motorcycle cannot be started by starter switch until the clutch lever is pressed, when the vehicle is engaged in gear.

IMPORTANT :To switch "OFF" the turn signal lamp after completing the turn, gently push inside as directed on the switch.

3. Turn signal lamp switch

Press the horn switch (4) to operate the horn.

1. Passing switch

2. Dimmer switch

Press the passing switch (1) towards the handle bar to operate the pass lamp to indicate for passing ahead.

LEFT HANDLEBAR CONTROLS1

2

3

4

5

RIGHT HANDLEBAR CONTROLS

1

2

1. HEADLAMP SWITCHThe switch has three positions.

and marked by red dot.

21

STEERING LOCK

Steering lock is with in the Ignition switch, turn the key (1) to ‘OFF’ position & turn the handle bar towards left or right & push the key downwards & turn towards “LOCK” position. After locking take out the key.

Ensure starter switch (2) is operated. when the vehicle is in neutral. If the vehicle is engaged in gear, press the clutch lever before operating the starter switch. Release starter switch after the engine has started.

2. Electric starter switch

Never hold starter switch continuously for more than 5 seconds as continuously cranking of engine will drain the battery.

CAUTION

Position Action“OFF”

Headlamp “ON”

• Position lampsFollowing is “ON”

• Tail/stop lamp• Position lamp indicator• Licence plate lamp• Pass lamp

1(1) Ignition key

Operation : Insert the ignition key (1) in seat lock (3) and turn it clockwise. Pull the knob (4) downwards, behind the lock to release the pillion seat (2).

SEAT LOCKLocation : On the rear left side of the seat, below the rear cowl.

SEAT REMOVALRemove the pillion seat (2) by releasing the tabs (5) from the brackets (6) located on the frame.Lift the rider seat (8) to release the lugs from the grommets (9) and pullout towards rear to release the tab (10) from the slot (11).

4

3

2

1(1) Ignition key (2) Pillion seat(3) Seat lock (4) Knob

22

SEAT INSTALLATIONTo install, engage the tab (10) of the rider seat with the slot (11) of the fuel tank and slide the seat towards front, then align the lugs (7) on to the grommets (9) located on the frame.

6

5

(5) Tabs (6) Brackets (10) Tab (11) Slot

7

8

9(7) Lugs (8) Rider seat (9) Grommets

Engage the tabs (5) of the pillion seat in to the brackets (6) and slide it forward, then press down until the lock clicks.HELMET HANGERThe helmet can be hung and locked on the helmet hanger (1) provided with the seat lock by rotating the key.

10

11

1

(1) Helmet hanger

23

Fuel tank capacity is 15.3 litres (minimum).î To unlock fuel tank cap (1) lift the key hole

cover (2), insert ignition key (3) turn it clockwise and remove the cap.

î Do not overfill the tank. There should be no fuel (4) in filler neck (5).

î To lock-Position the cap back on the opening with the arrow mark "D" on the cap facing towards the front of the motorcycle then press gently. The key springs back to the normal position and cap gets locked.

FUEL TANK

12

3

(1) Fuel tank cap (2) Key hole cover (3) Key

54

(4) Filler Neck (5) Fuel

Do not park the motorcycle under direct sunlight as it causes evaporation of petrol due to heat and deterioration of paint gloss due to ultra violet rays.

CAUTION

Petrol is extremely flammable and is explosive under certain conditions. Refill in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the petrol is refilled or where petrol is stored.

WARNING

To safely operate your motorcycle, your tyres must be of the proper type and size, in good condition with adequate tread, and correctly inflated for the load you are carrying. The fol lowing pages give more detai led information on how and when to check the air pressure, how to inspect your tyres for damage, and what to do when your tyres need to be repaired or replaced.

TYRESThe tyres fitted on your motorcycle are of TUBELESS type.

24

Tubeless tyres have some self-sealing ability if they are punctured. However, because leakage is often very slow, you should look closely for punctures whenever a tyre is not fully inflated.

Air pressureKeeping your tyres properly inflated provides the best combination of handling, tread life and riding comfort. Generally, under inflated tyres wear unevenly, adversely affect handling, and are more likely to fail from being overheated.Over inflated tyres make your motorcycle ride harshly, are more prone to damage from road hazards, and wear unevenly.We recommend that you visually check your tyres before every ride and use a gauge to measure air pressure at least once a month or any time you think the tyre pressure might be low.

Always check air pressure when your tyres are "cold" - when the motorcycle has been parked for at least three hours. If you check air pressure when your tyres are "warm"-when the motorcycle has been ridden for even a few Km.- the readings will be higher than if the tyres were "cold". This is normal, so do not let air out of the tyres to match the recommended cold air pressures given below. If you do, the tyres will be under-inflated.

î Using tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed.

î Follow all instruction in this owner’s manual regarding tyre inflation and maintenance.

WARNING

FrontRear

2 2.00 kgf/cm (29 psi)2 2.00 kgf/cm (29 psi)

2 2.00 kgf/cm (29 psi)2 2.25 kgf/cm (33 psi)

Rider only Rider and PillionThe recommended “cold” tyre pressures are:

1

(1) Tyre pressure gauge

Over inflation/Under inflation will affect the performance.

CAUTION

Whenever you check the tyre pressure, you should also examine tyre treads & side walls for wear, damage & foreign objects:

Inspection

Look for :î Bumps or bulges in the side of the tyre or the tread.

Replace the tyre if you find any bumps or bulges.î Cuts, splits or cracks in the tyre. Replace the

tyre if you can see fabric or cord.î Excessive tread wear.

25

Minimum tread depth

î Carefully inspect the tyres for any damage, if the motorcycle hits a pothole or hard object.

Check the tread wear indicator for tyre wear.Front: 1.5 mm Rear: 2.0 mm

Tread wearReplace tyres immediately when the wear indicator (1) appears on the tyre. The tread limits are :

Unidirectional tyresWhenever the tyre is removed and put back in case of puncture, ensure the arrow mark on the tyre is in the same direction as that of forward rotation of wheel.

to visit nearest tyre manufacture, Hero MotoCorp authorised dealer/workshop or the tyre repair shop who has expertise in repair ing methods of tubeless tyre.

You should not exceed 70 km/hour for the 1st 24 hours or 105 km/hour at any time thereafter. In addition, you may not be able to safely carry as much load as with a new tyre. If you decide to have a tyre replace be sure the wheel is balanced before you ride.

A tyre that is repaired either temporarily or permanently, will have lower speed and performance limits than a new tyre. After an emergency repair, always have the tyre inspected/replaced at our authorised dealer and replace the tyre if suggested.

(1) Tread wear indicator (2) Arrow mark

2

Tyre repairRepairing a puncture or removing a wheel requires special tools and technical expertise. If a tyre is punctured or damaged, it is advised

The tyres that were installed on your motorcycle were designed to match the performance capabilities of your motorcycle and provide the best combination of handling, braking, durability and comfort.

Tyre replacement

î Follow all instruction in this owner’s manual regarding tyre inflation and maintenance.

î Using tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed.

î Operation with excessively worn tyres is hazardous and will adversely affect traction and handling.

WARNING

26

1

Front : 80/100x18-47 P (Tubeless)The recommended tyre for your motorcycle are:

Rear : 120/80x18-62 P (Tubeless)

î Do not install a tube inside a tubeless tyre on this motorcycle. Excessive heat buildup can cause the tube to burst.

Important Safety Reminders

î Use only tubeless tyres on this motorcycle. The rims are designed for tubeless tyres, and during hard acceleration or braking, a tube-type tyre could slip on the rim and cause the tyre to rapidly deflate.

î Always use the size and type of tyres recommended in this owner’s manual.

î Under-inflation may result in the tyre slipping on or tyre coming off the rim.

WARNING

NOTEThe imported tyre(s) if fitted without ISI mark; are in compliance of BIS standard and Central Motor Vehicle Rules 1989, as declared by the Tyre manufacturer.

NOTEFor repair and replacement of tyre it is advised to visit your Authorised Hero MotoCorp workshop.

are not specifically designed for motorcycle surfaces. Inspect your motorcycle very day before you start the engine. The items listed here will only take a few minutes, and in the long run they can save time, expense and possibly your life. Please follow the tips as given below:

PRE-RIDE INSPECTIONYou should conduct pre-ride inspection before riding the motorcycle to enhance riding comfort and safety.Clean your motorcycle regularly. It protects the surface finish. Avoid cleaning with products that

î Clutch- check for smooth operation. Adjust free play (page 42).

î Fuel level- ensure sufficient fuel is available in the fuel tank for your journey (pages 24). Check for leaks.

î Programmed-FI malfunction indicator Lamp (MIL)- when the ignition switch is turned "ON" the Programmed-FI malfunction indicator lamp glows for few seconds and then it should go "OFF".

î Throttle - check for smooth opening and closing in all steering positions (page 41).

î Engine oil level- check and top up engine oil if required (page 36).

î Lamps and Horn- check that headlamp, position lamps, tail/stop lamp, turn signal lamps, indicators and horn function properly.

î Drive chain- check condition and slackness (pages 42). Lubricate if necessary.

î Tyres- check condition and pressure (pages 24).

Check for leaks.

î Front & Rear brake (Disc type)- check for correct brake fluid level in master cylinder (pages 46 & 47).

27

î Rear view mirror- ensure that the rear view mirror gives a good rear view when you are sitting on the motorcycle.

î Fitting & Fasteners- check & tighten if necessary.

î Side stand message- make sure that the side stand is up. If it is in down position the side stand message (page 14) will be displayed on the LCD panel.

î Steering- check for smooth action and for easy maneuverability.

STARTING THE ENGINEAlways follow the proper starting procedure described below :î To protect the catalytic converter in your

motorcycle's exhaust system, avoid extended idling and the use of leaded petrol.

î Your motorcycle's exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as garage. Do not run the engine with the garage door closed.

î Do not use electric starter for more than 5 seconds at a time. Release the starter switch for approximately 10 seconds before pressing it again.

î Find neutral position & check neutral N indicator (3) on instrument console with ignition "ON".

î Press the starter switch.Starting ProcedureThis motorcycle has a Fuel-Injected engine with an Idle Air Control Valve (IACV).

12

(1) Ignition switch (2) MIL

PreparationBefore starting insert the key and follow the below mentioned procedure :î Turn the ignition switch (1) "ON".î Conf i rm that the Programmed-FI

malfunction indicator lamp (MIL) (2) turns "OFF" after few seconds.

3

(3) Neutral indicator

28

î Press the starter switch for 5 seconds.

î If the engine starts with unstable idle, open the throttle slightly.

Your motorcycle is designed to automatically stop the engine and fuel pump, if the motorcycle is over-turned (Bank angle sensor cuts-off the ignition).

î Press the starter switch with the throttle completely closed.

Ignition cut-off

Flooded engine

Running-In

At any ambient temperature :

With the throttle completely closed, press the starter switch. The engine will not start if the throttle is fully open because the Electronic control unit (ECU) cuts-off the fuel supply.

Any air temperature

î Open the throttle fully.

If the engine fails to start after repeated attempts, it may be flooded with excess fuel.

î Follow the normal starting procedure.

î If the engine does not start wait for 10 seconds, then follow steps 1-3 again.

Bank Angle Sensor cuts-off the ignition system and fuel supply. Before restarting the engine you must turn the ignition switch to the "OFF" position and then back to "ON".

Follow the procedure mentioned below :

During initial running-in newly machined surfaces will be in contact with each other and

these surfaces will wear in quickly. Running-in precautions till 1000 km will reduce initial wear of engine components and increase its service life.

NOTE

î Do not open the throttle during starting the vehicle.

î To start the engine if any gear is engaged, press the clutch lever and press the starter switch.

Never run the engine in a closed area, the exhaust contains poisonous gases.

WARNING

Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when riding, idling or parking your motorcycle.

Review motorcycle Safe Riding Tips (page 4) before you ride.

î While the engine is idling, press the clutch lever and depress the gearshift pedal to shift

stinto 1 (low) gear.

RIDING

î After engine has been warmed up, the motorcycle is ready for riding.

î Slowly release the clutch lever and at the same time, gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start

29

î This sequence is repeated progressively rd th thto shift to 3 , 4 and 5 (top gear).

î Both front and rear brakes should be used at the same time and should not be applied strongly to lock the wheel, or else braking effectiveness will be reduced and control of the motorcycle will be difficult.

î When the motorcycle attains a moderate speed, close the throttle, press the clutch

ndlever and shift to 2 gear by raising the gearshift pedal.

î Coordinate the throttle and brakes for smooth deceleration.

2

3

4

N

1

5

Do not shift gears without operating clutch and without closing the throttle otherwise this would lead to damage of gears.

CAUTION

Important Safety Reminders:

apply the pedal and lever, pull in the clutch lever before coming to a complete stop to prevent stalling the engine.

î Independent operation of only the front brake lever or rear brake pedal reduces stopping performance.

î Extreme application of the brake controls may cause wheel lock, reducing control of the motorcycle.

î When possible, reduce speed or brake before entering a turn, closing the throttle or braking in mid-turn may cause wheel slip. Wheel slip will reduce control of the motorcycle.

î When riding in wet or rainy conditions, or on loose surfaces, the ability to maneuver and stop will be reduced. All of your actions should be smooth under these condition. Rapid acceleration, braking or turning may cause loss of control. For your safety, exercise extreme caution when braking, accelerating or turning.

î When descending a long, steep grade, use engine compression braking by down-shifting, with intermittent use of both brakes.

Continuous brake application can overheat the brakes and reduce their effectiveness.

î Riding with your foot resting on the brake pedal or your hand on the brake lever may actuate the brake lamp, giving a false indication to other drivers. It may also overheat and reduce effectiveness.

For normal braking, apply both the rear brake pedal and front brake lever simultaneously while down-shifting to match your road speed. For maximum braking, close the throttle and firmly

BRAKING

30

After stopping the motorcycle, shift the transmission into neutral and turn the ignition switch "OFF", park the motorcycle on main stand, lock the steering and remove the key.

PARKING

• Grip- 1 No.

• Pin spanner- 1 No.• Box wrench P18- 1 No.

• +, - No. 2 driver- 1 No.

• No. 3 cross point screw driver- 1 No.

The tool kit (1) is located below the seat in the rear. Some emergency repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit.

• Tool bag- 1 No.Kit consists of following tool :

TOOL KIT/FIRST AID KIT

î Park the motorcycle on firm level ground to prevent it from falling over.

î While parking on side stand ensure the vehicle is in first gear.

î Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your motorcycle. To avoid possible heat damage to your motorcycle or personal belongings, do not cover the exhaust muffler with the protective cover or any clothing within 20 minutes after shutting “OFF” the engine.

î Lock the steering to prevent theft.

CAUTION

Kit contains the following items :1) Anticeptic Cream - 1 No.

4) Elastic Bandage - 1 No.5) Gauze (Rolled Bandage) - 1 No.6) Sterilised Elastic Plaster - 1 No.

2) Sterilised Dressing - 1 No.3) Water Proof Plaster - 1 No.

7) First Aid Bag - 1 No.

The first aid kit (2) is located below the seat in the rear. For some emergency first aid can be performed by medicine contained in the kit.

1

2

(1) Tool kit (2) First aid kit

31

The Importance of Maintenance

Consult your Authorised Hero MotoCorp workshop for recommendation applicable to your individual needs and use.

A Well-maintained motorcycle is essential for safe economical and trouble-free riding. It will also help in reducing air pollution.

These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the Maintenance Schedule.

If your vehicle overturns or is involved in a crash, be sure that you visit your Authorised Hero MotoCorp workshop for detailed inspections.

MAINTENANCE

To help you, take proper care of your motorcycle, the following pages include a Maintenance Schedule and a Maintenance Record for regular scheduled maintenance.

This section includes instruction on some important maintenance tasks. You can perform some of these tasks with the tools provided - if you have basic mechanical skills.

Maintenance Safety

Other tasks that are more difficult and require special tools are best performed by professionals. It is recommended that wheel removal should normally be handled by a Hero MotoCorp authorised workshop.Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not to perform a given task.

î Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed.

î Always fo l low the inspect ion and maintenance recommendations and schedules in this owner’s manual.

WARNING

î Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt.

î Always fol low the procedures and precautions in this owner's manual.

WARNING

32

25

SAFETY PRECAUTIONî Make sure the engine is “OFF” before you

begin any maintenance or repair. This will help to eliminate several potential hazards:

* Carbon monoxide poisoning from engine exhaust.Be sure there is adequate ventilation whenever you operate the engine.

* Burns from hot parts.Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

î Read the instruction before you begin and make sure you have the tools and skills required.

* Injury from moving parts.

î To help prevent the motorcycle from falling over, park it on a firm, level surface on the main stand.

î To reduce the possibility of a fire or explosion, be careful when working around petrol or batteries. Use only nonflammable solvent, not petrol, to clean parts. Keep cigarettes, sparks and flames away from the battery and all fuel-related parts.

To ensure best quality and reliability, it is recommended to use genuine Hero MotoCorp parts for repair and replacement.

Remember that your Authorised Hero MotoCorp workshop knows your motorcycle best and is fully equipped to maintain and repair it.

33

* Should be serviced by your Authorised Hero MotoCorp workshop, unless the owner has proper tools, service information and is mechanically qualified. Refer to the Hero MotoCorp shop manual.

NOTE-2 : Replace engine oil once in every 6000 kms. Top up once in every 3000 kms.NOTE-1 : Early replacement may be required when riding in dusty areas.

I: INSPECT R: REPLACE C: CLEAN L: LUBRICATE A: ADJUST IF REQUIRED O: OIL CHANGE T:TOP UP E: EMISSION CHECK

We would strongly recommend the following schedule, to keep your motorcycle in perfect running condition and healthy environment. Motorcycle subjected to severe use or ridden in dusty area will require more frequent servicing.

** In the interest of safety, we recommend these items be serviced only by Authorised Hero MotoCorp workshop.

NOTE-6 : Check idle CO emission along with idle r/min/idle CO adjustment (if required).

NOTE-3 : Replace once in every two years or 30000 km. whichever is earlier.

NOTE-5 : Should be serviced if any complaint reported before the scheduled time.

Dear Customer,

NOTE-4 : Inspect & maintain specified torque.

Always wipe the water from the motorcycle after washing. Use clean soft cloth or pressurised air for completely drying the water.

The following items require more mechanical knowledge. Certain items (particularly those marked and ) may require more technical information and tools consult your Authorised * **Hero MotoCorp workshop.

Hero MotoCorp recommends that your Authorised Hero MotoCorp workshop road tests your motorcycle after each periodical maintenance is carried out.

MAINTENANCE SCHEDULE

34

3000-3500

6000-6500

9000-9500

12000-12500

Air Cleaner

Engine Idle Speed

NOTE-1

**

*

NOTES 3000 9000 12000 15000

st1 60Next 100

ITEMS

DURING FREE SERVICE PERIODst1 nd2

WHICHEVERCOMES FIRSTSERVICE

DAYS

KMS 500-750

AFTER FREE SERVICEONCE IN EVERY

th5th4rd3

Fuel LineThrottle Operation

Oil CirculationElectric Starter Switch

Idle Emission

Engine Oil Cooler

Spark Plug* NOTE-5** NOTE-5

*

*

*

NOTE-2

* I,C,L,A at every 1000 kms I,C,L,A at every 1000 kms

Valve ClearanceEngine OilEngine Oil Strainer ScreenEngine Oil Centrifugal Filter

Drive Chain

Wheels/Tyres

Battery Voltage *

* NOTE-3**

NOTE-4****** NOTE-3

Headlamp FocusStop Lamp Switch

Brake Pads WearBrake Fluid

Fasteners

Side Stand/Main StandClutch

Front Suspension/OilSteering Head Bearing

Side Stand Switch

Drive Chain Slider

Do not open air cleaner element unless there is a drivability problem

Muffler (Catalytic Converter) NOTE-6

Next 100

Next 100

Next 100

I

I

III

I

III

II

II

I

O O O

I

I

III

I

III

I

II

I

I

I

I

III

I

III

II

II

I

I

I

I

III

I

III

I

II

I

I

I

I

III

I

III

I

II

I

IR

I

I

III

I

III

II

II

I

I

I, A

I, AI, AI, A

I, A

I, A

I, AI, AI, A

I, A

I, AI, AI, A

I, A

I, A

I, AI, AI, A

I, A

I, AI, AI, A

I, A

I, A

I, AI, AI, A

I, A I, A I, L, A I, L, A

I, C, A I, C, A

R

R

I, T I, T I, TCC

CC

CC

L L L L L LI, C I, C I, C I, C I, C I, C

I, E I, E

6000

OI, A

I, A

I, A

CC

I, E

35

î Remove the oil level dipstick. The oil level should be between upper and lower level marks on the oil level dipstick.

î If required fill the crankcase with the recommended engine oil through the oil level dipstick opening. Insert the oil level dipstick and check the oil level. Do not overfill above the UPPER level mark.

O-ring & check for oil leaks.î Reinstall the oil level dipstick with a new

î Do top up if oil level reaches towards the lower level mark or on every 3000 km. whichever is earlier.

GRADE: SAE 10W 30 SL Grade BRAND: Hero 4T plus

(JASO MA2).

ENGINE OIL TOP UP PROCESS

î Tide Water Oil Co. (India) Ltd.

î Start the engine & let it idle for 3-5 minutes.

î Stop the engine & wait for 2-3 minutes .

Manufactured by:

î Savita Oil Technologies Limited.

Check engine oil level each day beforeoperating the motorcycle.î Park the motorcycle on its main stand .

î Remove the oil level dipstick (1), wipe it clean and insert the oil level dipstick without screwing it in.

ENGINE OIL

î Bharat Petroleum Corporation Limited.OIL CAPACITY: 1.35 litres

Use hero genuine engine oil or recommended grade oil.

UPPER

LOWER

1

(1) Oil level dipstick (1) Screws (2) Belly pan

NOTERunning the engine with insufficient oil may cause serious engine damage.ENGINE OIL REPLACEMENT PROCESSReplace engine oil once in every 6000 Km/ 6 months whichever is earlier.Change engine oil with the engine warm and the motorcycle on its side stand.

1

2

36

î To drain the oil remove the screws (1) from the front left and the belly pan (2).

î Place a drain pan under the crankcase.î Remove the oil level dipstick (3) and drain

cap (4).

UPPER

LOWER

3

(3) Oil level dipstick

4(4) Drain cap

î Fill the crankcase through the filler hole with approximately 1.10 litres of recommended engine oil.

î Start the engine and allow it to idle for few minutes.

î Stop the engine.î Make sure that oil level is at the upper level

mark on the oil level dipstick with the motorcycle in an upright position, and that there are no oil leaks.

î Reinstall the oil level dipstick with a new O-ring.

CENTRIFUGAL OIL FILTER Centrifugal oil filter needs to be cleaned periodically as per the maintenance schedule (page 35).

î After the oil has completely drained, reinstall the drain cap with a new ‘O’ ring.

î Running the engine with insufficient oil can cause serious engine damage.

î Engine oil is a major factor affecting the performance and service life of the engine. Non-detergent, vegetable, or castor based racing oils are not recommended.

î Running the engine with excessive oil can cause spark plug fouling & loss in performance.

CAUTION

It is advised that you visit your Authorised Hero MotoCorp workshop for this type of service.

37

For most riding conditions this spark plug heat range number is satisfactory.Spark plug needs to be cleaned periodically as per the maintenance schedule (page 35).It is advised that you visit your Authorised Hero MotoCorp workshop for this type of service.

SPARK PLUG

OIL COOLER

1

(1) Oil cooler(1) Heat deflector (2) Screws

î No hard objects to be used for cleaning the oil cooler (1), otherwise the fins will get damaged.

î No high pressure washing of the oil cooler as it may damaged the fins, any physical contact with fins is to be avoided.

CAUTION

SPARK PLUG REMOVAL:

î Clean dirt around the spark plug base.î Disconnect the noise suppressor cap (3)

and remove the spark plug (4) with the help of box wrench provided in the tool kit.

î Visually inspect the spark plug electrodes for wear. The center electrode should have square edges and the side electrode should not be eroded.

Remove the heat deflector (1) by removing the screws (2).

2

1

3

4(3) Nosie suppressor cap (4) Spark plug

38

Recommended spark plugs: NGK-DPR 8 EA 9, BOSCH XR5DE

î Tighten a new spark-plug 1/2 turn after the plug seats, with a spark plug box wrench to compress the washer. If you are reusing a plug, it should only take 1/8-1/4 turn after the plug seats.

î With the plug washer attached, thread the spark plug in by hand to prevent cross-threading.

î Make sure that the spark plug gap is 0.8-0.9 mm using a wire-type feeler gauge. If adjustment is necessary bend the side electrode carefully. Make sure the plug washer is in good condition.

Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.

0.8-0.9 mm

The air cleaner is a viscous type paper filter which has enhanced filtering efficiency.The air cleaner should be replaced at regular intervals (page 35). When riding at dusty areas, more frequent replacement may be necessary.

AIR CLEANER

Remove the pillion and rider seats (page 22).

Remove the left side cover screw (3).

Remove the left side rear grip by removing the nuts (1) and bolts (2) as marked.

Remove the left side cover screws (4).

Remove the left side cover under screws (5).Remove the left side cover screws (6).

1

2 3(1) Nuts (2) Bolts (3) Left side cover screw

4(4) Screws

39

(5) & (6) Screw5

6

î Remove the air cleaner element cover screws (8) and the cover (7).

î Remove the air cleaner element (9).

8

7

(7) Cover (8) Screw

9(9) Air cleaner element

Install a new air cleaner element in the reverse order of removal.

(10) Wire mesh side10

40

Replace paper filter element once in every 15 000 Km.î Replace it earlier if it becomes very dirty,

damaged on surface or on the sealing area.

Never wash or blow air to clean the element. Always replace the element with a new one according to the maintenance schedule.

CAUTION

Refer to the safety precautions on (page33).

î Measure the throttle grip free play (1) at the throttle grip flange.

î Check for smooth rotation of the cable inspection (sub head) throttle grip from the fully open to the fully closed position at both full steering positions.

Cable inspection

THROTTLE OPERATION

î The standard free play should be approximately 2-6 mm of grip rotation.

î If the cable is kinked, chafed or improperly routed, it should be replaced or rerouted.

1

(1) Free play 2-6 mm

Free play adjustmentTo adjust the free play, slide the grommet (2), then loosen the lock nut (3). Turn the adjuster (4) to adjust free play. After adjustment, tighten the lock nut and reinstall the grommet securely.

A

B

3 4

2

(2) Grommet (A) Decrease free play (3) Lock nut (B) Increase free play(4) AdjusterVALVE CLEARANCEExcessive valve clearance will cause noise, and little or no clearance will prevent the valve from closing and cause valve damage and power loss. To ensure proper operation of the valves the valve clearance should be inspected and adjusted if necessary by your Authorised Hero MotoCorp workshop as per the maintenance schedule (page 35).

41

CLUTCH

î To adjust the free play move the clutch lever dust cover (3), loosen the lock nut (4). Turn the adjuster (5) to obtain the specified free play. To increase the clutch lever free play turn the adjuster in direction (A). To decrease the clutch lever free play turn the adjuster in direction (B).

Refer to the safety precautions (page 33).Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep or if the clutch slips, causing acceleration to lag behind engine speed. Normal clutch lever free play (1) is 10-20 mm at the clutch lever (2).

1 A

B

2 4

3

5(1) Free play 10-20 mm (2) Clutch lever(3) Dust cover (4) Lock nut (5) Adjusterî Start the engine, press the clutch lever and

shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. The motorcycle should start smoothly and accelerate.

NOTEIf proper adjustment cannot be obtained or the clutch does not work properly, visit your Authorised Hero MotoCorp workshop.

The service life of the drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets. The drive chain (1) should be checked and lubricated as part of the pre-ride Inspection (page 31). Under severe usage, or when the motorcycle is ridden in unusually dusty areas, more frequent maintenance will be necessary.

DRIVE CHAIN

î Turn the engine “OFF”, park the motorcycle on its main stand and shift the gear to neutral.

Inspection

î Remove the lower chain guard by removing the bolts (2).

1 2(1) Drive chain (2) Bolts

42

Rotate the wheel and check drive chain slack as the wheel rotates. Drive chain slack should remain constant as the wheel rotates. If the chain is slack in one section and tight in another, some links are kinked and bound. Binding can frequently be eliminated by lubrication.

î Drive chain slack (3) should be checked in the lower run midway between the sprockets. Move the drive chain up and down by hand and chain slack should be adjusted to 25 mm vertical movement by hand.

3(3) Drive chain slack 25 mm

NOTEDrive chain slack should be adjusted at your Authorised Hero MotoCorp workshop as per the specification.î Turn the chain to view chain lock plate (4).

Ensure that the chain lock plate open end (5) is installed in the opposite direction of the chain rotation.

î Rotate the rear wheel slowly, inspect the drive chain and sprockets for any of the following conditions.

Drive chain

• Loose pins• Dry or rusted links• Kinked or binding links• Excessive wear• Improper adjustment• Damaged or missing O-rings

• Damaged rollers

(4) Chain lock plate (5) Open end

45

Sprockets

• Broken or damaged teethIf the drive chain has damaged rollers, loose links or missing o-rings, replace it. If the chain is dry or rusted, it should be lubricated.

• Excessively worn teeth

43

Worn Sprocket Teeth

NormalSprocket Teeth

DamagedSprocket Teeth

Never install a new drive chain on a worn sprocket or a worn chain on new sprocket. Always replace drive chain and both sprocket as set.

NOTE

î Park the motorcycle on i ts main stand with the transmission in neutral and the ignition switch in "OFF" position.

î Loosen the rear axle nut (1) and sleeve nut (2).

Adjustment

î Turn the adjusting nut (4) in an equal number of turns until the correct drive chain slack is obtained. Turn the adjusting nut clockwise to decrease the slack or anticlockwise to increase the slack of the chain.

î Loosen the drive chain lock nut (3).

1(1) Rear axle nut

2

5 6 4

3

(2) Sleeve nut (3) Drive chain lock nut(4) Drive chain adjusting nut (5) Index mark(6) Rear edge of adjusting slot

Rear axle nut torque : 5.9 kgf-m.

î Align the chain adjuster index mark (5) with the rear edge (6) of the adjusting slots on both sides of the swing arm equally.

î Tighten the rear axle nut and sleeve nut.

î If the drive chain slack is excessive when the rear axle is moved to the furthest limit of adjustment, the drive chain is worn and must be replaced.

î Check the drive chain slack again. Sleeve nut torque : 6.8 kgf-m.

44

Cleaningî If the drive chain becomes extremely dirty, it

should be removed and cleaned prior to lubrication.

î Wait for approx 3-5 minutes to allow the mixture to penetrate in between bush and roller for proper cleaning of the drive chain. Repeat the process few times depending on the dirt accumulation on the drive chain.

î Dip a soft nylon brush in a mixture of kerosene and 10W30 engine oil (in the ratio of 1:1) and clean the dirt accumulated on the chain with the help of this soft brush.

î Finally wipe the chain with a dry shop towel to remove the oil + kerosene traces from it. Visibly inspect the chain after cleaning and ensure no mud or dust is left out.

Lubricationî Apply SAE 90 Grade oil on the inner side of

the entire length of the chain using the oil can.î Wait for 7-10 minutes for penetration of

the lubricant inside the bush & roller for better lubrication. Wipe the excess lubricant from the chain and nearby parts by using a dry shop towel.

î Ensure that the cleaner & lubricant used is the one recommended for use on an O-ring chain, otherwise O-ring may deteriorate, fail and lose their sealing properties.

î Visit Authorised Hero MotoCorp workshop for inspection, cleaning, lubrication and adjustment of drive chain at every 1000 km.

NOTE

î Steam cleaning, high pressure washers and certain solvents can damage the drive chain O-rings.

î While lubricating and cleaning hold the rear wheel with one hand to prevent the possibility of your finger being trapped between the chain and sprocket.

î The drive chain is fitted with O-rings between the link plates. These O-rings retain grease inside the chain to improve its service life. However, special precautions must be taken when adjusting, lubricating, washing and replacing the chain.

î Regular adjustment and lubrication as per the maintenance schedule would ensure high performance and longer life.

CAUTION

Drive chain sliderRefer to “Maintenance schedule” (page 35).Check the drive chain slider (1) for wear, the chain slider must be replaced if it is worn to the bottom of the cutout (2) or wear limilt (3).

2 3

1(1) Drive chain slider (2) Cut out (3) Wear limit

45

Wear limit : 4 mmFor replacement, visit your Authorised HeroMotoCorp workshop.

Rear: Reservoir (1-A), Location- Inside right side cover next to the battery.

BRAKES

Front: Master Cylinder (1), Location- Front handlebar.

Refer to the safety precautions (page 33).

Fluid level- Ensure that the brake fluid level does not fall below "LWR'' mark (2) on front brake master cylinder and "Lower" mark (3) on the reservoir parallel to the ground. The level decreases gradually due to piston movement to compensate pad wear. If the level decreases abruptly, check for the leakages in the brake system and consult your Authorised Hero MotoCorp workshop.

Brake fluid recommended : DoT 3 or DoT 4

2

1

Master Cylinder

UPPER

LOWER

Reservoir

1-A

3

NOTEClean the dirt and mud accumulation between the front and rear caliper (4), brake pads (5) and the disc (6) by using a water jet.

65

4

Front Caliper

(4) Caliper (5) Brake pads (6) Disc

46

(1) Master cylinder (2) Lower mark

(3) Lower mark

Always contact your Authorised Hero MotoCorp workshop for top-up of master cylinder and reservoir when necessary. Do not mix DoT3 or DoT4 brake fluids.BRAKE PAD WEAR

Check the wear indicator grooves (1) in each pad.If either pad is worn to the bottom of the grooves, replace both as a set. Visit your Authorised Hero MotoCorp workshop.

Brake pad wear depends upon the severity of usage, type of riding & road conditions. Generally, the pads wear faster on wet & dirty roads. Inspect the pads at each regular maintenance interval.Front brake

If either pad is worn to the bottom of the grooves, replace both as a set. Visit your Authorised Hero MotoCorp workshop for this service.

Rear brakeCheck the wear indicator grooves (1) in each pad.

4

5

6

Rear Caliper

(4) Caliper (5) Brake pads (6) Disc

1 1

1

47

Refer to the safety precautions on (page 33).BATTERY

LocationThe battery (1) is located behind the rightside cover.

*MF Battery 12V-6AhIt is not necessary to check the battery electrolyte level or add distilled water as the battery is a Maintenance-Free (sealed) type. If your battery seems weak and/or electrolyte is leaking (causing hard starting or other electrical troubles), contact your Authorised Hero MotoCorp workshop.

Specification

1

(1) Battery

This symbol on the battery means that this product must not be treated as household waste.

NOTE

This symbol on the battery means the old battery must be returned to yoaur Authorised Hero MotoCorp workshop as it must be treated as recyclable material.

î An improperly disposed battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal.

î Battery is a Maintenance-Free (sealed) type and can be permanently damaged if the sealing strip is removed.

î The battery gives off explosive hydrogen gas during normal operation.

î Wear protective clothing and a face shield, or have skilled technician do the battery maintenance.

î A spark or flame can cause the battery to explode with enough force to seriously hurt you.

WARNING

Battery charging Always visit your Authorised Hero MotoCorp workshop if you see any symptom of battery discharge as earliest as possible to get the battery charged. The battery has a tendency to discharge rapidly if additional electrical accessories are fitted on the motorcycle.Battery storage î If in case your motorcycle is not used for

more then a month remove the battery, fully charge and store in a cool and dry place.

î If the battery is expected to be stored for more then two months, ensure to fully charge the battery once in a month.

48*MF stands for Maintenance Free

Battery removal

î Remove the pillion and rider seats (page 22).

î Remove the right side cover screw (3).

î Make sure the ignition switch is "OFF".

î Remove the right side rear grip by removing the nuts (1) and bolts (2) as marked.

Remove the right side cover screw (4).Remove the right side cover under screws (5).

î Always ensure the battery is fully charged before installation.

î Ensure the battery leads are properly connected to the battery terminals during installation.

1

2 3(1) Nuts (2) Bolts (3) Right side cover screw

4

5

(4) & (5) ScrewRemove the right side cover screws (6).

Remove the battery (11) from the battery case.

Remove the battery clamp bolt (7) and the clamp (8).Disconnect the (-) ve terminal lead (9) from the battery first, then disconnect the (+) ve terminal lead (10) from the battery.

6

10

11

9

8 7

49

Battery installation

î Check all bolts and other fasteners are secure.

î Reinstall in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (-) terminal.

Refer to the safety precautions (page 33).FUSE REPLACEMENT

Fuse Box (A) Location : Below the seat Fuse Type : Blade fuse

Start Mag. Switch (B)Location : Inside right side cover Fuse Type : Blade fuse

A

54

1

2

3

7B

6

Description Rating Location 1. Clock 7.5 A Fuse Box 2. Ignition 7.5 A Fuse Box 3. Lamps 15 A Fuse Box 4. Spare Fuse 7.5 A Fuse Box 5. Spare Fuse 15 A Fuse Box 6. Main Fuse 20 A Start Mag. Switch 7. Spare Fuse 20 A Start Mag. Switch

î Battery gives off explosive gases. Keep sparks, flames & cigarettes away.

î Never use a fuse with a different rating from that specified. It may lead to serious damage to the electrical system or a fire due to short circuit.

WARNING

50

HEADLAMP ADJUSTMENTHeadlamp (twin) (1 & 2) is factory pre-set. However in case of adjustment required, please visit your Authorised Hero MotoCorp workshop as per the maintenance schedule (page 35).

• Do not attempt to start or ride the motorcycle without a charged battery, it can cause fusing of the bulbs and permanent damage to certain electrical components.

• Turn the ignition switch "OFF" before checking or replacing the fuse to prevent accidental short-circuiting.

CAUTION

NOTEHeadlamp adjustment is done by the headlamp adjusting screw (A) for Lo-beam and (B) for Hi-beam located behind the headlamp assembly.

B

2

1

A

(1) Headlamp (Lo-beam) (2) Headlamp (Hi-beam)(A) & (B) Headlamp adjusting screws (Lo& Hi-beam)

An improperly adjusted headlamp may blind oncoming driver or it may fail to light road for a safe distance.

WARNING

STOP LAMP SWITCH

î Turn the ignition switch to the “ON” position.

î Turn the adjusting nut (2) to position stop lamp switch at a point where the stop lamp glows just before the brake pedal is depressed. Turn the adjusting nut in direction (A) to advance switch timing or in direction (B) to retard switch timing.

The stop lamp switch (1) must be adjusted so that stop lamp glows when rear brake is applied. The procedure for adjusting stop lamp switch is as follows.

B A

2

1

(1) Stop lamp switch (2) Adjusting nut(A) Advance (B) Retard

51

SIDE STAND/SIDE STAND SWITCHCheck the side stand for proper function.î Check the spring (1) for damage or loss of

tension and the side stand assembly for free movement.

î Check whether the “SIDE STAND IS ON” scroll message display on the meter console, when the side stand is down.

î When the side stand is up, “SIDE STAND IS ON” message disappears from the meter console (page 10).

î If the side stand switch is not functioned properly as described above, please visit your Authorised Hero MotoCorp workshop.

1(1) Side stand spring (2) Side stand switch

2

Refer to the safety precautions (page 33).SUSPENSION

Front shock absorber

Check the front forks by locking the front brake and pumping the front fork up and down vigorously. The suspension action should be smooth and there should be no oil leakage.

Check the rear shock absorber by pushing hard downwards on rear grip while the motorcycle is not parked on stand. The suspension action should be smooth and there should be no oil leakage.

Inspection

Rear shock absorber

Front RearRear shock absorber adjustmentIt is recommended you visit to your Authorised Hero MotoCorp workshop for rear shock absorber adjustment. Adjustment can be made according to the load/road conditions.

In direction A stiffer.In direction B softer.

52

NOTEAlways adjust both the rear shock absorber to the same position. Use the rear shock absorber adjustment tool (pin spanner) (1) available in the tool kit.

B

A

1

(1) Pin spanner(A) Stiffer (B) Softer

Refer to the safety precautions (page 33).

FRONT WHEEL

î Remove the collar (2) and speed sensor (3) from the wheel.

î Support the motorcycle securely on the main stand and raise the front wheel off the ground.

î Remove the front axle nut (1) remove the axle and wheel.

REMOVAL

1(1) Axle nut

2

3(2) Collar (3) Speed sensor

î Install the side collar (2) to the right side of the wheel hub and then install the speed sensor (3) on the left side of the wheel hub.

î Position the front wheel between the fork legs by aligning the slot on the speed sensor with the lug on the fork legs and the disc

INSTALLATION

53

î After installing the wheel apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely.

î Tighten the front axle nut to the specified torque.

TORQUE : 5.9 kgf-m

between the brake pads to avoid damage to the pads. Insert the axle from the right side through the fork legs and wheel hub.

NOTEî Do not depress the brake lever when the

wheel is removed. The caliper pistons will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs, servicing of the brake system will be necessary. Visit your Authorised Hero MotoCorp workshop for this service.

î Avoid grease, oil or dirt on the disc or pads surfaces. Any contamination can cause poor brake performance or rapid pad wear after re-assembly.

î Be careful to install the speed sensor in the wheel hub with the lugs on the speed sensor aligned with the slot in the wheel hub.

î If a torque wrench was not used for installation visit your Authorised Hero MotoCorp workshop as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking force.

î Remove the rear axle nut (1) along with the rear axle washer (2).

î Remove the axle (3) and dislodge the rear caliper assembly (4) from the swingarm slot.

î Tilt the motorcycle and remove the wheel.

î Support the motorcycle securely on the main stand and raise the rear wheel off the ground.

î Remove the right side collar (5).

(1) Rear axle nut (2) Rear axle washer (3) Axle (4) Rear caliper assembly (5) Right side collar

1 3

25

4

î Tilt the motorcycle and position the rear wheel between the swingarm.

î Insert the disc between the pads in the caliper assembly. When installing the wheel, carefully fit the brake disc between the brake pads to avoid damage to the pads.

INSTALLATION

î Align the caliper assembly bracket with the swingarm slot.

REAR WHEEL

Refer to the safety precautions (page 33).REMOVAL

54

î Insert the axle along with a washer from the left side through the swingarm with chain adjuster assembly, wheel hub, side collar, caliper assembly bracket and right side rear axle washer.

î Install and tighten the rear axle nut to the specified torque.

TORQUE : 6.8 kgf-m

SWINGARM SLOT

ALIGN

CALIPER ASSY. BRACKET

î After installing the wheel apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely.

NOTEî Do not depress the brake pedal when the

wheel is removed. The caliper piston will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs servicing of the brake system will be necessary. Visit your Authorised Hero MotoCorp workshop for this service.

î Avoid grease, oil or dirt on the disc or pads surfaces. Any contamination can cause poor brake performance or rapid pad wear after re-assembly.

î If a torque wrench was not used for installation visit your Authorised Hero MotoCorp workshop as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking force.

While tilting the motorcycle during rear wheel removal and installation be extremely careful not to move the motorcycle off the main stand.

CAUTION

WASHING THE MOTORCYCLEFollow the below mentioned steps for washing the motorcycle.î Wet the motorcycle with light water spray.

Avoid directing high pressure water spray onto muffler outlet, electrical/electronic parts, meter console and oil cooler.

î Clean the headlamp lens and other plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water.

î Dry the motorcycle by wiping with dry soft cloth.

î After cleaning spray water thoroughly.

NOTEOur authorised dealership take all above mentioned precautions like recommended detergents and usage of muffler caps/plugs and oil cooler covers during wash to ensure quality wash.

55

Avoid direct high pressure water spray on any electrical, electronic components and oil cooler.

WARNING

This motorcycle is equipped with a catalytic converter in the muffler to meet the emission norms. The catalytic converter contains precious metals that serve as Catalysts, promoting chemical reactions to Convert the exhaust gasses without affecting the metals. The Catalytic Converter acts on HC, CO and NOx. A replacement unit must be a genuine Hero MotoCorp part.

î Always use unleaded petrol. Even a small amount of leaded petrol can contaminate the catalyst metals, making the catalytic converter ineffective.

CATALYTIC CONVERTER

The catalytic converter must operate at a high temperature for the chemical reactions to take place. It can set on fire any combustible material that come near it. Park your motorcycle away from high grasses, dry leaves, or other flammable material.A defective catalytic converter contributes to air pollution, and can impair your engine's performance. Follow these guidelines to protect your motorcycle's catalytic converter.

î If your engine is misfiring, backfiring, stalling, or otherwise not running properly, stop riding and turn “OFF” the engine. Have your motorcycle serviced as soon as possible.

î Keep the engine in good running condition. A poorly running engine can cause the catalytic converter to overheat.

56

BASIC TROUBLESHOOTING

Check Fuse

Inspect Battery

Check connections, Ignition switch/starter switch

OK

OK

OK Loose

Replace Fuse (ref. page 50)

Secure connectionsWeak

Fuse

Consult Authorised Hero MotoCorp WorkshopConsult Authorised Hero MotoCorp Workshop

B. Electric Starter Not Working

RefillConsult Authorised Hero MotoCorp WorkshopConsult Authorised Hero MotoCorp Workshop

Check Ignition SwitchOK

OK

OK

Turn ignition switch “ON” (page 14)“OFF”

C. No Spark At Spark Plug

No Spark

Consult Authorised Hero MotoCorp Workshop

Check Spark Plug for Fouling/Improper Electrode Gap

Replace Spark Plug/Adjust (page 38)Spark Plug Gap (0.6-0.7 mm)

LooseContactCheck for Poorly Connectedor Loose Spark Plug Wire Secure Properly

Check fuel gaugeON

Check fuel linesOK

OKCheck for operating sound of fuel pump Broken fuel pump

wire/connector

Refill the fuel tank (page 24)

Secure connectionsLeakage

Only one segment displayed

A. Fuel System


1. STARTING TROUBLE - ENGINE DOES NOT START

RefillConsult Authorised Hero MotoCorp WorkshopConsult Authorised Hero MotoCorp Workshop

57

Spark Plug Loose in Cylinder HeadOK

Check Air FilterOK

OKCheck Brake Binding Improper

Functioning

Tighten the Spark Plug (page 38)

ReplaceDirty/Clogged

Loose3. POOR PICK UP

OKCheck Tyre Inflation Pressure Under Inflated Correct Tyre Pressure (page 25)


Check FuseOK

Inspect BatteryOK

OKCheck Bulbs Fuse/Wrong Wattage

Replace Fuse (page 50)

Weak

FuseFeeble Horn Sound or No Light

Replace Bulbs

4. ELECTRICAL SYSTEM

OKCheck Connections Loose Secure Connections




Consult Authorised Hero MotoCorp WorkshopCheck fuel linesOK

Check Air FilterOK

ReplaceDirty/Clogged

Leakage


2. ENGINE STARTS BUT STALLS

BASIC TROUBLESHOOTING

58

ROAD SIGNSMandatory signs: These road signs inform drivers/riders of the traffic rules that apply on a certain stretch of road, thereby instructing them on how to drive/ride. Mandatory signs are distinguished by the bright red circle with black and blue markings. It is imperative that all riders follow these signs as they help avoid accidents. Their violation can be penalised under the Motor Vehicle Act.

Mandatory

Stop Give way One way No horn No biycles No automobiles

No hand craft No pedestrians No right turn No ‘U’ turn Overtaking prohibited Speed limit

No stopping or standing No parking Length limit High limit Restriction ends Compulsory-ahead

only

Compulsory-turn left

Compulsory-right ahead

Compulsory-ahead or turn right

Compulsory-keep left

Compulsory-bicycle track

Compulsory-sound horn

59

Cautionary

Right hand curve Right reverse bend Incline ahead Narrow road ahead Narrow bridge Pedestrian crossing

School ahead Gap in medium Cross road Men at work Roundabout Hump Road

Cautionary signs: These signs inform the driver/rider of the road conditions ahead. Cautionary signs therefore serve as a warning. They are usually in a red triangle with black pictures on a white background. Illustrations, diagrams and symbols are used to forewarm about dangers ahead. Cautionary road signs are as important as mandatory signs. However, the violation of cautionary signs does not attract penalty.

Informatory

TaxistandParking both sides

Park this side

Light Refreshment

Signs and Signals are language of the road. Learn them, respect them .

NEW DELHI ROHTAK

NAJAFGARH

NEW DELHI 40ROHTAK 58NAJAFGARH 3

RohtakBahadurgarh

4810

Delhi

Destination Sign

Re-assure sign Public Telephone

Petrol Pump Hospital First Aid Post Eating Place

Resting place

Place identification sign

No through road

No through side road

Informatory signs: These are facility signs that provide important information about road directions are maps of specific destinations. On highways, they provide information about the location of public telephones, restaurants, hospitals, parking, petrol pumps, resting-places and more. These signs are usually rectangular, with black or white pictures on a blue background.

60

WARRANTYHero MotoCorp Ltd.

Scope of warranty

Terms & conditions

Hero MotoCorp Ltd. Hero MotoCorp (hereinafter called ‘ ') warrants its Karizma ZMRvehicles, assembled/manufactured in its to be Plants and sold through its channel partners,free from any defect-both in material and workmanship, under normal use and conditions, subject to the following terms & conditions.

b) It is advised that the purchaser avails all free and paid services from the Hero MotoCorp’s authorized workshop as per the recommended schedule, to be eligible for warranty benefits. Each paid service should be availed within 90 days from the date of previous service or as per the recommended schedule, whichever is earlier.

c) Hero MotoCorp'sIf any is observed in vehicle, only obligation/ problem Karizma ZMRliability is to repair or replace that part/those parts which is/are considered to be the cause of such , provided however that such has not resulted due to problem problemmisuse/improper handling etc. of the vehicle. Any vehicle needing repair Karizma ZMR should be brought along with owner's manual to authorized workshop Hero MotoCorp's for necessary inspection and carrying rectification job.

a) vehicle is warranted for a period of , whichever 5 years or 70000 KmKarizma ZMRis earlier, from the date of purchase.

Hero MotoCorp Ltd.LIMITATIONS OF WARRANTY

The warranty shall not apply—(1) If all free services/paid services/oil top-ups are not availed as per the recommended schedule at authorized Hero MotoCorp's

workshop.

(7) For normal phenomena like noise vibration, oil seepage etc., which do not affect the performance of the .vehicle

(10) If any maintenance/repairs required due to bad road conditions or misuse of . Karizma ZMR vehicle

(13) To any part of the vehicle which has been tampered or repaired in such a manner which has resulted in Karizma ZMRmalfunction of the vehicle.

(15) To proprietary items like Tyres, Tubes, Batteries etc, as they are subjected to the warranty terms & conditions of respective manufacturers and directly handled by them only.

(12) For consumables like oil, grease, gasket etc to be used during free services and/or warranty repairs.

(2) If any other engine oil which is non compatible with product is used other than SAE 10W30 S Grade (JASO M ).L A2(3) To normal wear & tear components including (but not limited to) brake shoes/pads, clutch plates, drive chain & sprockets, bulbs,

electrical wiring, filter, spark plug, fasteners, shims, washers, oil seals, gaskets, rubber parts, bush, rubber bellows, plastic parts breakage and wheel rim for misalignment/bend.

(4) If additional wheel(s) is/are fitted and/or any other modification carried out/unauthorized accessories fitted which shall be responsible for malfunction/detoriation of the vehicle.

(5) If has been used in any competitive events like races or rallies or for any commercial purposes as taxi etc.Karizma ZMR vehicle(6) To any damage on 's painted surface cropping due to industrial pollution or other external factors.vehicle

(8) To any damage caused due to usage of improper oil/grease, non-genuine parts.(9) If any defect crops or repairs needed as a result of using adulterated fuel.

(11) If any defect crops or repairs needed as a result of meeting to some accident. Karizma ZMR vehicle

(14) For not used in accordance with the guidelines given in this Owner's Manual.Karizma ZMR vehicle

(16) Any defect(s) developing on account of external factors such as environmental factors; including but not limited to fading/peeling/rusting of paint and/or stripes and/or plated parts, seat leather tearing & cracking, aluminium parts oxidation and cracking & discoloring of control switches etc.

Decision regarding warranty settlement shall be taken by and the same shall be final and binding Hero MotoCorpon all concern.

Subject to DELHI JURISDICTION only.

Hero MotoCorp Ltd.1. 18 months from date of sale of vehicle or 20000 km. or

3. 3 months idle period is allowed from the date of charging to date of sale on vehicle.

The warranty commences from the date of delivery to the original purchase of the vehicle.

3. This warranty card accompanies a battery sold as OEM fitment only. Claims should be supported with vehicle purchase invoice to enable processing.

8. Breakage of container and cover do not come under the purview of this warranty.

BATTERY WARRANTY PERIOD

2. 21 months from the date of charging (whichever is earlier).

Terms and condition of warranty1. Batteries are warranted against all defects in material and workmanship. Liability under this warranty is limited to making good of

defects rising solely from the use of faulty material or workmanship during manufacturing and developing under proper use.

2. In the event of any complaint the battery is to be returned complete with electrolyte to nearest battery service station or any OEM dealer. On inspection, battery would be returned or replaced.

4. The right to determine whether a battery needs repair or totally replacement lies with the company. In case where the battery is replaced, the defective battery becomes the property of the company and no scrap rebate will be given for it. The warranty period on the battery being repaired/replaced shall commence from the date of sale of the original battery as stated in the original warranty card.

5. All liabilities under this warranty will cease if the battery is used on the vehicle other than that on which the battery was originally fitted and on the expiry of the warranty period as mentioned above.

6. Recharging is not covered under the purview of this warranty and shall be billed as extra. However, FOC battery replacement/ repair includes cost of charging.

7. This warranty does not cover damage to the battery caused by faulty electrical systems, incorrect charging and filling, improper handling of the battery by unauthorized dealers/auto electricians, maintenance, willfull abuse, destruction by fire, collusion, theft or recharging.

9. Adjudication and settlement of claim will take a couple of days as a battery has to be tested for the reported failure.10. In case of tempering of the original wiring circuit in any manner whatsoever.11. If a battery which is not recommended is fitted on the vehicle then such battery will not carry any warranty.12. The applicable taxes which is leviable on the battery under repair or replacement will be borne by the customer.13. Customers are deemed to have read, understood and agreed to these conditions at the time of purchase of the vehicle.

Hero MotoCorp Ltd.

Subjected to Delhi jurisdiction only.

g) Please It is recommended to avail the services as per the recommended schedule to be eligible for the emission warranty benefits.ensure that each paid service is availed within 90 days from the date of previous services or as per the recommended schedule, whichever is earlier. All service details should be completely filled by the dealer, in the Service Record Sheet given in the owner's manual.

i) All decisions regarding emission warranty settlement shall be taken by Hero MotoCorp Ltd. and shall be final binding on all concerned.

EMISSION WARRANTYScope of warranty

Terms & conditionsa) The emission warranty shall be applicable in India and shall remain valid for a period of 3 years or 30000 kms, whichever

occurs earlier, from the date of vehicle purchase.

Hero MotoCorp Ltd. Warrants all its vehicles, assembled/manufactured at its various Plants and sold through its Authorised dealers, to comply with emission standards as specified in S.No. 5 of table in item(i) of sub rule (2) of Rule 115 of Central Motor Vehicles Rules, 1989, which stipulates that "Idle CO (Carbon monoxide) emission limit for all two wheeled petrol driven vehicles shall not exceed 3.0 percent by volume and HC (Hydro Carbon) 3000 ppm, subject to following terms & conditions.

b) In case any defect is observed in any emission-related component, Hero MotoCorp only obligation/liability shall be to repair and/or replace those part (s) which is/are considered to be the cause of non-compliance with the emission standards.

c) The emission warranty shall be applicable only to those vehicles, which are being regularly maintained at Hero MotoCorp Authorised Dealers/Service Points in accordance with the maintenance schedule provided in the owner's manual.

d) The customer should follow the recommended parts replacement as per the maintenance schedule in order to avail the emission warranty.

e) If any part (s) related to emission characteristics of the vehicles is/are tampered and/or repaired by unauthorised person/workshops etc, then the emission warranty shall stand cancelled.

f) Any part (s) suffering wear and tear under the normal course of running shall not be covered under the emission warranty. Therefore, all such parts should be replaced by the customer from time to time, on payment basis, as per the maintenance schedule provided in owner's manual and dealer's advice.

h) It is mandatory to obtain a PUC certificate from the Authorised PUC center. In case of non-compliance with the emission standards please contact the /authorised workshop immediately alongwith the previous OK certificate, for the necessary rectification. The channel partnermanufacturer or the dealer is not responsible for any penalty levied on you on account of non-compliance with the emission standards.

8. Function of Side Stand Switch.

1. Function and operation of all digital display of multifunction meter console.2. Explanation on collapsible visor mounted rear view mirrors.3. Headlamp adjustment procedure.4. Retractable rider foot rest.5. Minor clutch adjustment procedure.6. Function and operation of clutch switch.7. Programmed-FI Malfunction Indicator Lamp (MIL).

9. Bank angle sensor activation and resetting of ignition switch.10. Inspection and maintenance of Oil Cooler.

12. Engine oil level inspection, replacement and top-up procedure.13. Procedure of removing/installing seat, side covers and fuel tank lid.

11. Brand and grade of engine oil used, top-up & replacement schedule.

14. Explanation on Maintenance-Free Battery.

20. Importance of availing all the free services.

22. Warranty terms and conditions.

15. Location of Tool Kit & First-Aid Kit.

18. Tubeless tyre and importance of tyre pressure.17. Inspection of brake fluid and pads.

23. Water wash precautions.

16. Location of Fuse Box and explanation/replacement procedure of various fuses.

24. Explain the service facilities available.

19. Inspection of tyre wear (TWI mark).

21. Maintenance Schedule.

INSTALLATIONExplanation on important "Must know" points to customer during

delivery of motorcycle by Dealer sales executive.

CUSTOMER SALES EXECUTIVE DEALER

Stamp & Signature :Signature :

Name :.....................................................................................

Signature :

Name :.....................................................................................

Hero MotoCorp Ltd.

î Assures long life

î Value for money

î Ensures economy for a long time

WHAT ARE THE BENEFITS OF Hero MotoCorp GENUINE SPARE PARTS ?

î Safety of vehicle and rider

î Assured quality

î Peace of mind

CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS

Clutch Plateî Damages other parts of clutch like, clutch center and

outer clutch

î Engine knocking

î Affects fuel efficiencyî Poor acceleration

î Higher emission level

î Reduced life

î Material used is inferior

î Poor performance

î Improper sealing

î Leads to leakage and smoky exhaust

Cam Chain Kit

Gasket Cylinder Head

CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS

Element Air Cleanerî Poor engine performance

î Frequent stalling of engine

î Discs/Drum wear out, resulting in subsequent repair cost

î Improper air filtration resulting in premature engine failureî Affects fuel efficiency

î Higher emission levelî Poor engine performanceî Affects fuel efficiency

î Poor braking efficiencyî Rider safety-an issue

î Noisy Operationî Failure of chain can cause fatal accidentChain Sprocket Kit

Brake Pads/Shoes

Spark Plug

For any of your service related query/requirements you may contact the respective Zonal/Regional/Area Offices

Hero MotoCorp Ltd., Flat No: 1002. 10th Floor, Martin Burn Business Park, BP3, Salt Lake, Sector-V, Kolkata-700091, West Bengal, India. Tel : +91-33-44026841,+91-33-44026830, E-mail : [email protected] MotoCorp Ltd., Odyssa Business Centre, Plot no. 30, 30/982, 172/1030, 4th Floor Cuttack, Bhubaneshwar highway road, Rasulgarh, Bhubaneswar-751010, Odisha, India. Tel: +91-674-2581161, 62, 63, 64, E-mail: [email protected]

Hero MotoCorp Ltd., Yash Heights, 1st Floor Bariatu Road, Above Basudeb Tata Showroom Ranchi-834009, Jharkhand, India. Tel: +91-651-2542222, 2542224, 2542225, E-mail: [email protected]

Tel: +919334280555/7004569648 E-mail: [email protected] MotoCorp Ltd., Sai Corporate Park, A Block, 6th Floor, Rukanpura, Bailey Road Patna, Bihar – 800014

EAST ZONE

Hero MotoCorp Ltd., 3rd Floor, Tower-A, DLF Centre Court, Sector-42, Golf Course Road, DLF Phase 5, Gurgaon -122002, Haryana, India. Tel: 0124-4754800, E-mail: [email protected]

Hero MotoCorp Ltd., S.C.O-367-368, First Floor, Sector-34A, Chandigarh-160022, India.Tel: +91-172-2623773, 2623774, 2623775, E-mail: [email protected] MotoCorp Ltd., Kapoor Towers, Plot No- 284, 15-B, Rajpur Road, Dehradun-248001, India.Tel:0135-2714661,2713662,2714663, E-mail: [email protected]

NORTH ZONE

Hero MotoCorp Ltd., No. 209-210, Ganpati Plaza, M.I. Road, Jaipur-302001, (Rajasthan).Tel: +91 141 2389031, +91 141 2389156, E-mail: [email protected]

Hero MotoCorp Ltd., Third Floor, Alankar Palace, Plot No. 11, Zone II, M.P. Nagar Bhopal-462011, India. Tel: +91-755-4203160, 2553697, 4272429, 2550086, E-mail: [email protected]

Hero MotoCorp Ltd., Maloo-01, 601-602, 6th Floor, Plot No. 26C, Scheme No. 94, Ring Road, Indore, M.P.-452010,Tel: +91-731-4978269, 70, E-mail: [email protected]

CENTRAL ZONE

Hero MotoCorp Ltd., Office. No.401, 4th Floor, Offizo, Magneto Mall, Labhandi, G.E. Road, Raipur -492 001, (Chhattisgarh)Tel: +91-771-4034749, E-mail: [email protected]

Hero MotoCorp Ltd., Office No. 705-706, 7th Floor, Fun Square, Durga Nursery Road, Udaipur -313001 (Rajasthan). Tel: +91 0294-2980578, 79, E-mail: [email protected]

Hero MotoCorp Ltd., 602, 6th Floor, Office Tower-1, Plot No BW58, Logix City Center, Sector-32, Noida – 201301. Tel: 0120-4631000, E-mail: [email protected]


Pune-411014, India. Tel: +91-020-71903500, E-mail: [email protected] MotoCorp Ltd., Chrome Building, Sr. No. 33, Hissa-A-1/1/2, Plot - 2, Viman Nagar Avenue 2, Nagar Road,

Tel: +91-265-2286569/2286570, E-mail: [email protected] MotoCorp Ltd., 603-604, Gunjan Tower, Off Alembic Gorwa Road, Baroda-390023, India.

Hero MotoCorp Ltd., Ground Floor, Block No.2, Vishnu Vaibhav Complex, 222, Palm Road, Civil Lines, Nagpur-440001, India. Tel: +91-712-2545990-91, E-mail: [email protected]

WEST ZONE

Hero MotoCorp Ltd., Astarc House-Third Floor, 76/79, Makwana Lane, Off. Andheri-Kurla Road, Andheri (East), Mumbai-400059, India. Tel: +91-22-28562071, E-mail: [email protected]

Tel: 0281-2460622, 2460623, E-mail: [email protected] MotoCorp Ltd., 604, Kings Plaza, Astron Chowk, Rajkot, Gujarat - 360001

Hero MotoCorp Ltd., First Floor VA Kalburgi Mahalakshmi Mansion, Mandakini Hospital Road, New Cotton Market, Hubli-580029, India. Tel: 0836-2269717, 2361038, E-mail: [email protected] MotoCorp Ltd., D.NO. 54-11-18 E, 2nd Floor, Sai Oddessey Building, Opp Executive Club, Near NH-5, Vijayawada-520008, Andhra Pradesh, India. Tel: +91-866-2546859, 2546860, E-mail: [email protected]

Hero MotoCorp Ltd., 3-6-289, 3rd Floor, Kareem Manzil, Hyderguda, Hyderabad-500029, India.Tel:+91-40-23223735, 23223727, 23223570, E-mail: [email protected]

SOUTH ZONE

Hero MotoCorp Ltd., 9th Floor Seshachalam Centre No.636/1. Anna Salai, Nandanam, Chennai-600035, India.Tel: +91-44- 24340974, 24340977, 24340978, E-mail: [email protected]

Tel: +91-422-2200058, 2200061, E-mail: [email protected] MotoCorp Ltd., No 1547, 2nd Floor Classic Towers, Trichy Road, Coimbatore - 641018

NORTH ZONE

Tel: +91- , E-mail: [email protected] 2390949,2390241Hero MotoCorp Ltd., , Varanasi, Uttar Pradesh - 221010, India.C-19/134-B ,Third Floor I .P Grand, Lallapura, Sigra


Hero MotoCorp Ltd., Summit Building (10th Floor) Plot No TCG 3/3 Vibhuti Khand, Gomti Nagar Lucknow – 226010, India. Tel: 0522-4006594, E-mail: [email protected]

Hero MotoCorp Ltd., 6-A, DD Trade Tower, (6th Floor), Kaloor-Kadavanthra Road, Kaloor , Kochi-682017, -682 017India. Tel: +91-0484- 4039646 -7, E-mail: [email protected]

Tel: +91-80- 46881000, E-mail: [email protected] MotoCorp Ltd., SKAV 909, 3rd Floor, 9/1, Lavelle Road, Bangalore-560001, India.

OM KARIZMA ZMR-1.cdr - Hero MotoCorp

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