Hero Hunk (2015) Handleiding
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PREFACE
We at are committed to demonstrate excellence in our environment Hero MotoCorp,
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.
This booklet is your guide to the basic operation and maintenance of your new
Hero MotoCorp . Please take time to read it carefully. As with any fine machine, HUNK
proper care and maintenance are essential for trouble-free operation and optimum
performance.
Thank you for selecting a . We wish you many miles of continued Hero MotoCorp HUNK
riding pleasure in the years ahead.
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.
Your Authorised dealer will be glad to provide further information or Hero MotoCorp
assistance and is equipped to handle your future service needs.
Let us make this world a safer, healthier and more environment friendly place.
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. RESERVES THE RIGHT TO MAKE Hero MotoCorp Ltd
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.
CONTENTS
Pg. No.
îImportance of maintenance 27
MAINTENANCE 27
TIPS FOR HEALTHY ENVIRONMENT 8
MOTORCYCLE VIEWS 9
PARTS FUNCTION 12
îOdometer/Tripmeter 15
îSide stand switch/Side stand 17
MOTORCYCLE SAFETY 4
îIgnition switch 13
îDigital clock 14
îProtective apparel 5
SAFE RIDING TIPS 6
îSteering lock/Side stand indicator 17
îSeat Lock 20
îLeft handlebar controls 15
MOTORCYCLE IDENTIFICATION 1
PRODUCT SPECIFICATION 2
îImportant safety information 4
ACCESSORIES & MODIFICATIONS 7
îInstruments & Indicators 12
îRight handlebar controls 16
îFuel Valve 18
îFuel Tank 19
STARTING THE ENGINE 24
RIDING/BRAKING 25
PARKING/TOOL KIT/FIRST AID KIT 26
TYRES 20
PRE-RIDE INSPECTION 23
ANTI-THEFT TIPS 27
îMaintenance schedule 29
îEngine oil/Engine oil top up process 32
îEngine oil replacement process 32
îOil filter screen & centrifugal filter 33
îSpark plug 34
îMaintenance safety/Maintenance precaution 28
BASIC TROUBLESHOOTING 54
îThrottle operation/Valve clearance 37
îCarburetor/Clutch 39
HERO GENUINE PARTS
îAir cleaner 35
CATALYTIC CONVERTER 53
îFuse replacement/Stop lamp switch 48
AIR SUCTION VALVE 53
îRear brake (Drum type)/Brake wear indicator 45
îBattery 46
îDrive chain slider/Front brake 42
îAir cleaner drain tube 36
ZONAL/REGIONAL/AREA OFFICES
îHeadlamp adjustment/Suspension 49
îDrive chain 40
ROAD SIGNS 55
WARRANTY DETAILS
îRear brake (Disc type) 43
îFront wheel removal 50
îRear wheel removal (Disc type) 51
îRear wheel removal (Drum type) 52
WASHING THE MOTORCYCLE 52
MOTORCYCLE IDENTIFICATION
MBLXXXXELYZXYYYYY
Location: Stamped on the right side of the
steering head tube.
Vehicle Identification Number (VIN)
VIN: MBLXXXXELYZXYYYYY
MBL XXXXEL Y Z X YYYYY
Manufacturer
code Vehicle
Description Year of
Manufacturing Assembly Plant Month of
Manufacturing Serial Number
Engine No.: XXXXEGYZXYYYYY
XXXXEG Y Z X YYYYY
Engine
Description Year of
Manufacturing Assembly Plant Month of
Manufacturing Serial Number
VIN and Engine No. may be required:
1. During registration of the motorcycle.
2. For dealing with Legal & Insurance Departments.
Model: HUNK
VIN
EL
Engine
EG
EG
HUNK Electric Start/Disc/Cast (RR Disc)
Variants
HUNK Electric Start/Disc/Cast (RR Drum)
XXXXEGY
ZXYYYYY
Engine No.
Location : Stamped on the lower side of the
left Crankcase.
EM
1
SPECIFICATIONSITEM
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Saddle height
Ground clearance
Kerb weight
2080 mm
765 mm
1095 mm
1325 mm
800 mm
163 mm
147 kg (Front Disc/Rear Disc)
145 kg (Front Disc/Rear Drum)
Weight
PRODUCT SPECIFICATION
Engine oil
Fuel tank
Fuel reserve capacity
Front fork oil disassembly
Brake fluid
1.2 litres at disassembly and 1 litre at draining
12.4 litres (Minimum)
2.2 litre (Usable)
143 ml
Castrol Q Stop-DoT 3 or DoT 4
Capacities
Engine
Front Suspension
Rear Suspension
Telescopic Hydraulic Shock Absorbers
Rectangular Swingarm with 5 step adjustable
Inverted Gas Reservoir Suspension
Chassis and suspension
Caster 26°
Maximum power
Maximum torque
Bore and stroke
Compression ratio
Displacement
Spark plug
Spark plug gap
Valve clearance
Idle speed
11.64 kW (15.6 BHP) @ 8500 r/min
13.50 N-m @ 7000 r/min
57.3x57.8 mm
10:1
149.2 cc
NGK-CPR 8 EA 9
0.8-0.9 mm
0.08 mm
0.12 mm
1400±100 r/min
Intake (cold)
Exhaust (cold)
2
Chassis Type Tubular, Diamond Type
SPECIFICATIONS
*MFR stands for Multi-Focal Reflector
**MF stands for Maintenance Free
3
12V-0.5W/4.1W LED Lamps
96.2 mm
80/100x18-47 P (Tubeless Tyre)
100/90x18-56 P (Tubeless Tyre)
3.3500 (67/20)
3.0714 (43/14)
3.0769 (40/13)
1.7895 (34/19)
1.3043(30/23)
1.0909 (24/22)
**MF Battery, 12V-4 Ah ETZ-5
140 W
Kick/Electric Start
Cast Wheel
Cast Wheel
Dia. 240 mm
Dia. 220 mm
Dia. 130 mm
Front (Disc type)
Rear (Disc type)
Rear (Drum type)
12V-35/35W Halogen Bulb Trapeziodal-MFR*
12V/5W
LED
LED
10A, 15A, 20A
12V-3.0W
LED
12V-2.3W
LED
12V-10Wx4 (Amber bulb) with clear lens-MFR*
0.9375 (30/32)
PRODUCT SPECIFICATION
ITEM
Trail length
Tyre size Front
Rear
Primary reduction
Final reduction
st
Gear ratio, 1
rd
3th
4
Battery
Alternator
Starting system
Headlamp (High/Low)
Tail/Stop lamp
Turn signal lamp
Meter illumination
Neutral indicator
Turn signal indicator
Position lamp
Hi Beam indicator
Licence plate lamp
Side stand indicator
Fuse
Transmission
Electricals
Front Wheel
Rear Wheel
nd
2
Brakes
th
5
3
MOTORCYCLE SAFETY
There is much that you can do to protect
yourself when you ride. You will find many
helpful recommendations through out this
manual. Following are a few that we consider
most important.
Take time to learn & practice your
motorcycle
Even if you have ridden other motorcycles,
practice riding in a safe area to become
familiar with how this motorcycle works and
handles, and to become accustomed to the
motorcycle's size and weight.
Your motorcycle can provide many years of
service and pleasure if you take responsibility
for your own safety and understand the
challenges you can meet on the road.
Always wear a helmet
Make sure that you are physically fit, mentally
focused and free of alcohol and drugs. Check
that you and your pillion are both wearing an
approved motorcycle helmet and protective
apparel. Instruct your pillion on holding onto
the grab rail or your waist, leaning with you in
turns, and keeping their feet on the footrest,
even when the motorcycle is stopped.
IMPORTANT SAFETY INFORMATION
It is a proven fact, Helmet significantly reduces
the number and severity of head injuries. So
always wear a helmet and make sure your pillion
rider does the same. We also recommend that
you wear eye protection, sturdy boots, gloves
and other protective gear.
Before riding your motorcycle
Riding under the influence of alcohol or drugs
is dangerous. Alcohol can reduce your ability
to respond to changing conditions and reduce
the reaction time. Do not drink and ride.
For safe riding, its important to inspect your
motorcycle before every ride and perform all
recommended maintenance. Never exceed
load limits, and use accessories that have been
recommended by for this Hero MotoCorp
vehicle.
Keep your motorcycle in safe condition
Do not drink and ride
Ride defensively
Always pay due attention to other vehicles
around you, and do not assume that other
drivers see you. Be prepared to stop quickly or
perform an evasive maneuver.
Make yourself easily visible
Some drivers do not see because motorcycles
they are not looking for them. To make yourself
more visible, wear bright reflective clothing,
position yourself so that others can see you,
signal before turning or changing lanes, and use
horn which will help others to notice you.
Ride within your limits
Pushing the limits is another major cause of
motorcycle accidents. Never ride beyond your
personal abilities or faster than conditions
demand. Remember that fatigue and
negligence can significantly reduce your ability
to make good judgements and ride safely.
4
îSturdy boots with non-slip soles to help
protect your feet and ankles.
îLeather gloves to keep your hands warm
and help prevent blisters, cuts, burns, and
bruises.
Helmets and eye protection
In addition to a helmet and eye protection, we
also recommend:
Your Helmet is your most important piece of
riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and securely.
A bright coloured helmet can make you more
noticeable in traffic, as can reflective strips.
An open-face helmet offers some protection,
but a full-face helmet offers more. Always
wear face shield or goggles to protect your
eyes and help your vision.
Additional riding gear
îA two wheeler riding suit or jacket for
comfort as well as protection. Bright
coloured reflective clothing can help make
you more noticeable in traffic. Be sure to
avoid loose clothes that could get caught on
any part of your motorcycle.
îNot wearing a helmet increases the chance
of serious injury or death in a crash.
îBe sure you and your pillion always wear a
helmet, eye protection and other protective
apparel when you ride.
WARNING
If you decide to continue riding, first evaluate
the condition of your motorcycle. If the engine
is still running, turn it off. Inspect for fluid
leaks, check the tightness of critical nuts and
bolts, and check the handlebar, brake levers,
brakes, and wheels. Ride slowly and
cautiously. Your motorcycle may have
suffered damage that is not immediately
apparent. Have your motorcycle thoroughly
checked at a qualified service facility as soon
as possible.
If you are involved in a crash
For your safety, we strongly recommend that
you always wear an approved helmet (ISI
marked), eye protection, boots, gloves, long
pants and a long sleeve shirt or jacket
whenever you ride. Take care of loose/
hanging clothes while solo/pillion riding.
Although complete protection is not possible,
wearing proper gear can reduce the chance of
injury when you ride.
Personal safety is your first priority. If you or
anyone else has been injured, take time to
assess the severity of the injuries and whether
it is safe to continue riding. Call for emergency
assistance if needed. Also follow applicable
laws and regulations if another person or
vehicle is involved in the crash.
Following are suggestions to help you choose
proper riding gear.
PROTECTIVE APPAREL
5
Do's:
îAlways conduct simple pre-ride inspection
(page 23).
îWhile riding, sit in a comfortable position
with your legs close to fuel tank.
îRide defensively and at a steady speed
(between 40-50 km/hr).
îFor stopping motorcycle, use both brakes
simultaneously, keeping throttle in the close
position.
îTightly wrap loose/hanging clothes & avoid
entangling with moving parts.
îGet your motorcycle serviced regularly by
the Authorised Hero MotoCorp workshop.
îRespect road signs and obey traffic rules for
your own safety and that of others on the
road (page 56 & 57).
îAlways wear a helmet (ISI marked) with
chinstrap securely fastened and insist on a
helmet for your pillion rider.
îDuring night time, dip headlamps of your
motorcycle for oncoming traffic, or when
following another vehicle.
îTo make yourself more visible, wear bright
reflective clothing that fits well.
îGive way to others on the road and signal
before you make a turn.
îDo not litter the road.
îNever ride under the influence of alcohol or
drugs.
îNever use cell phone while riding the
motorcycle.
îAvoid sudden acceleration, braking and
turning of your motorcycle.
Don't
îNever shift gears without disengaging the
clutch and closing the throttle.
îNever touch any part of the hot exhaust
system like muffler.
îConcentrate on the road and avoid talking
to the pillion rider or others on the road.
îDo not attach large or heavy items to the
handlebars, front forks, or fenders.
îNever take your hands off the steering
handle while riding.
îDo not cross the continuous white/
yellow line in the center of the road, while
overtaking.
SAFE RIDING TIPS
6
Modifications
We strongly advise you not to remove any
original equipment or modify 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.
Accessories
îMake 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.
îBe sure electrical equipment does not exceed
the motorcycle's electrical system capacity
(page 3). A blown fuse can cause a loss of
lights.
îDo 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.
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
7
îFollow all instructions in this owner's manual
regarding accessories and modifications.
îImproper accessories or modifications can
cause a crash in which you can be seriously
hurt or killed.
WARNING
îFuel 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.
îRegular 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.
îNoise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or
defective mufflers, excessive noise will cause headaches and discomfort.
îHealthy 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.
îGenuine spares: Always insist on Hero MotoCorp genuine parts as spurious or incompatible
spares and accessories can upset or deteriorate your motorcycle’s running condition.
îThe following tips shall ensure a healthy motorcycle, healthy environment, and a healthy you.
îGenuine 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 kms. (with top
up every 3000 kilometres) to keep the engine fit and environment healthy.
îEmission 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.
TIPS FOR HEALTHY ENVIRONMENT
8
(13) Turn signal indicator
(14) Side stand indicator
(15) Tachometer
(16) LCD (Liquid Crystal Display) panel
(17) Neutral indicator
(20) Electric switch
(22) Ignition switch with steering lock
(18) Front brake lever
(21) Headlamp switch
(19) Throttle grip
(23) Fuel tank cap
(2) Fuel gauge
(12) High beam indicator
(1) Leg guard
(3) Bystarter lever
(7) Rear view mirror
(8) Pass lamp switch
(9) Headlamp dimmer switch
(10) Reset button
(11) Select button
(4) Horn switch
(5) Turn signal switch
(6) Clutch lever
8
2
4
6
5
7
TOP VIEW
MOTORCYCLE VIEWS
9 10
18
19
20
17
21
22
123
3
11 12 13 14 15 16
*Accessories and features shown may not be part of standard fitment.
9
(2) Air suction valve (inside)
(1) Fuel valve
(7) Side stand
(3) Starter motor
(5) Side stand switch
(4) Gear shift pedal
(6) Main stand
(9) Pillion foot rest
(11) Saree guard
(8) Rider foot rest
(10) Women pillion step
(optional)
(12) Rear reflex reflector
(15) Rear grip
(13) Rear turn signal lamp
(16) Seat lock
(14) Tail/Stop lamp
(17) Side cover left
(18) Front turn signal lamp
15
18
16
*Accessories and features shown may not be part of standard fitment.
LEFT SIDE VIEW
MOTORCYCLE VIEWS
1 2 3 4 56 7 8 9 10 11
12
13
14
17
10
(4) Brake pedal
(7) Front caliper assembly
(5) Carburetor
(Optional)
(1) Rear disc (Optional)
(3) Rear master cylinder
(2) Kick start pedal
(6) Oil level dipstick
MOTORCYCLE VIEWS
RIGHT SIDE VIEW
(11) Front brake master cylinder
(9) Headlamp
(8) Front disc
(13) Rear brake fluid reservoir
(Optional)
(10) Front visor
(12) Battery compartment
(inside)
1213
(14) Seat
(17) Licence plate lamp
(16) Document & tool kit
compartment
(18) Rear caliper assembly
(Optional)
(15) Fuse box
141516
17
18
*Accessories and features shown may not be part of standard fitment.
11
9
10
11
51 2 46 7 83
12
The indicators are in the speedometer panel
above the headlamp. The functions are as
below.
PARTS FUNCTION
Instruments and Indicators
2 5
Sl. No. Description Function
1 Select button To select odometer, tripmeter, hours & minutes.
2 High beam indicator Light glows when headlamp is in Hi-Beam.
3 Tachometer Indicates engine r/min.
9Tripmeter Shows the distance traveled during a trip after setting
to zero (page 15)
6Speedometer Indicates riding speed
5Side stand indicator Light glows when the side stand is put down.
7Digital clock Indicates hours & minutes (page 14)
4
Turn signal indicator
Flash when turn signal switch is operated.
12 Reset button To adjust time & Reset Tripmeter.
10 Neutral indicator Light glows when vehicle is in neutral position.
11 Fuel gauge Indicates approximate fuel quantity.
1 3 4
6
781012 911
8 Odometer Shows accumulated mileage.
“OFF” Position/
Lock Open
“LOCK” Position
“ON” Position
IGNITION SWITCH
The LCD panel illuminates & initial display
of multi function digital segments are
displayed. The tachometer needle and the
fuel gauge needle will swing to the maximum
scale once and back to its normal position.
The engine can be started. Turn signal lamp,
Horn, Tail/Stop lamp, Fuel gauge, Pass
lamp, Position lamp, Licence plate lamp &
Neutral indicator will be functional.
Key cannot be removed
Engine cannot be started and no electrical
system will be functional. Key can be removed
Key can be removed
Key Removal
Steering can be locked
Function
“LOCK”
“ON”
“OFF”
Key Position
2
1
3
(1) Ignition switch
(2) Ignition key
(3) Steering lock position
13
DIGITAL CLOCK
Digital Clock (1) shows hour and minute. To
adjust the time, proceed as follows :
îTurn the ignition switch "ON".
îPress 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 hour's digit display blinking.
• The time is advanced by 1 hour each
time the button is pressed.
îTo set the hour, press Reset Button (3)
until the desired hour is displayed.
• The time advances fast when the
button is pressed and held.
îPress the Select Button (2). The minutes
display starts blinking.
îTo set the minute press Reset Button (3)
until the desired minute is displayed. The
minute display will return to " " when " "
is reached without affecting the hour
display.
x1000r/min
2
10
3
4
5
6
789
10
11
F
E
TRIP
TOTAL
PM
km
km/h
x1000 r/min
2
10
3
4
5
6
789
10
11
F
E
TRIP
TOT AL
PM
km
km/h
x1000 r/min
2
10
3
4
5
6
789
10
1
1
F
E
TRIP
TOT AL
PM
km
km/h
2
2
3 1
3
• The time advances by 1 minute, each
time the button is pressed.
14
îTo end the adjustment press Select Button
(2). The display will stop flashing
automatically and the adjustment will be
saved or if the button is not pressed for
about 40 seconds.
ODOMETER/TRIPMETER
x1000 r/min
2
10
3
4
5
6
789
10
11
F
E
TRIP
TOT AL
PM
km
km/h
The Odometer (B) shows accumulated
distance traveled.
The Tripmeter (A) shows distance traveled
per trip.
The clock will reset " " if the battery is
disconnected.
NOTE
The Odometer can be displayed from " to
Push Select button (2) to select the Odometer
& Tripmeter. Tripmeter can be displayed
from " " Km. If the Tripmeter exceeds
" " Km. it will return to " " Km.
automatically.
x1000r/min
2
10
3
4
5
6789
10
11
F
E
TRIP
TOTAL
PM
km
km/h
km.
TOTAL
km..
TRIP
1. Headlamp Dimmer Switch
LEFT HANDLEBAR CONTROLS
2
• The time advances fast when the
button is pressed and held.
2
15
Press the switch (1) upwards for High Beam
“ ” downwards for Low Beam “ ” .
2
43
1
2. Passing lamp switch
Press the passing lamp switch (2) to operate
the passing lamp.
3. Clutch switch
There is a clutch switch (3) provided for the
4. Bystarter lever
safety of the rider. The motorcycle cannot be
started by starter switch until the clutch lever is
operated when the vehicle is engaged in gear.
To apply Bystarter, pull the lever (4)
downwards, towards the rider, as directed on
the switch.
RIGHT HANDLEBAR CONTROLS
1. Headlamp switch
The switch has three positions.
Position Action
“Following is “ON”
• Tail/Stop lamp
• Position lamp
“OFF”
• Console lamp LED
marked by dot.and white
Headlamp “ON”
• Tachometer lamp LED
• Speedometer LED
2. Starter switch ( )
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.
1
2
16
Do not accelerate during starting when the
Bystarter is “ON”.
NOTE
6. Horn switch ( )
Press the switch (6) to operate the horn.
6
5
Shift the turn signal switch (5) sideways for
Right/Left indications and leave it to come
back to its normal position on its own.
IMPORTANT: To switch off the turn signal
after completing the turn, gently push the
switch inside as directed on the switch.
5. Turn Signal Lamp Switch ( ).
Steering lock is within 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.
STEERING LOCK
Never hold starter switch continuously for
more than 5 seconds as continuous cranking
of engine will drain the battery.
CAUTION
(1) Ignition key
1
SIDE STAND INDICATOR
For the safety of the customer a side stand
indicator (1) is provided.
When the side stand is down (Ignition Switch
“ON”), an indicator lamp glows in the
speedometer panel.
(1) Side stand indicator
1
SIDE STAND SWITCH/SIDE STAND
A side stand switch (2) is provided in the side
stand, when the side stand is down (Ignition
Switch “ON”), the switch enables the side
stand indicator lamp to glow on the
speedometer panel.
2
3
(2) Side stand switch (3) Side stand spring
17
(2) “ON” Position
“ON” Position
At “ON” position, marked ( ) on the left side
cover, fuel will flow from fuel tank to the carburetor
The three way fuel valve is on the left side of the
carburetor.
FUEL VALVE
“OFF” Position
At “OFF” position, marked ( )on the left side O
cover, fuel cannot flow from the tank to the
carburetor. Turn the valve “OFF” whenever
the motorcycle is not in use.
(1) “OFF” Position
“RESERVE” Position
At “RESERVE” position, marked ( ) on the left
side cover, fuel will flow from the reserve fuel
supply to the carburetor. Use the reserve fuel
only when the main supply is exhausted. Refill
the tank as soon as possible after switching to
îWhen the side stand is up, the side stand
indicator (1) should not glow.
îCheck whether the side stand indicator (1)
glows when the side stand is down.
îCheck the side stand for proper function and
the spring (3) for damage or loss of tension and
the side stand assembly for free movement.
îIf the side stand indicator (1) does not operate
as described in above steps, please visit your
Authorised workshop.Hero MotoCorp
(3) “RESERVE” Position
18
Ensure that adequate care should be taken while
cleaning the side stand switch.
CAUTION
1
1
1
11
2
2
2
22
îDo not operate the motorcycle with the fuel
valve in the “RESERVE” ( ) position after
refilling. You may run out of fuel, with no reserve.
îDo not keep the fuel valve between “ON”
( )and “OFF” ( )position while driving,
since this may drain reserve fuel from the
tank.
NOTE
FUEL TANK
Fuel tank capacity is 12.4 litres (minimum)
including a reserve supply of 2.2 litres
(usable).
îTo unlock fuel tank cap, lift the key hole cover
(1) and insert key (2) turn it clockwise and
remove the cap (3).
îDo not overfill the tank. There should be no fuel
in the filler neck (4). Fill the tank with fuel (5).
îRemove the key and put back the keyhole
cover.
(3) Fuel tank cap
springs back to the normal position and cap
gets locked.
(1) Key hole cover (2) Ignition Key
1
2
Front
5
(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
4
5
3
“RESERVE”. The reserve fuel supply is 2.2
litre (usable).
îTo lock fuel tank cap close the cap back on
the opening and press gently. The key
19
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
SEAT LOCK
Operation : Insert the key and turn it clock
wise to unlock. To install, engage the hook on
the underside of the seat with the frame and
slide the seat to the front until the lock clicks.
Location : On the rear left side of the seat, on
the rear cowl.
(1) Seat lock
1
20
TYRES
The tyres fitted on your motorcycle are of
TUBELESS type.
inflated for the load you are carrying. The
following pages give more detailed following
To safely operate your motorcycle, your tyres
must be of the proper type and size, in good
condition with adequate tread, and correctly
îUsing tyres that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or killed.
îFollow all instructions in this owner’s
manual regarding tyres inflation and
maintenance.
WARNING
Air Pressure
wear unevenly, adversely affect handling and are
more likely to fail from being overheated.
Keeping your tyres properly inflated provides
the best combination of handling, tread life and
riding comfort. Generally, under-inflated tyres
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.
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.
pages give more detailed 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.
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
21
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.
The recommended “COLD” tyre pressures are:
Front
Rear
2
2.00 kg/cm (29 psi)
2
2.00 kg/cm (29 psi)
2
2.00 kg/cm (29 psi)
2
2.25 kg/cm (33 psi)
Rider only Rider and Pillion
(1) Tyre pressure gauge
îBumps or bulges in the side of the tyre or
the tread. Replace the tyre if you find any
bumps or bulges.
Over inflation/Under inflation will affect the
performance.
Inspection
Whenever you check the tyre pressure, you
should also examine tyre treads & side walls
for wear, damage & foreign objects:
Look for :
1
îCuts, splits or cracks in the tyre. Replace the
tyre if you can see fabric or cord.
îExcessive tread wear.
Check the tread wear indicator for tyre wear.
Replace tyres immediately when the wear
indicator (1) appears on the tyre. The tread
limits are :
Tread Wear
MINIMUM TREAD DEPTH
Front: 1.5 mm Rear: 2.0 mm
îCarefully inspect the tyres for any damage, if
the motorcycle hits a pothole or hard object.
22
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.
Tyre Replacement
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.
If you decide to have a tyre replace be sure the
wheel is balanced before you ride.
(1) Tread wear indicator (2) Arrow mark
1
2
Unidirectional Tyres
Repairing a puncture or removing a wheel
requires special tools and technical expertise.
If a tyre is punctured or damaged, it is advised
to visit nearest tyre manufacture, Hero
MotoCorp authorised dealer/workshop or the
tyre repair shop who has expertise in
repairing methods of tubeless tyre.
Whenever 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.
Tyre Repair
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.
îFollow all instructions in this owner’s
manual regarding tyres inflation and
maintenance.
îAlways use the size and type of tyres
recommended in this owner’s manual.
îUsing tyres that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or killed.
îOperation with excessively worn tyres is
hazardous and will adversely affect traction
and handling.
îUnder-inflation may result in the tyre
slipping on or tyre coming off the rim.
WARNING
îThe 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.
NOTE
23
îFor repair and replacement of tyre it is
advised to visit your Authorised Hero
MotoCorp workshop.
The recommended tyre for your motorcycle
are :
Rear: 100/90x18-56 P (Tubeless Tyre)
Front: 80/100x18-47 P (Tubeless Tyre)
î Do not install a tube inside a tubeless tyre
on this motorcycle. Excessive heat buildup
can cause the tube to burst.
îUse 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.
Important Safety Reminders
You should conduct pre ride inspection -
before riding the motorcycle to enhance riding
comfort and safety.
îFuel Level- Ensure sufficient fuel is
available in your journey fuel tank for
(page 19). Check for leaks.
îEngine Oil Level-Check and top up engine
oil if required (page 32). Check for leaks.
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:
Clean your motorcycle regularly. It protects the
surface finish. Avoid cleaning with products that
are not specifically designed for motorcycle
surfaces. Inspect your motorcycle very day
before you start the engine. The items listed here
PRE-RIDE INSPECTION
îSteering-Check for smooth action for
easy maneuverability.
îClutch-Check for smooth operation.
Adjust free play (page 39).
îSide stand indicator-Make sure the side
stand is up. If it is in down position the side
stand indicator will glow on (page 17)
speedometer panel.
îRear brake (Drum type)-Check
operation and if necessary, adjust free play.
îThrottle-Check for smooth opening and
closing in all steering positions (page 37).
îTyres-Check condition and pressure
(page 20 .)
îFront brake-Check for correct brake fluid
level in master cylinder (page 4 ).2
îRear brake (Disc type)-Check for
correct brake fluid level in the reservoir
(page 4 ).3
îLamps and Horn- Check that headlamp,
tail/stop lamp, turn signal lamps and horn
function properly.
îRear View Mirror-Ensure that the rear
view mirror gives a good rear view when
you are sitting on the motorcycle.
îDrive Chain-Check condition and
slackness (page 40). Adjust and lubricate if
necessary.
îAir Suction Valve-Make sure all tube
connections are secured properly (page 53).
îFitting & Fasteners-Check & tighten if
necessary.
24
îTo start the engine in any gear position, press the clutch lever and press the starter
switch/kick start the engine.
îDo not accelerate while starting when the Bystarter lever is "ON".
îNever attempt to kick start while motorcycle is moving forward or backward. This may lead to
damage to the product and is not safe as well.
NOTE
Never run the engine in a closed area, the exhaust contains poisonous gases.
WARNING
STARTING THE ENGINE
3. Find neutral position &
check N indicator
glows on instrument
cluster with ignition
“ON”.
1. Turn the ignition
switch “ON”.
2. Turn the fuel valve
“ON” ( ).
4. Pull the Bystarter lever downwards as indicated
(Use Bystarter during
cold conditions)
(Alternatively, kick start
pedal can be used for
starting).
5. Press the starter switch.
6. Push the Bystarter lever upwards, ( ) position as
indicated, after the engine
gets sufficiently warmed up
to have a stable throttle
response.
Flooded Engine
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
To clear a flooded engine, turn the ignition
switch “OFF” and move Bystarter lever fully
upwards “OFF” position ( ). Close the
throttle fully and crank the engine several
times with the kick starter. Turn the ignition
switch “ON” and start the engine without
using Bystarter.
Running In
Helps to assure your motorcycle's future reliability
and performance by paying extra attention to
how you ride during the first 500 km.
îWhile the engine is idling, press the clutch
lever and depress the gearshift pedal
st
downwards using the toe to shift into 1
(low) gear.
îSlowly 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.
îThe sequence is repeated progressively to
rd th th
shift 3 , 4 and 5 gear.
RIDING
During this period, avoid full-throttle starts
and rapid acceleration.
îWhen the motorcycle attains a moderate speed,
close the throttle, press the clutch lever and shift
nd
to gear by lifting the gear pedal upwards
2
using the toe the gearshift pedal.
îAfter the engine has been warmed up, the
motorcycle is ready for riding.
25
Do not shift gears without operating clutch
and without closing the throttle otherwise this
would lead to damage of gears.
CAUTION
îFor normal braking, close the throttle and
gradually apply both front and rear brakes
simultaneously while shifting down gears to
suit your road speed.
îFor maximum deceleration/quick stopping,
close the throttle and apply the front and
rear brakes simultaneously.
BRAKING
WARNING
îExtreme braking may cause wheel locking
and reduce control over the motorcycle.
îWherever possible, reduce speed or apply
brake before entering a turn, closing the
throttle or braking in mid turn may cause
wheel slip. Wheel slip will reduce control
over the motorcycle.
îIndependent use of only the front or rear
brake increases stopping distance.
5
4
3
2
N
1
îAll your actions should be smooth under
these conditions. Sudden acceleration,
braking or turning may cause loss of control.
For your safety, exercise extreme caution
when braking, accelerating or turning.
îWhen descending a long steep slope use
engine braking (power) by changing to lower
gears, with intermittent use of both brakes.
Continuous brake application can overheat the
brakes a nd r educe their effectiveness.
îWhen riding in wet or rainy conditions, or on
loose surfaces the ability to stop the
motorcycle reduces.
After stopping the motorcycle, shift the
transmission to neutral, turn the fuel valve in
“OFF”, turn the ignition switch “OFF”, park
the motorcycle on main stand, lock the
steering and remove the key.
PARKING
îPark the motorcycle on firm level ground to
prevent overturning.
îWhile parking vehicle on side stand engage
the first gear.
CAUTION
TOOL KIT
îTool Bag -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.
Kit consists of following tool:
î+, - No. 2 Driver-1 No.
26
îGrip-1 No.
îPin Spanner-1 No.
îNo. 3 cross point screw driver-1 No.
îBox wrench P16x14-1 No.
Kit contains the following items:
îSterilized Elastic Plaster-1No.
îSterilized Dressing-1 No.
îGauze (Rolled Bandage)-1 No.
FIRST AID KIT
îFirst Aid Bag-1No.
îWater Proof Plaster-1No.
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.
îElastic Bandage-1No.
îAntiseptic Cream-1 No.
1
(1) Tool kit (2) First aid kit
2
_______________________________________________________
PHONE NO : _____________________________________
ADDRESS: _______________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
ANTI-THEFT TIPS
îBe sure the registration information for your
motorcycle is accurate and correct.
îPark your motorcycle in a locked garage
whenever possible.
îAlways lock the steering and never leave the
key in the ignition switch. This sounds
simple but people do forgets.
îUse an additional anti-theft device of good
quality.
îNever park your motorcycle in an isolated
area. Park as far as possible in a designated
area.
îEnter your name, address and phone
number in this Owner's Manual and keep it
in your motorcycle at all times. Many times
stolen motorcycles are identified by
information in the Owner's Manuals that are
still with them.
NAME: _____________________________________________
27
To help you, take proper care of your
motorcycle, the following pages include a
Maintenance Schedule and a Maintenance
Record for regular scheduled maintenance.
Consult your Authorised Hero MotoCorp
workshop for recommendation applicable to
your individual needs and use.
MAINTENANCE
Importance of Maintenance
A well-maintained motorcycle is essential for
safe economical and trouble-free riding. It will
also help reduce 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.
îAlways follow the inspection and maintenance
recommendations and schedules in this
owner’s manual.
îImproperly maintained motorcycle or failing
to correct a problem before you ride can
cause a crash in which you can be seriously
hurt.
WARNING
28
This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools
provided (if you have basic mechanical skills).
MAINTENANCE SAFETY
You will come across some of the most
important safety precautions in the following
pages of this manual.
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.
However, we cannot warn you of every
conceivable hazard that can arise in
performing maintenance. Only you can decide
whether or not you should perform a given
task.
WARNING
îAl way s follo w th e proce dur es a nd
precautions in this owner's manual.
îFailure to follow maintenance instructions
and precautions properly can seriously
injure you.
SAFETY PRECAUTION
Remember that your Authorised Hero MotoCorp
workshop knows your motorcycle best and is fully
equipped to maintain and repair it.
îMake sure the engine is “OFF” before you
begin any maintenance or repair. This will
help to eliminate several potential hazards:
Do not run the engine unless instructed to
do so.
* Burns from hot parts.
îTo 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.
* Injury from moving parts.
Let the engine and exhaust system cool
before touching.
îTo help prevent the motorcycle from
falling over, park it on a firm, level surface
on the main stand.
* Carbon monoxide poisoning from
engine exhaust.
To ensure best quality and reliability, it is
recommended to use genuine Hero MotoCorp
parts for repair and replacement.
Be sure there is adequate ventilation
whenever you operate the engine.
îRead the instruction before you begin and
make sure you have the tools and skills
required.
29
MAINTENANCE SCHEDULE
Perform the Pre-ride Inspection (page 38 ) at each scheduled maintenance period.
I: INSPECT C: CLEAN R: REPLACE A: ADJUST L:LUBRICATE T: TOP UP
E: EMISSION CHECK
The following Maintenance Schedule specifies all maintenance required to keep your
motorcycle in peak operating condition. Maintenance work should be performed in accordance
with standards and specifications of by properly trained and equipped Hero MotoCorp
technicians. Your Authorised Hero MotoCorp workshop meets all of these requirements.
Ensure that each paid service is availed within 90 days or 3000 km from the date of previous
service, whichever is earlier.
To be serviced by your Authorised Hero MotoCorp workshop unless the owner has
the relevant tools, technical information and is technically qualified.
In the interest of safety, we recommend that these jobs are carried out only by your
Authorised Hero MotoCorp workshop.
Replace air cleaner element once in every 15000 km or early replacement may be
*required when riding in dusty areas.
Replace engine oil once in every 6000 km. Top up once in every 3000 km.
** Inspect & maintain specified torque.
*** Replace once in every two years or 30000 km, whichever is earlier.
****
• Check idle CO emission along with idle r/min/idle CO adjustment (if required).
@ Visit Authorised Hero MotoCorp workshop for inspection, cleaning, lubrication and
adjustment of drive chain at every 2000 km.
Note-1: At higher odometer readings, repeat the frequency interval established here.
Note-3: Replace front fork oil once in a every 2 years or 30000 km, whichever is earlier.
Note-2: Service more frequently when riding in rain or at full throttle.
Note-4: Inspect the bearings free play, replace if necessary.
Note-5: Inspect for any play in the mounting bushes, replace if necessary.
30
Dear Customer,
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.
MAINTENANCE SCHEDULE
3000-
3500
6000-
6500
9000-
9500
12000-
12500
WHICHEVER
COMESFIRST
ITEMS
DURING FREE SERVICE PERIOD
SERVICE st
1nd
2rd
3th
4th
5
AFTER FREE SERVICE
ONCE IN EVERY
6000 9000 12000 15000
DAYS
KM NOTE-1
500-
750
I
I
I
I
I
I
I
I
I
I
I
I
3000
Next
100 Next
100 Next
100
1st 60
Next
100
Fuel Line
I,A I, A I, A I,A I, AI, A
Throttle Operation
C, A
A
C, A
A
C, A
A
I, C I, C I, CI, C I, C I, C
C, A
R
R
O
C
C
I
I
I I
I
I I
I
I
CCC
CCC
I, T
O
I, T
O
I, T
O
I, A I, A I, A I, A I, A I, A
I, C, AI, C, AI, C, AI, C, AI, C, A R
I I I
Do not open air cleaner element unless is a
drivability problem
Engine Idle Speed
/Carburetor
Air Cleaner
element*
Spark Plug
Valve Clearance
Engine Oil**
Engine Oil
Strainer Screen
Engine Oil
Centrifugal Filter
Oil Circulation
Electric Starter
Air cleaner drain
tube
Bystarter
Operation
I,C,L,A at every 000 km I,C,L,A at every 000 km 2 2Drive Chain@
NOTE-2
2931
L L L L L L
I, L, AI, A
I
I, L, AI, A
I
I, A
I
Brake Fluid**** I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Brake System
(Brake Cam &
Brake Pedal) C, LC, LC, L
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
I, A
Brake Shoe/
Pad Wear
IIIIII
I II I I
Drive Chain
Slider
3000-
3500
6000-
6500
9000-
9500
12000-
12500
WHICHEVER
COMESFIRST
ITEMS
DURING FREE SERVICE PERIOD
SERVICE st
1nd
2rd
3th
4th
5
AFTER FREE SERVICE
ONCE IN EVERY
6000 9000 12000 15000
DAYS
500-
750 3000
Next
100
Next
100
Next
100
1st 60
Next
100
Stop Lamp
Switch
Head amp Focusl
Clutch
Side Stand/
Main Stand
Side Stand
Switch I, C I, CI, C I, CI, CI, C
Nuts, Bolts &
Fasteners***
Wheel Bearings
Wheel /Tyress
Steering Head
Bearing
Front Suspension/
Oil****
I I I I I I
Secondary Air
Injection I I I
Muffler (Catalytic
Converter)
•
•
•
••
I, E I, E I, E
Rear Suspension
I I I I I I
Battery Voltage
NOTE-3
NOTE-4
KM NOTE-1
NOTE-5
32
(JASO MA2).
BRAND: Hero 4T plus
GRADE: SAE 10W 30 SL Grade
Use hero genuine engine oil or recommended
grade oil.
ENGINE OIL
Manufactured by:
îTide Water Oil Co. (India) Ltd.
: 1 liter at draining
: 1.2 litres at disassembly
OIL CAPACITY
îBharat Petroleum Corporation Limited.
Engine oil level check
The oil level dipstick (1) is on the right crankcase
cover for measuring oil level. Oil level
must be maintained between the upper (2) and
lower (3) level marks on the oil level dipstick.
Do top up if oil level reaches towards the lower level
mark or every 3000 km. whichever is earlier.
Check engine oil level each day before operating
the motorcycle.
îSavita Oil Technologies Limited.
UPPER
LOWER
(1) Oil level dipstick (2) Upper level mark
(3) Lower level mark
123
îStart the engine & let it idle for 3-5
minutes.
îRemove the oil level dipstick, wipe it clean
and insert without screwing it in.
îEngine oil top up process
îRemove the oil level dipstick and check the
oil level.
îPark the motorcycle on its main stand.
îStop the engine and wait for 2-3 minutes.
îIf required, add the specified oil up to the
“UPPER” level mark. Do not overfill.
îReinstall the oil level dipstick with new
O-ring and check for oil leaks.
Replace engine oil once in every 6000 km/
6 months whichever is earlier.
Engine oil replacement process
îStart the engine and allow it to idle for few
minutes.
îTo drain the oil, remove the oil level dipstick,
drain bolt (1) and sealing washer (2).
Drain engine oil with the engine warm and the
motorcycle on its main stand.
îFill the crankcase through the oil filler hole with
approximately 1.0 litre of recommended grade
oil during oil change when right crankcase
cover is not removed.
îAfter the oil has completely drained, reinstall
the drain bolt with a new sealing washer.
îReinstall the oil level dipstick with a new O-ring.
îMake sure that oil level is at the UPPER“ ”
level mark of the oil level dipstick with the
îStop the engine and let the engine oil settle down.
33
(1) Drain bolt (2) Sealing washer
1
2
îRunning the engine with excessive oil can
cause spark plug fouling & loss in
performance.
îRunning the engine with insufficient oil can
cause serious engine damage.
îEngine 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.
CAUTION
motorcycle in an upright position and that
there are no oil leaks.
(1) Clutch cable (2) Kick start pedal
(3) Kick stopper (4) Right crankcase cover
îRemove the oil filter screen (5) and wash it
in clean non flammable or high flash point
solvent (kerosene).
OIL FILTER SCREEN & CENTRIFUGAL
FILTER
îDisconnect the clutch cable (1), remove the
kick start pedal (2) and kick stopper (3)
remove right crankcase cover (4).
îDrain the engine oil throughly (page 32).
îRemove centrifugal filter cover (6) & clean
the centrifugal filter (7) with non flammable
or high flash point solvent (kerosene).
2
3
1
4
îReinstall the filter screen with the tapered
end facing in.
(5) Oil Filter Screen (6) Centrifugal Filter Cover
(7) Centrifugal Filter
6
5
7
îReinstall the centrifugal filter cover, right
crankcase cover and connect the clutch cable.
(1) Noise suppressor cap (2) Spark plug
Recommended plug : NGK-CPR 8 EA 9
For most riding conditions this spark plug heat
range number is satisfactory. However, if the
motorcycle is going to be operated for
extended periods at high speeds or near
maximum power in hot climates, the spark
plug should be changed to a cold heat range
number, consult Authorized Hero MotoCorp
workshop on this if required.
îClean dirt around the spark plug base.
îDisconnect the noise suppressor cap (1)
and remove the spark plug (2) with the help
SPARK PLUG
2
1
34
Install kick stopper and kick start pedal.
îFill the crankcase with clean engine oil as
per specification.
îClean filters as specified in the
maintenance schedule.
îEnsure to replace gasket once removed.
NOTE
0.8-0.9 mm
of spark plug box wrench provided in the
tool bag.
îVisually inspect the spark plug electrodes
for wear. The center electrode should have
square edges and the side electrode should
not be eroded. Discard the spark plug if
there is apparent wear or if the insulator is
cracked or chipped.
îMake 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 conditions.
îTighten a new spark plug 1/2 turn after
plug seats, with 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.
îWith the plug washer attached, thread the
spark plug in by hand to prevent cross-
threading.
(1) Side cover (2) Side cover screws
1
îRemove the seat assembly (page 20).
îRemove the side cover (1) by removing
side cover screws (2).
T is viscous type paper filter he air cleaner
which enhances filtering efficiency. The air
cleaner replacedshould be at regular
intervals When riding in dusty (page 3 ).0
areas, more frequent may be replacement
necessary.
AIR CLEANER
îRemove the air cleaner cover screws
washers (3) and the cover (4).
2
35
(5) Element air cleaner screws/washers
(6) Element air cleaner
(3) Air cleaner cover screws/washers
(4) Air cleaner cover
4
3
îRemove the element air cleaner
washers (5) and remove the elem
cleaner (6).
6
5
îRemove the air cleaner elemen
from housing (7).
îClean the air cleaner housing (7)
shop towel.
(6) Element air cleaner
(7) Air cleaner housing
6
îReplace it earlier if it becomes very dirty,
damage on surface or on the sealing area.
îNever wash or clean the viscous filter.
Replace filter element once in every 15000
km.
CAUTION
7
îInstall a new air cleaner element in the
reverse order of removal.
36
AIR CLEANER DRAIN TUBE
Remove the drain tube (1) from the a
assembly (2) and drain the deposi
suitable container. Reinstall the drain
Follow the above process more f
when riding in rain or at full throttle
Always ensure to reinstall the drain tube
draining the deposit.
NOTE
(1) Drain tube (2) Air cleaner assembl
1
2
Valve clearance
Excessive valve clearance will caus
little or no clearance will prevent
from closing and cause valve dam
power loss. Check valve clearanc
specified intervals (page 30).
(1) Crankshaft hole cap (2) Timing hole
(3) 'T' mark (4) Index mark
(1) Free play 2-6 mm
To adjust free play slide the boot (2), loosen
the lock nut (3). Turn the adjuster(4) to
adjust free play. After adjustment, tighten the
lock nut and slide the boot on the adjuster and
locknut securely.
Direction A - to decrease the free play
Direction B - to increase the free play
Free play adjustment
4
1
Check for smooth rotation of the throttle grip
from the fully open to the fully closed position.
Cable Inspection
Check at full left and full right steering
positions. Inspect the condition of the throttle
cable from the throttle grip down to the
carburetor. If the cable is kinked, chafed or
improperly routed, it should be replaced or
rerouted. Standard throttle grip free play (1)
is approximately 2-6 mm of grip rotation.
THROTTLE OPERATION
3
2
1
3
2
4
(2) Boot (3) Lock nut (4) Adjuster
(A) Decrease free play (B) Increase free
A
B
37
(5) Adjusting screw (6) Lock nut
îCheck the clearance by inserting t
gauge (7) between the adjusting sc
and valve stem.
îInstall the parts in the reverse o
disassembly.
If adjustment is required, adjust by
the lock nut (6) and turning the a
screw (5) until there is a slight dra
feeler gauge (7).
Intake:0.08 mm; Exhaust: 0.12 mm
After tighten the lock nut (6), ch
clearance again.
Standard clearance (Cold condition
(7) Feeler gauge
Before inserting the feeler gauge, smear a bit
of engine oil on the feeler gauage to avoid
damage to the feeler gauge.
NOTE
7
6
5
The checking or adjusting of valve clearance
should be performed while the engine is cold.
The clearance will change as the engine
temperature rises.
NOTE
îRemove the crankshaft hole cap (1) and
timing hole cap (2)
îRemove the cylinder head cover.
îRotate the flywheel anticlockwise until th
“T” mark (3) on the flywheel coincides with
the index mark (4) or the left crankcase
cover. In this position the piston will either
be on the compression or exhaust stroke.
The adjustment must be made when the
piston is at Top Dead Center and both the
inlet and exhaust valves are closed.
This condition can be determined by
moving the rocker arms. If they are free, it is
an indication that the valves are closed and
the piston is in compression stroke. If they
are tight the valves are open, rotate the
flywheel 360° anticlockwise and re-align
the“T” mark with the index mark.
38
Do not attempt to compensate for faults in
other systems by adjusting idle speed. Visit
your Authorised workshop for Hero MotoCorp
scheduled carburetor adjustment.
CAUTION
CLUTCH
îTo adjust the free play, loosen the lock nut
(3). Turn the adjusting nut (4) to obtain the
specified free play. Tighten the lock nut and
check the adjustment.
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 lever (2).
îStart 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.
(1) Throttle stop screw
(A) Increase r/min (B) Decrease r/min
(1) Free play 10-20 mm (2) Clutch lever
2
1
AB
1
IDLE SPEED: 1400 100 R/MIN±
39
CARBURETOR
Idle speed
The carburetor is factory pre-set in order to
achieve optimum performance and meet
emission standards.
However in case of specific requirement of
tuning due to engine stalling in idle speed,
please follow the instructions given hereunder:
îWarm up the engine and rest the
motorcycle on the main stand.
îAdjust idle speed with the throttle stop
screw (1).
If proper adustment cannot be obtained or the
clutch does not work correctly, visit your
Authorised Hero MotoCorp workshop.
NOTE
îCheck that the clutch cable routing is
correct.
Other Checks
îCheck for clutch cable model. Use genuine
clutch cables.
îCheck the clutch cable for kinks or signs of
wear that could cause sticking or failure.
The drive chain (1) should be checked and
lubricated as part of the Pre-ride Inspection
(page 23). Under severe usage, or when the
motorcycle is ridden in unusually dusty areas.
more frequent maintenance will be necessary.
The service life of the drive chain depends
upon proper lubrication and adjustment.
DRIVE CHAIN
Poor maintenance can cause premature wear
or damage to the drive chain and sprockets.
Inspection
îTurn the engine “OFF”, park the motorcycle
on its main stand and shift the transmission to
neutral. Remove hole cap (2).
îDrive chain slack (3) should be adjusted to
allow approximately 30 mm (1¼ inch)
vertical movement by hand.
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 binding.
Binding can be eliminated by frequent
lubrication.
(1) Drive chain (2) Hole cap
(3) Drive chain slack 30 mm
2
1
30 mm
3
îTurn the chain to view chain lock plate (4)
inside the hole. Ensure that the chain lock
plate open end (5) is installed in the
opposite direction of the chain rotation.
(1) Lock nut (2) Clutch cable adjuster nut
(A) Decrease free play (B) Increase free play
A
B
3 4
40
îIf the drive chain or sprockets are
excessively worn or damaged, they should
be replaced. Never use a new chain with
worn out sprockets since this will result in
rapid chain wear.
îPark the motorcycle on its main stand with
the transmission in neutral and the ignition
switch in "OFF" position.
Adjustment
îIf the drive chain slack is excessive when the
rear axle is moved to the farthest limit of
adjustment, the drive chain is worn and
must be replaced.
îLoosen the rear axle nut (1) and sleeve
nut (2).
îCheck the drive chain slack again.
- Rear axle nut torque 6.8 kgf-m.
îTurn both the adjusting nuts (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.
îAlign the chain adjuster index mark (5) with
the corresponding scale graduations (6) on
both the sides of the swing arm equally.
îLoosen the drive chain lock nut (3).
îTighten the rear axle nut and sleeve nut.
- Sleeve nut torque 5.9 kgf-m.
(1) Rear axle nut
1
41
Worn Sprocket Teeth
Damaged
Sprocket Teeth
Normal
Sprocket Teeth
îInspect the sprocket teeth for wear or
damage.
(4) Chain lock plate (5) Open end
4
5
Regular adjustment and lubrication as per the
maintenance schedule would ensure high
performance and longer life.
CAUTION
Visit Authorised workshop Hero MotoCorp
for inspection, cleaning, lubrication and
adjustment of drive chain at every 2000 km.
NOTE
Lubrication
îRear brake pedal free play is affected when
repositioning the rear wheel to adjust drive
chain slack. Check rear brake pedal free
play and adjust as necessary (page 45).
îTurn the engine “OFF”, park the
motorcycle on its main stand and shift the
transmission into neutral.
îLubricate the drive chain by applying liberal
amount of SAE#90 oil or chain lubricant.
(2) Sleeve nut (3) Drive chain lock nut
(4) Drive chain adjusting nut (5) Index mark
(6) Scale graduation
2 65 4
3
42
(Refer to “Maintenance Schedule” on
(page 30).
Drive Chain Slider
Check the chain slider (1) for wear, The chain
slider must be replaced if the or wear limit is
reached. For replacement, visit your
authorised Hero MotoCorp workshop.
(1) Chain slider (2) Wear limit
CUTOUT
CUTOUT
CUTOUT
CUTOUTCUTOUT
2
1
Master cylinder (1)
Location: Right handlebar.
FRONT BRAKE
Refer to the safety precautions on (page 28).
Brake fluid recommended: Castrol Q
Stop- DoT 3 or DoT 4
Fluid level- Ensure that the brake fluid level
does not fall below "MIN'' mark (2) on front
brake master cylinder 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.
43
Brake pad wear depends upon the severity of
usage, the type of riding & road conditions.
Generally, the pads will wear faster on wet &
dirty roads. Inspect the pads at each regular
maintenance interval.
Brake Pad Wear
îIf either pad is worn to the bottom of the
grooves replace both pads as a set. Visit
your authorised Hero Moto Corp workshop
for this service.
îCheck the brake pads for wear by
examining the wear limit groove on each
pad.
(1) Wear Indicator Grooves
11
(3) Brake pads (4) Caliper (5) Disc
3
4
5
(1) Master cylinder (2) “MIN” mark
2
1
îAlways contact your Authorised Hero
MotoCorp workshop for refilling of master
cylinder when necessary. Do not mix DoT 3
and DoT 4 brake fluid.
îClean the dirt and mud accumulation
between the brake pads (3) caliper (4) and
the disc (5) by using a water jet.
NOTE
Al way s ap pl y fr ont and rear brakes
simultaneously to avoid skidding of vehicle.
WARNING
REAR BRAKE
Disc type
Refer to the safety precautions on (page 28).
Rear: Reservoir (1)
44
Location: Inside right side cover next to the battery.
Brake fluid recommended: Castrol Q
Stop-DoT 3 or DoT 4
Fluid level- Ensure that the brake fluid level
does not fall below "Lower" mark (2) 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.
Reservoir
(1) Reservoir (2) Lower mark
Rear Caliper
(3) Rear caliper (4) Brake (5) Disc
3
4
5
Check the wear indicator grooves (6) in each
pad.
îClean the dirt and mud accumulation
between the brake pads (3) caliper (4) and
the disc (5) by using a water jet.
îAlways contact your Authorised Hero
MotoCorp workshop for refilling of master
cylinder when necessary. Do not mix DoT 3
and DoT 4 brake fluid.
NOTE
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.
(6) Wear indicator grooves
6
1
2
45
Drum Type
REAR BRAKE
îPark the motorcycle on its main stand.
îMeasure the distance of brake pedal (1)
moves before the brake starts to take hold.
Free play (2) should be 20-30 mm.
îIf adjustment is necessary, turn the real
brake adjusting nut (3).
(1) Rear brake pedal (2) Free play 20-30 mm
1 2
20-30 mm
If proper adjustment cannot be obtained by
this method, visit your Authorised Hero
MotoCorp workshop.
NOTE
the arrow aligns with the reference mark on
full application of the brake, the brake shoes
must be replaced.
When the brake is applied, an arrow (1), fixed
to the brake arm (2), moves towards a
reference mark (3) on the brake panel (4). If
BRAKE WEAR INDICATORS
îApply the brake serveral times and check
for free wheel rotation when released.
(3) Adjusting nut (4) Brake joint pin
(A) Cut-out not seated ( ) Cut-out seatedB
43 34
(3) Adjusting nut (4) Brake arm pin
(A) Decrease free play (Clockwise)
(B) Increase free play (Counter clockwise)
3A
B
4
Make sure that the cut-out on the adjusting
nut is seated on the brake arm pin (4) after
the final adjustment has been made.
BATTERY
Refer to the safety precautions on (page 28).
Location
The battery (1) is located behind the right side
cover.
1
(1) Battery
1
46
REAR BRAKE WEAR INDICATION
(1) Arrow (2) Brake arm (3) Reference mark
(4) Brake penal
3
4
1
2This symbol on the battery means that
this product must not be treated as
household waste.
This symbol on the battery means the
old battery must be returned to your
Authorised Hero MotoCorp workshop
as it must be treated as recyclable
material.
NOTE
îBattery is a Maintenance-Free (sealed) type
and can be permanently damaged if the
sealing strip is removed.
îAn improperly disposed battery can be
harmful to the environment and human
health. Always confirm local regulations for
battery disposal.
WARNING
Specification
It is not necessary to check the battery
electrolyte level or add distilled water as the
battery is an Maintenance-Free (sealed)
type. If your battery seems weak and/or
electrolyte is leaking (causing hard starting or
other electrical troubles), contact your
Authorised HeroMotoCorp workshop.
*MF Battery,12V-4 Ah ETZ-5
îThe battery gives off explosive hydrogen gas
during normal operation.
îA spark or flame can cause the battery to
explode with enough force to seriously hurt you.
îWear protective clothing and a face shield,
or have skilled technician do the battery
maintenance.
*MF stands for Maintenance Free
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
îIf 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.
îIf the battery is expected to be stored for
more then two months, ensure to fully
charge the battery once in a month.
îAlways ensure the battery is fully charged
before installation.
îEnsure the battery leads are properly
connected to the battery terminals during
installation.
îDisconnect the negative (-)ve terminal lead
from the battery first, then disconnect the
positive (+)ve terminal lead (6).
îPullout the battery from the battery box.
îRemove the battery clamp bolt (3) and the
battery clamp (4).
îRemove the seat (page 20).
Battery removal
îMake sure the ignition switch is "O FF"
îRemove the right side cover screws (1) and
remove the side cover (2).
47
(1) Right side cover screws (2) Side cover
(3) Bolt (4) Band battery (5) Negative (-)ve
terminal (6) Positive (+)ve terminal
îCheck all fasteners are secure.
îReinstall in the reverse order of removal. Be
sure to connect the positive (+)ve terminal
first, then the negative (-)ve terminal.
Battery installation
5
34
2
1
6
Fuse Box (A) Location : Below the seat
Fuse Type: Blade fuse
Fuse Type: Blade fuse
Start Mag. Switch (B)
Location: Inside right side cover
Location: Below start mag switch.
1
B
2
A
2 1
48
(1) In circuit fuse 15A, 10A
(2) Spare fuse 15A, 10A
(1) In circuit fuse 20A (2) Spare fuse 20A
Refer to the safety precautions on (page 28).
FUSE REPLACEMENT
CAUTION
STOP LAMP SWITCH
The stop lamp switch (1) must be adjusted so
that stop lamp will glow when rear brake is
applied. Rear brake free play (page 45) should
be adjusted before performing stop lamp switch
adjustment. The procedure for adjusting stop
lamp switch is as follows:
îTurn the ignition switch to the “ON”
position.
îTurn the adjusting nut (2) to position stop
lamp switch at a point where the stop lamp
will glow just before the brake pedal is
depressed to the limit of its free play. Turn
the adjusting nut in direction (A) to advance
switch timing or in direction (B) to retard
switch timing.
îNever 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.
îBattery gives off explosive gases. Keep
sparks, flames & cigarettes away.
WARNING
îTurn the ignition switch "OFF" before checking
or replacing the fuse to prevent accidental
short-circuiting.
îDo 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.
HEADLAMP ADJUSTMENT
îHeadlamp adjustment is done by the
loosening the bolt (1) located below the
headlamp.
îHeadlamp is preset. However in case of
adjustment required, please follow the steps
as given below:
(1) Stop lamp switch (A) Advamce
(2) Adjusting nut (B) Retard
A
B
2
1
(1) Bolt
1
49
SUSPENSION
îCheck 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.
îCheck the rear shock absorber by pushing
hard downwards on rear grip while the
motorcycle is not parked on stand. The
motorcycle action should be smooth and
there should be no oil leakage.
Inspection
îPark the motorcycle on level ground.
îAdjust the headlamp beam by loosening the
bolt (1) and moving the headlamp unit
forward and backward for correct focus
adjustment.
îTighten the bolt after adjustment.
An improperly adjusted headlamp may blind
oncoming rider/driver or it may fail to light the
road for a safe distance.
WARNING
Front Rear
Rear shock absorber adjustment
îIn direction A stiffer
Rear shock absorber adjustment can made
according to the load/road conditions.
îIn direction B softer
NOTE
Always adjust both the rear shock absorber to
the same position. Use the rear shock absorber
adjustment tool (1) available in the tool kit.
(1) Shock absorber adjustment tool
îRemove the side collar from the wheel.
Refer to the safety precautions on (page 28).
îSupport the motorcycle securely on the
main stand and raise the front wheel off the
ground.
FRONT WHEEL REMOVAL
îRemove the front axle nut (1) remove the
speed sensor (2), axle and wheel.
A
B
1
50
îInstall the side collar (1) to the right side of
the wheel hub and then install the speed
sensor (2) on the left side of the wheel hub.
FRONT WHEEL INSTALLATION
CAUTION
Do not operate front brake lever when the
wheel is removed.
1
2
(1) Side collar (2) Speed sensor
(1) Axle nut (2) Speed sensor
1
2
îPosition the front wheel between the fork
legs by aligning the slot on the speed sensor
with the lug on the fork leg and the disc
between the brake pads to avoid damage to
the pads. Insert the axle from the right side
through the fork legs and wheel hub.
îTighten the front axle nut to the specified
torque.
TORQUE : 5.9 kgf-m
îInstall the stay and speed sensor cable stay
bolt (1) on the left fork leg.
îAfter 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.
51
REAR WHEEL REMOVAL
Disc type
îRefer safety precautions on (page 28).
îSupport the motorcycle securely on the
main stand and raise the rear wheel off the
ground.
îRemove the rear axle nut (1) and washer
(2).
îMove the caliper assembly (5) upwards.
îRemove the axle (3) and the right side
collar (4).
îSlide the wheel out from left side.
îInstall the side collar (1) to the right side of
the wheel hub.
îInsert the disc (2) 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.
REAR WHEEL INSTALLATION
îTilt the motorcycle and position the rear
wheel between the swingarm.
îAlign the rear caliper holder (3) with the
swingarm (4).
îInsert the axle (5) from the left side through
the swingarm, wheel hub, collar and rear
caliper holder .
(1) Rear axle nut (2) Washer (3) Axle (4) Right
side collar (5) Caliper assembly
2
1
4
3
5
52
îInstall the washer (6) and tighten the rear
axle nut (7) to the specified torque.
TORQUE : 6.8 kgf-m
(1) Side Collar (2) Disc (3) Rear caliper holder
(4) Swingarm (5) Axle (6) Washer (7) Axle nut
1
5
4
3
5
7
6
2
REAR WHEEL REMOVAL
Drum type
(1) Rear brake adjusting nut (2) Rear brake
rod (3) Brake arm (4) Brake stopper arm (5)
Brake panel (6) Split pin (7) Lock nut (8) Axle
nut (9) Axle
465
3
2
71
8
9
îAfter cleaning spray water thoroughly.
îDry the motorcycle by wiping with dry soft
cloth.
Follow the below mentioned steps for washing
the motorcycle.
WASHING THE MOTORCYCLE
îWet the motorcycle with light water spray.
Avoid directing water to muffler outlets and
electrical parts.
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.
îClean the headlamp lens and other plastic
CAUTION
Always replace used split pins with new ones.
îRaise the rear wheel off the ground.
îRemove the rear brake adjusting nut (1) and
disconnect the brake rod (2) from the brake
arm (3) by pushing down the brake pedal.
Disconnect the brake stopper arm (4) from
the brake panel (5) by removing split pin (6)
and lock nut (7).
îRemove the axle nut (8) and pull out the
axle (9). Remove the wheel.
Brake stopper arm nut torque:2.2 kgf-m
îAdjust the brake (page 45).
îReverse the removal procedure
Installation
îAfter installing the wheel, apply the brake
several times and check for free wheel
rotation when released.
îAxle nut torque : 6.8 kgf-m
NOTE
This motorcycle is equipped with a catalytic
converter in the muffler to meet the emission
norms . The catalytic converter contains noble
metals that serve as catalyst, promoting
chemical reactions to convert CO and HC in
the exhaust to CO and H O (water vapour).
2 2
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.
îAlways use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
converter ineffective.
îKeep the engine tuned up.
CATALYTIC CONVERTER
îDo not put water inside the muffler
during washing. It is advisable to put a
cover over the Exhaust pipe to avoid water
entering the muffler.
îDo not use high pressure water (or air).
It can damage certain parts of the
motorcycle.
îOur authorised dealership take all above
mentioned precautions like recommended
detergents and usage of muffler caps/plugs
during wash to ensure quality wash.
53
AIR SUCTION VALVE
Further to meet emission standards this
motorcycle is provided with the air suction
valve.
Air Suction Valve (1) supplies fresh air from
the air filter to the exhaust manifold to convert
carbon monoxide to carbon dioxide. This
reduces the CO% in the vehicles exhaust.
(1) Air suction valve
1
BASIC TROUBLESHOOTING
Check Fuse
Inspect Battery
Check connections, Ignition switch/starter switch
OK
OK
OK Loose
Replace Fuse (ref. page 48)
Secure connections
Weak
Fuse
B. Electric Starter Not Working
Check Ignition Switch
OK
OK
OK
Turn ignition switch “ON”
“OFF”
C. No Spark At Spark Plug
No Spark
Check Spark Plug for Fouling/
Improper Electrode Gap Replace Spark Plug/Adjust
Spark Plug Gap (0.8-0.9 mm)
LooseContact
Check for Poorly Connected
or Loose Spark Plug Wire Secure Properly
Check fuel valve position
“ON” Position
Check fuel in Fuel Tank
OK
OK
Check fuel Lines Leakage/Air Lock
Turn to “ON” position
Refill
Rectify
No Fuel
“OFF”
A. Fuel System
1. STARTING TROUBLE - ENGINE DOES NOT START
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
54
Spark Plug Loose in Cylinder Head
OK
Check Air Cleaner element
OK
OK
Check Brake Binding
Improper Adjustment (Drum Type)
Tighten the Spark Plug
Replace
Readjust free play of rear Brake brake pedal
Clogged
Loose
3. POOR PICK UP
OK
Check Tyre Inflation Pressure Under Inflated Correct Tyre Pressure
Check Fuse
OK
Inspect Battery
OK
OK
Check Bulbs Fuse/Wrong Wattage
Replace Fuse
Weak
Fuse
Feeble Horn Sound or No Light
Replace Bulbs
4. ELECTRICAL SYSTEM
OK
Check Connections Loose Secure Connections
Check Bystarter lever position
“OFF” Position
Check Air Cleaner element
OK
Turn to “OFF” position
Replace
Dirty/Clogged
“ON”
2. ENGINE STARTS BUT STALLS
BASIC TROUBLESHOOTING
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
Consult Authorised Hero MotoCorp Workshop
55
Improper functioning (Disc Type)
Consult Authorised Hero MotoCorp Workshop
ROAD SIGNS
Mandatory 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
56
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 40
ROHTAK 58
NAJAFGARH 3 Rohtak
Bahadurgarh48
10
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.
57
WARRANTY
Scope of warranty
Hero MotoCorp Ltd.
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.
Hero MotoCorp Ltd. Hero MotoCorp Hunk (hereinafter called ‘ ') warrants its vehicles,
assembled/manufactured in its to be free from Plants and sold through its channel partners,
any defect-both in material and workmanship, under normal use and conditions, subject to the
following terms & conditions.
a) vehicle is warranted for a period of , whichever is earlier, Hunk 5 years or 70000 Km
from the date of purchase.
c) Hunk Hero MotoCorp'sIf any is observed in vehicle, only obligation/ liability is problem
to repair or replace that part/those parts which is/are considered to be the cause of such
problem problem, provided however that such has not resulted due to misuse/improper
handling etc. of the vehicle. Any vehicle needing repair should be brought along Hunk
with owner's manual to authorized workshop for necessary inspection Hero MotoCorp's
and carrying rectification job.
Hero MotoCorp Ltd.
LIMITATIONS OF WARRANTY
The warranty shall not apply—
(12) For consumables like oil, grease, gasket etc to be used during free services and/or warranty repairs.
Subject to DELHI JURISDICTION only.
(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.
(11) If any defect crops or repairs needed as a result of meeting to some accident. Hunk vehicle
(2) If any other engine oil which is non compatible with product is used other than SAE 10W30 S Grade (JASO M ).L A2
(7) For normal phenomena like noise vibration, oil seepage etc., which do not affect the performance of the .vehicle
(8) To any damage caused due to usage of improper oil/grease, non-genuine parts.
(6) To any damage on 's painted surface cropping due to industrial pollution or other external factors.vehicle
(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.
(9) If any defect crops or repairs needed as a result of using adulterated fuel.
(1) If all free services/paid services/oil top-ups are not availed as per the recommended schedule at authorized Hero MotoCorp's
workshop.
(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.
(13) To any part of the vehicle which has been tampered or repaired in such a manner which has resulted in malfunction of the Hunk
vehicle.
(14) For not used in accordance with the guidelines given in this Owner's Manual.Hunk 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.
(5) If has been used in any competitive events like races or rallies or for any commercial purposes as taxi etc.Hunk vehicle
(10) If any maintenance/repairs required due to bad road conditions or misuse of . Hunk vehicle
Decision regarding warranty settlement shall be taken by and the same shall be final and binding Hero MotoCorp
on all concern.
Hero MotoCorp Ltd.
8. Breakage of container and cover do not come under the purview of this warranty.
BATTERY WARRANTY PERIOD
3. 3 months idle period is allowed from the date of charging to date of sale on vehicle.
1. 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.
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.
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.
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.
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.
2. 21 months from the date of charging (whichever is earlier).
9. Adjudication and settlement of claim will take a couple of days as a battery has to be tested for the reported failure.
Terms and condition of warranty
1. 18 months from date of sale of vehicle or 20000 km. or
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.
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.
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.
EMISSION WARRANTY
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.
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.
d) The customer should follow the recommended parts replacement as per the maintenance schedule in order to avail the emission
warranty.
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 given in the Service Record Sheet
owner's manual.
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 partner
manufacturer or the dealer is not responsible for any penalty levied on you on account of non-compliance with the emission standards.
a) 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.
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.
Scope of warranty
i) All decisions regarding emission warranty settlement shall be taken by Hero MotoCorp Ltd. and shall be final binding on
all concerned.
Subjected to Delhi jurisdiction only.
îSafety of vehicle and rider
îPeace of mind
WHAT ARE THE BENEFITS OF Hero MotoCorp GENUINE SPARE PARTS ?
îAssured quality
îEnsures economy for a long time
îAssures long life
îValue for money
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
Clutch Plate
îDamages other parts of clutch like, clutch center and
outer clutch
îMaterial used is inferior
îAffects fuel efficiency
îPoor acceleration
îReduced life
îPoor performance
îImproper sealing
îLeads to leakage and smoky exhaust
îHigher emission level
îEngine knocking
Cam Chain Kit
Gasket Cylinder Head
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
Element Air Cleaner îAffects fuel efficiency
îPoor engine performance
îImproper air filtration resulting in premature engine failure
îAffects fuel efficiency
îPoor engine performance
îFrequent stalling of engine
îHigher emission level
îDiscs/Drum wear out, resulting in subsequent repair cost
îRider safety-an issue
îPoor braking eff ciencyi
îFailure of chain can cause fatal accident
îNoisy Operation
Chain 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 : kolkata@heromotocorp.com
Hero 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: bhubaneshwar@heromotocorp.com
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: ranchi@heromotocorp.com
Hero MotoCorp Ltd., Sai Corporate Park, A Block, 6th Floor, Rukanpura, Bailey Road Patna, Bihar – 800014
Tel: +919334280555/7004569648 E-mail: patna@heromotocorp.com
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: delhi@heromotocorp.com
Hero MotoCorp Ltd., S.C.O-367-368, First Floor, Sector-34A, Chandigarh-160022, India.
Tel: +91-172-2623773, 2623774, 2623775, E-mail: chandigarh@heromotocorp.com
Hero MotoCorp Ltd., Kapoor Towers, Plot No- 284, 15-B, Rajpur Road, Dehradun-248001, India.
Tel:0135-2714661,2713662,2714663, E-mail: dehradun@heromotocorp.com
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: jaipur@heromotocorp.com
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: bhopal@heromotocorp.com
Tel: +91-731-4978269, 70, E-mail: indore@heromotocorp.com
Hero MotoCorp Ltd., Maloo-01, 601-602, 6th Floor, Plot No. 26C, Scheme No. 94, Ring Road, Indore, M.P.-452010,
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: raipur@heromotocorp.com
Hero MotoCorp Ltd., Office No. 705-706, 7th Floor, Fun Square, Durga Nursery Road, Udaipur -313001 (Rajasthan).
Tel: +91 0294-2980578, 79, E-mail: udaipur@heromotocorp.com
Hero MotoCorp Ltd., 602, 6th Floor, Office Tower-1, Plot No BW58, Logix City Center, Sector-32, Noida – 201301.
Tel: 0120-4631000, E-mail: noida@heromotocorp.com
ZONAL/REGIONAL OFFICES/AREA
Hero MotoCorp Ltd., Chrome Building, Sr. No. 33, Hissa-A-1/1/2, Plot - 2, Viman Nagar Avenue 2, Nagar Road,
Pune-411014, India. Tel: +91-020-71903500, E-mail: pune@heromotocorp.com
Tel: +91-265-2286569/2286570, E-mail: baroda@heromotocorp.com
Hero 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: nagpur@heromotocorp.com
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: mumbai@heromotocorp.com
Tel: 0281-2460622, 2460623, E-mail: rajkot@heromotocorp.com
Hero 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: hubli@heromotocorp.com
Hero 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: vijayawada@heromotocorp.com
Tel:+91-40-23223735, 23223727, 23223570, E-mail: hyderabad@heromotocorp.com
Hero MotoCorp Ltd., 3-6-289, 3rd Floor, Kareem Manzil, Hyderguda, Hyderabad-500029, India.
SOUTH ZONE
Tel: +91-44- 24340974, 24340977, 24340978, E-mail: chennai@heromotocorp.com
Hero MotoCorp Ltd., 9th Floor Seshachalam Centre No.636/1. Anna Salai, Nandanam, Chennai-600035, India.
Hero MotoCorp Ltd., No 1547, 2nd Floor Classic Towers, Trichy Road, Coimbatore - 641018
Tel: +91-422-2200058, 2200061, E-mail: coimbatore@heromotocorp.com
NORTH ZONE
Tel: +91- , E-mail: varanasi@heromotocorp.com0542- 2390949,2390241
Hero MotoCorp Ltd., , Varanasi, Uttar Pradesh - 221010, India.C-19/134-B ,Third Floor I .P Grand, Lallapura, Sigra
ZONAL/REGIONAL OFFICES/AREA
Hero MotoCorp Ltd., Summit Building (10th Floor) Plot No TCG 3/3 Vibhuti Khand, Gomti Nagar Lucknow – 226010,
India. Tel: 0522-4006594, E-mail: lucknow@heromotocorp.com
Hero MotoCorp Ltd., 6-A, DD Trade Tower, (6th Floor), Kaloor-Kadavanthra Road, Kaloor , Kochi-682017, -682 017
India. Tel: +91-0484- 4039646 -7, E-mail: cochin@heromotocorp.com
Tel: +91-80- 46881000, E-mail: bangalore@heromotocorp.com
Hero MotoCorp Ltd., SKAV 909, 3rd Floor, 9/1, Lavelle Road, Bangalore-560001, India.
Product specificaties
Merk: | Hero |
Categorie: | Motor |
Model: | Hunk (2015) |
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