PREFACE No : IBQD

Thank you for selecting a Hero MotoCorp HUNK. We wish you many miles of continued
riding pleasure in the years ahead.
We, at Hero MotoCorp, are committed to demonstrate excellence in our environment
performance on a continual basis, as an intrinsic element of our corporate philosophy. To
achieve this we commit ourselves to continue product innovations to improve environment
compatibility and strengthen the green supply chain. We are also using non asbestos brake
shoes and engine gaskets which are environment friendly in nature.
This booklet is your guide to the basic operation and maintenance of your new Hero
MotoCorp HUNK. Please take time to read it carefully. As with any fine machine, proper care
and maintenance are essential for trouble-free operation and optimum performance.
Authorised Distributor or the authorised dealer(s) of the Distributor (”Dealer”) will be glad to
provide you further information or assistance and to handle your future service needs.
Let us make this world a safer, healthier and more environment friendly place.
 NOTE
All information, illustration, photograph, directions, specifications and other
contents covered in this owner's manual are based on the latest product information
available at the time of its printing approval, and the accuracy or correctness of the
same is not undertaken or guaranteed. Hero MotoCorp Ltd reserves the right to
make changes in its contents at any time without notice and/or incurring any
obligation, whatsoever. no one is allowed to reproduce any part of this publication
without obtaining prior written permission from Hero MotoCorp Ltd.
 CONTENTS
Pg. No. Pg. No.
MOTORCYCLE IDENTIFICATION 1 î Maintenance schedule 29
PRODUCT SPECIFICATION 2 î Engine oil/Engine oil top up process 32
MOTORCYCLE SAFETY 4 î Engine oil replacement process 32
î Important safety information 4 î Oil filter screen & centrifugal filter 33
î Protective apparel 5 î Spark plug 34
SAFE RIDING TIPS 6 î Air cleaner 35
ACCESSORIES & MODIFICATIONS 7 î Air cleaner drain tube 36
TIPS FOR HEALTHY ENVIRONMENT 8 î Throttle operation/Valve clearance 37
MOTORCYCLE VIEWS 9 î Carburetor/Clutch 39
PARTS FUNCTION 12 î Drive chain 40
î Instruments & Indicators 12 î Drive chain slider/Front brake 42
î Ignition switch 13 î Rear brake (Disc type) 43
î Digital clock 14 î Rear brake (Drum type)/Brake wear indicator 45
î Odometer/Tripmeter 15 î Battery 46
î Left handlebar controls 15 î Fuse replacement/Stop lamp switch 48
î Right handlebar controls 16 î Headlamp adjustment/Suspension 49
î Steering lock/Side stand indicator 17 î Front wheel removal 50
î Side stand switch/Side stand 17 î Rear wheel removal (Disc type) 51
î Fuel Valve 18 î Rear wheel removal (Drum type) 52
î Fuel Tank 19 WASHING THE MOTORCYCLE 52
î Seat Lock 20 CATALYTIC CONVERTER 53
TYRES 20 AIR SUCTION VALVE 53
PRE-RIDE INSPECTION 23 BASIC TROUBLESHOOTING 54
STARTING THE ENGINE 24 DELIVERY CERTIFICATE
RIDING/BRAKING 25 HERO GENUINE PARTS
PARKING/TOOL KIT 26 JOB APPLICABLE TO PERIODIC SERVICES
ANTI-THEFT TIPS 27 SERVICE RECORD SHEET
MAINTENANCE 27 SERVICE ADVICE SHEET
î Importance of maintenance 27 OWNERSHIP RECORD AND DATA
î Maintenance safety/Maintenance precaution 28
 MOTORCYCLE IDENTIFICATION

MBLX

HER
MB
XXXXEFY

XXXE

OM
LXX

OTO
XXE
ZXYYYYY

CO
RYZ
RYZX

RP
X
YYY

LTD
YY

.
YYYY
Y
VIN No. Engine No.
Location: Stamped on the right side of the Location : Stamped on the lower side of the
steering head tube. left Crankcase.
VIN No.: MBLXXXXERYZXYYYYY
MBL XXXXER Y Z X YYYYY
Manufacturer Vehicle Year of Month of
code Description Manufacturing Assembly Plant Manufacturing Serial Number
Engine No.: XXXXEFYZXYYYYY
XXXXEF Y Z X YYYYY
Engine Year of Assembly Plant Month of Serial Number
Description Manufacturing Manufacturing
Model: HUNK
Variants Frame Engine
HUNK Electric Start/Disc/Cast (RR Disc) ER EF
HUNK Electric Start/Disc/Cast (RR Drum) ES EF
VIN and Engine No. may be required:
1. During registration of the motorcycle.
2. For dealing with Legal & Insurance Departments.

1
PRODUCT SPECIFICATION
ITEM SPECIFICATIONS
Dimensions
Overall length 2080 mm
Overall width 765 mm
Overall height 1095 mm
Wheelbase 1325 mm
Saddle height 800 mm
Ground clearance 163 mm
Weight
Kerb weight 147 kg (Front Disc/Rear Disc)
145 kg (Front Disc/Rear Drum)
Capacities
Engine oil 1.2 litres at disassembly and 1 litre at draining
Fuel tank 12.4 litres (Minimum)
Fuel reserve capacity 2.2 litre (Usable)
Front fork oil disassembly 143 ml
Brake fluid Castrol Q Stop-DoT 3 or DoT 4
Engine
Maximum power 10.6 KW (14.4 PS) @ 8500 rpm
Maximum torque 12.80 N-m @ 6500 rpm
Bore and stroke 57.3x57.8 mm
Compression ratio 10:1
Displacement 149.2 cc
Spark plug NGK-CPR 8 EA 9
Spark plug gap 0.8-0.9 mm
Valve clearance Intake (cold) 0.08 mm
Exhaust (cold) 0.12 mm
Idle speed 1400±100 rpm
Chassis and suspension
Chassis Type Tubular, Diamond Type
Front Suspension Telescopic Hydraulic Shock Absorbers
Rear Suspension Rectangular Swingarm with 5 step adjustable
Inverted Gas Reservoir Suspension
Caster 26°
2
PRODUCT SPECIFICATION
ITEM SPECIFICATIONS
Trail length 96.2 mm
Tyre size Front 80/100x18-47 P (Tubeless Tyre)
Rear 100/90x18-56 P (Tubeless Tyre)
Front (Disc type) Dia. 240 mm
Brakes Rear (Disc type) Dia. 220 mm
Rear (Drum type) Dia. 130 mm
Front Wheel Cast Wheel
Rear Wheel Cast Wheel
Transmission
Primary reduction 3.3500 (67/20)
Final reduction 3.0714 (43/14)
Gear ratio,1stnd 3.0769 (40/13)
2 1.7895 (34/19)
3rdth 1.3043(30/23)
4th 1.0909 (24/22)
5 0.9375 (30/32)
Electricals
Battery **MF Battery, 12V-4 Ah ETZ-5
Alternator 140 W
Starting system Kick/Electric Start
Headlamp (High/Low) 12V-35/35W Halogen Bulb Trapeziodal-MFR*
Tail/Stop lamp 12V-0.5W/4.1W LED Lamps
Turn signal lamp 12V-10Wx4 (Amber bulb) with clear lens-MFR*
Meter illumination LED
Neutral indicator 12V-2.3W
Turn signal indicator LED
Position lamp 12V-3.0W
Hi Beam indicator LED
Licence plate lamp 12V/5W
Side stand indicator LED
Fuse 10A, 15A, 20A
*MFR stands for Multi-Focal Reflector
**MF stands for Maintenance Free
3
MOTORCYCLE SAFETY
IMPORTANT SAFETY INFORMATION
Your motorcycle can provide many years of Ride defensively
service and pleasure if you take responsibility Always pay due attention to other vehicles
for your own safety and understand the around you, and do not assume that other
challenges you can meet on the road. drivers see you. Be prepared to stop quickly or
There is much that you can do to protect perform an evasive maneuver.
yourself when you ride. You will find many Make yourself easily visible
helpful recommendations through out this Some drivers do not see motorcycles because
manual. Following are a few that we consider they are not looking for them. To make yourself
most important. more visible, wear bright reflective clothing,
Always wear a helmet position yourself so that others can see you,
It is a proven fact, Helmet significantly reduces signal before turning or changing lanes, and use
the number and severity of head injuries. So horn which will help others to notice you.
always wear a helmet and make sure your pillion Ride within your limits
rider does the same. We also recommend that Pushing the limits is another major cause of
you wear eye protection, sturdy boots, gloves motorcycle accidents. Never ride beyond your
and other protective gear. personal abilities or faster than conditions
Before riding your motorcycle demand. Remember that fatigue and
Make sure that you are physically fit, mentally negligence can significantly reduce your ability
focused and free of alcohol and drugs. Check to make good judgements and ride safely.
that you and your pillion are both wearing an Do not drink and ride
approved motorcycle helmet and protective Riding under the influence of alcohol or drugs
apparel. Instruct your pillion on holding onto is dangerous. Alcohol can reduce your ability
the grab rail or your waist, leaning with you in to respond to changing conditions and reduce
turns, and keeping their feet on the footrest, the reaction time. Do not drink and ride.
even when the motorcycle is stopped. Keep your motorcycle in safe condition
Take time to learn & practice your For safe riding, its important to inspect your
motorcycle motorcycle before every ride and perform all
Even if you have ridden other motorcycles, recommended maintenance. Never exceed
practice riding in a safe area to become load limits, and only use accessories that have
familiar with how this motorcycle works and been approved by Hero MotoCorp for this
handles, and to become accustomed to the motorcycle.
motorcycle's size and weight.
4
If you are involved in a crash WARNING
Personal safety is your first priority. If you or î Not wearing a helmet increases the chance
anyone else has been injured, take time to of serious injury or death in a crash.
assess the severity of the injuries and whether î Be sure you and your pillion always wear a
it is safe to continue riding. Call for emergency helmet, eye protection and other protective
assistance if needed. Also follow applicable apparel when you ride.
laws and regulations if another person or Helmets and eye protection
vehicle is involved in the crash. Your Helmet is your most important piece of
If you decide to continue riding, first evaluate riding gear because it offers the best
the condition of your motorcycle. If the engine protection against head injuries. A helmet
is still running, turn it off. Inspect for fluid should fit your head comfortably and securely.
leaks, check the tightness of critical nuts and A bright coloured helmet can make you more
bolts, and check the handlebar, brake levers, noticeable in traffic, as can reflective strips.
brakes, and wheels. Ride slowly and An open-face helmet offers some protection,
cautiously. Your motorcycle may have but a full-face helmet offers more. Always
suffered damage that is not immediately were face shield or goggles to protect your
apparent. Have your motorcycle thoroughly eyes and help your vision.
checked at a qualified service facility as soon
as possible. Additional riding gear
PROTECTIVE APPAREL In addition to a helmet and eye protection, we
For your safety, we strongly recommend that also recommend:
you always wear a helmet which should î Sturdy boots with non-slip soles to help
conform as per your country standards, in protect your feet and ankles.
addition to eye protection, boots, gloves, long î Leather gloves to keep your hands warm
pants and a long sleeve shirt or jacket and help prevent blisters, cuts, burns, and
whenever you ride. Take care of loose/ bruises.
hanging clothes while solo/pillion riding. î A two wheeler riding suit or jacket for
Although complete protection is not possible, comfort as well as protection. Bright
wearing proper gear can reduce the chance of coloured reflective clothing can help make
injury when you ride. you more noticeable in traffic. Be sure to
Following are suggestions to help you choose avoid loose clothes that could get caught on
proper riding gear. any part of your motorcycle.

5
 SAFE RIDING TIPS
Do's: Don't
î Always conduct simple pre-ride inspection î Never use cell phone while riding the
(page 23). motorcycle.
î Always wear a helmet with chinstrap î Avoid sudden acceleration, braking and
securely fastened and insist on a helmet for turning of your motorcycle.
your pillion rider. Helmet should conform as î Never shift gears without disengaging the
per safety standards applicable in your clutch and closing the throttle.
country. î Never touch any part of the hot exhaust
î While riding, sit in a comfortable position system like muffler.
with your legs close to fuel tank. î Never ride under the influence of alcohol or
î Ride defensively and at a steady speed drugs.
(between 40-50 km/hr). Concentrate on the road and avoid talking
î For stopping motorcycle, use both brakes î to the pillion rider or others on the road.
simultaneously, keeping throttle in the close
position. î Do not litter the road.
î During night time, dip headlamps of your î Do not cross the continuous white/ yellow
motorcycle for oncoming traffic, or when line in the center of the road, while
following another vehicle. overtaking.
î Give way to others on the road and signal î Do not attach large or heavy items to the
before you make a turn. handlebars, front forks, or fenders.
î To make yourself more visible, wear bright î Never take your hands off the steering
reflective clothing that fits well. handle while riding.
î Tightly wrap loose/hanging clothes & avoid
entangling with moving parts.
î Get your motorcycle serviced regularly by
the Authorised Distributor/Dealer.
6
ACCESSORIES & MODIFICATIONS Modifications
Modifying your motorcycle or using non- We strongly advise you not to remove any
Hero MotoCorp accessories can make your original equipment or modify your motorcycle
motorcycle unsafe. Before you consider in any way that would change its design or
making any modifications or adding an operation. Such changes could seriously
accessory, be sure to read the following impair your motorcycle's handling, stability
information. and braking, making it unsafe to ride.
WARNING Removing or modifying your lamps, mufflers,
î Improper accessories or modifications can emission control system or other equipment
cause a crash in which you can be seriously can also make your motorcycle illegal.
hurt or killed.
î Follow all instructions in this owner's manual
regarding accessories and modifications.
Accessories
î Make sure that the accessory does not
obscure any lamps, reduce ground
clearance, limit suspension travel or
steering travel, affect your riding position or
interfere with operating any controls.
î Be sure electrical equipment does not exceed
the motorcycle's electrical system capacity
(page 3). A blown fuse can cause a loss of
lights.
î Do not pull a trailer or sidecar with your
motorcycle. This motorcycle was not
designed for these attachments, and their
use can seriously impair your motorcycle's
handling.
7
TIPS FOR HEALTHY ENVIRONMENT
The following tips shall ensure a healthy motorcycle, healthy environment, and a healthy you.
î Healthy engine: The engine is the lifeline of every vehicle. To keep it healthy, it should be
tuned regularly, which will also help reduce pollution and improve vehicle performance &
fuel efficiency.
î Regular Servicing: Get your motorcycle serviced at an Authorised Distributor/Dealer
workshop, as per the service schedule, for an optimum performance and keep the emission
level under check.
î Genuine Spares: Always insist on Hero MotoCorp genuine parts as spurious or
incompatible spares and accessories can upset or deteriorate your motorcycle’s running
condition.
î Genuine engine oil: Hero 4T Plus SAE 10W 30 SJ grade (JASO MA) engine oil
recommended by Hero MotoCorp and make sure you change it every 6000 km. (with
top up every 3000 kilometres) to keep the engine fit and environment healthy.
î Noise pollution : Noise beyond a certain decibel is pollution. Whether it is from horns or defective
mufflers, excessive noise will cause headaches and discomfort.
î Fuel Saving & Reduce Pollution : Switch "OFF" the engine while waiting at traffic signal
points to save fuel and reduce pollution, if the waiting period is long.

8
 MOTORCYCLE VIEWS
TOP VIEW
9 10 11 12 13 14 15 16 17
8
7
7 8 9 10
6
11
5

18
F
4
3 x1000r/min km/h
TRIP
E
2 TOTAL km

1 0
PM

6 N

5
4 19
3 20
2 21
1 22
23

(1) Leg guard (12) High beam indicator

(2) Fuel gauge (13) Turn signal indicator
(3) Bystarter lever (14) Side stand indicator
(4) Horn switch (15) Tachometer
(5) Turn signal switch (16) LCD (Liquid Crystal Display) panel
(6) Clutch lever (17) Neutral indicator
(7) Rear view mirror (18) Front brake lever
(8) Pass lamp switch (19) Throttle grip
(9) Headlamp dimmer switch (20) Electric switch
(10) Reset button (21) Headlamp switch
(11) Select button (22) Ignition switch with steering lock
(23) Fuel tank cap
*Accessories and features shown may not be part of standard fitment.
9
 MOTORCYCLE VIEWS
LEFT SIDE VIEW
17 16 15

14
18
13
ON

W
FLO
GY
LE
MBNOLO
TU
ED TECH
RES NC N
VA TIO
AD UC
IND

12

1 2 3 4 5 6 7 8 9 10 11
(1) Fuel valve (7) Side stand (13) Rear turn signal lamp
(2) Air suction valve (inside) (8) Rider foot rest (14) Tail/Stop lamp
(3) Starter motor (9) Pillion foot rest (optional) (15) Rear grip
(4) Gear shift pedal (10) Women pillion step (16) Seat lock
(5) Side stand switch (11) Saree guard (17) Side cover left
(6) Main stand (12) Rear reflex reflector (18) Front turn signal lamp
*Accessories and features shown may not be part of standard fitment.
10
 MOTORCYCLE VIEWS
RIGHT SIDE VIEW 15
16 15 14 13 12 11
18 10

9
17
ADV
INDU ANC
CTIO ED TUM
N TEC BLE
HNO FLO
LOG W
Y

18

1 2 3 4 5 6 7 8
(1) Rear disc (Optional) (8) Front disc (14) Seat
(2) Kick start pedal (9) Headlamp (15) Fuse box
(3) Rear master cylinder (10) Front visor (16) Document & tool kit
(Optional) (11) Front brake master cylinder compartment
(4) Brake pedal (12) Battery compartment (17) Licence plate lamp
(5) Carburetor (inside) (18) Rear caliper assembly
(6) Oil level dipstick (13) Rear brake fluid reservoir (Optional)
(7) Front caliper assembly (Optional)
*Accessories and features shown may not be part of standard fitment.
11
PARTS FUNCTION 1 2 3 4 5
Instruments and Indicators
The indicators are in the speedometer panel
above the headlamp. The functions are as
below. 6

12 11 10 9 8 7
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 rpm.
4 Turn signal indicator Flash when turn signal switch is operated.
5 Side stand indicator Light glows when the side stand is put down.
6 Speedometer Indicates riding speed
7 Digital clock Indicates hours & minutes (page 14)
8 Odometer Shows accumulated mileage.
9 Tripmeter Shows the distance traveled during a trip after setting
to zero (page 15)
10 Neutral indicator Light glows when vehicle is in neutral position.
11 Fuel gauge Indicates approximate fuel quantity.
12 Reset button To adjust time & Reset Tripmeter.

12
IGNITION SWITCH 1

“ON” Position
2
“OFF” Position/ 3
Lock Open
(1) Ignition switch
(2) Ignition key
(3) Steering lock position
“LOCK” Position

Key Position Function Key Removal

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
“ON” scale once and back to its normal position. Key cannot be removed
The engine can be started, Head lamp, Turn
signal lamp, Horn, Tail/Stop lamp, Fuel
gauge, Pass lamp, Position lamp, Licence
plate lamp & Neutral indicator will be
functional.
“OFF” Engine cannot be started and no electrical Key can be removed
system will be functional.
“LOCK” Steering can be locked Key can be removed
13
DIGITAL CLOCK 2
Digital Clock (1) shows hour and minute. To
adjust the time, proceed as follows : 7 8 9
10

î Turn the ignition switch "ON".

6
11
5
F
4

î Press and hold Select Button (2) and Reset

3 x1000r/min km/h
TRIP
E
2 TOTAL km

1 0
PM

Button (3) simultaneously for more than 2

seconds. The clock will be set in the adjust
mode with the hour's digit display blinking.
2
î To set the minute press Reset Button (3)
7 8 9
10 until the desired minute is displayed. The
minute display will return to "00" when "60 "
6
11
5
4

is reached without affecting the hour

F
3 x1000r/min km/h
TRIP
E
2 TOTAL km

1 PM

display.
0

3 1 7 8 9
6 10
11
5

î To set the hour, press Reset Button (3) F

4
3 x1000r/min km/h
TRIP

until the desired hour is displayed. E

2 TOTAL km

1 0
PM

• The time is advanced by 1 hour each

time the button is pressed.
• The time advances fast when the
button is pressed and held. 3
î Press the Select Button (2). The minutes • The time advances by 1 minute, each
display starts blinking. time the button is pressed.

14
 • The time advances fast when the 2
button is pressed and held.
2
7 8 9
6 10
11
TRIP . km.
5
F
4
3 x1000r/min km/h
TRIP
7 8 9 E
2 TOTAL km

6 10 1 0
PM

11
5
F
4
3 x1000r/min km/h
TRIP
E
2 TOTAL km

1 0
PM

TOTAL km.

LEFT HANDLEBAR CONTROLS

î To end the adjustment press Select Button
1. Headlamp Dimmer Switch
(2). The display will stop flashing Press the switch (1) upwards for High Beam
automatically and the adjustment will be “ ” downwards for Low Beam “ ” .
saved or if the button is not pressed for 2. Passing lamp switch
about 40 seconds. Press the passing lamp switch (2) to operate
NOTE the passing lamp.
The clock will reset "1:00" if the battery is
disconnected. 2
ODOMETER/TRIPMETER
The Tripmeter (A) shows distance traveled
per trip.
The Odometer (B) shows accumulated 1
distance traveled.
Push Select button (2) to select the Odometer
& Tripmeter. Tripmeter can be displayed
from "9999.9" Km. If the Tripmeter exceeds 4 3
"9999.9" Km. it will return to "0.0" Km.
automatically. 3. Clutch switch
The Odometer can be displayed from "0 to There is a clutch switch (3) provided for the
999999" Km.
15
safety of the rider. The motorcycle cannot be RIGHT HANDLEBAR CONTROLS
started by starter switch until the clutch lever is
operated when the vehicle is engaged in gear.
4. Bystarter lever
To apply Bystarter, pull the lever (4)
downwards, towards the rider, as directed on
the switch. 1
NOTE
Do not accelerate during starting when the 2
Bystarter is “ON”.
5. Turn Signal Lamp Switch ( ).
Shift the turn signal switch (5) sideways for 1. Headlamp switch
Right/Left indications and leave it to come The switch has three positions.
back to its normal position on its own. and marked by white dot.
IMPORTANT: To switch off the turn signal
after completing the turn, gently push the Position Action
switch inside as directed on the switch. “OFF”
“Following is “ON”
• Position lamp
• Tail/Stop lamp
• Console lamp LED
• Tachometer lamp LED
5 • Speedometer LED
Headlamp “ON”
6 2. Starter switch ( )
Ensure starter switch (2) is operated when the
vehicle is in neutral. If the vehicle is engaged in
6. Horn switch ( ) gear press the clutch lever before operating
Press the switch (6) to operate the horn. the starter switch. Release starter switch after
the engine has started.

16
 CAUTION 1
Never hold starter switch continuously for
more than 5 seconds as continuous cranking
of engine will drain the battery.
STEERING LOCK
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.
(1) Side stand indicator
SIDE STAND SWITCH/SIDE STAND
A side stand switch (2) is provided in the side
1 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

(1) Ignition key

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 3
speedometer panel. (2) Side stand switch (3) Side stand spring

17
î Check the side stand for proper function and “ON” Position
the spring (3) for damage or loss of tension and
the side stand assembly for free movement. ON 2
î Check whether the side stand indicator (1)
glows when the side stand is down.
î When the side stand is up, the side stand
indicator (1) should not glow.
î If the side stand indicator (1) does not operate OFF
as described in above steps, please visit your
Authorised Distributor/Dealer.
CAUTION RES
Ensure that adequate care should be taken while (2) “ON” Position
cleaning the side stand switch.
FUEL VALVE At “ON” position (2), fuel will flow from fuel
tank to the carburetor
The three way fuel valve is on the left side of the “RESERVE”
carburetor. Position
“OFF” Position
ON
ON

OFF
OFF 1
3 RES
RES
(3) “RESERVE” Position
(1) “OFF” Position At “RESERVE” position (3), fuel will flow from
At “OFF” position (1), fuel cannot flow from the reserve fuel supply to the carburetor. Use the
the tank to the carburetor. Turn the valve reserve fuel only when the main supply is
“OFF” whenever the motorcycle is not in use. exhausted. Refill the tank as soon as possible
18
after switching to “RESERVE”. The reserve springs back to the normal position and cap
fuel supply is 2.2 litre (usable). gets locked.
NOTE
î Do not operate the motorcycle with the fuel
valve in the “RESERVE” position after refilling. 3
You may run out of fuel, with no reserve.
î Do not keep the fuel valve between “ON”
and “OFF” position while driving, since this
may drain reserve fuel from the tank.
FUEL TANK
Fuel tank capacity is 12.4 litres (minimum)
including a reserve supply of 2.2 litres
(usable).
î To unlock fuel tank cap, lift the key hole cover (3) Fuel tank cap
(1) and insert key (2) turn it clockwise and î Remove the key and put back the keyhole
remove the cap (3). cover.
î Do not overfill the tank. There should be no
fuel in the filler neck (4). Fill the tank with Front
fuel (5).
2 4
55
1

(4) Filler Neck (5) Fuel

CAUTION
(1) Key hole cover (2) Ignition Key Do not park the motorcycle under direct
sunlight as it causes evaporation of petrol due
î To lock fuel tank cap close the cap back on to heat and deterioration of paint gloss due to
the opening and press gently. They key ultra violet rays.
19
 WARNING pages give more detailed information on how
Petrol is extremely flammable and is explosive and when to check the air pressure, how to
under certain conditions. Refill in a well ventilated inspect your tyres for damage, and what to do
area with the engine stopped. Do not smoke or when your tyres need to be repaired or replaced.
allow flames or sparks in the area where the petrol
is refilled or where petrol is stored. WARNING
î Using tyres that are excessively worn or
SEAT LOCK improperly inflated can cause a crash in
Location : On the rear left side of the seat, on which you can be seriously hurt or killed.
the rear cowl. î Follow all instructions in this owner’s
Operation : Insert the key and turn it clock maintenance. manual regarding tyres inflation and
wise to unlock. To install, engage the hook on
the underside of the seat with the frame and Air Pressure
Keeping your tyres properly inflated provides
slide the seat to the front until the lock clicks. the best combination of handling, tread life and
riding comfort. Generally, under-inflated tyres
wear unevenly, adversely affect handling and are
more likely to fail from being overheated.
Over-inflated tyres make your motorcycle ride
harshly, are more prone to damage from road
hazards, and wear unevenly.
We recommend that you visually check your tyres
before every ride and use a gauge to measure air
pressure at least once a month or any time you
1 think the tyre pressure might be low.
(1) Seat lock Tubeless tyres have some self-sealing ability if
they are punctured. However, because
TYRES leakage is often very slow, you should look
The tyres fitted on your motorcycle are of closely for punctures whenever a tyre is not
TUBELESS type. fully inflated.
To safely operate your motorcycle, your tyres Always check air pressure when your tyres are
must be of the proper type and size, in good "cold"-when the motorcycle has been parked
condition with adequate tread, and correctly for at least three hours. If you check air
inflated for the load you are carrying. The pressure when your tyres are "warm"-when
following pages give more detailed following the motorcycle has been ridden for even a few
20
km-the readings will be higher than if the î Cuts, splits or cracks in the tyre. Replace the
tyres were "COLD". This is normal, so do not tyre if you can see fabric or cord.
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:
Rider only Rider and Pillion
Front 2.00 kg/cm2 (29 psi) 2.00 kg/cm2 (29 psi)
2 2
Rear 2.00 kg/cm (29 psi) 2.25 kg/cm (33 psi)

1 î Excessive tread wear.

(1) Tyre pressure gauge

Over inflation/Under inflation will affect the
performance. î Carefully inspect the tyres for any damage, if
Inspection the motorcycle hits a pothole or hard object.
Whenever you check the tyre pressure, you Tread Wear
should also examine tyre treads & side walls Replace tyres immediately when the wear
for wear, damage & foreign objects: indicator (1) appears on the tyre. The tread
Look for : limits are :
î Bumps or bulges in the side of the tyre or MINIMUM TREAD DEPTH
the tread. Replace the tyre if you find any Front: 1.5 mm Rear: 2.0 mm
bumps or bulges. Check the tread wear indicator for tyre wear.
21
 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
1 safely carry as much load as with a new tyre.
Therefore, we strongly recommend that you
replace a damaged tyre. If you decide to have a
tyre replaced be sure the wheel is balanced
2 before you ride.
Tyre Replacement
The tyres that were installed on your
(1) Tread wear indicator (2) Arrow mark motorcycle were designed to match the
Unidirectional Tyres performance capabilities of your motorcycle
Whenever the tyre is removed and put back in and provide the best combination of handling,
case of puncture, ensure the arrow mark on braking, durability and comfort.
the tyre is in the same direction as that of
forward rotation of wheel. WARNING
Tyre Repair î Using tyres that are excessively worn or
If a tyre is punctured or damaged, you should whichimproperly inflated can cause a crash in
you can be seriously hurt or killed.
replace it, not repair it. As mentioned below, a î Operation
tyre that is repaired either temporarily or hazardous and with excessively worn tyres is
permanently, will have lower speed and and handling. will adversely affect traction
performance limits than a new tyre. Follow all instructions in this owner’s
A temporarily repaired, such as an external î manual regarding tyres inflation and
tubeless tyre plug, may not be safe for normal maintenance.
speeds and riding conditions. If a temporary or î Under-inflation may result in the tyre
emergency repair is made to a tyre, you should slipping on or tyre coming off the rim.
ride slowly cautiously to your Authorised î Always use the size and type of tyres
Distributor/Dealer and have the tyre replaced. recommended in this owner’s manual.
If possible you should not carry a pillion or
load until a new tyre is installed. NOTE
Even if a tyre is professionally repaired with a For repair and replacement of tyre it is advised
permanent internal patch plug, it will not be as to visit your Authorised Distributor/Dealer.
good as a new tyre.
22
The recommended tyre for your motorcycle î Front brake-Check for correct brake fluid
are : level in master cylinder (page 42).
Front: 80/100x18-47 P (Tubeless Tyre) î Rear brake (Drum type)-Check
Rear: 100/90x18-56 P (Tubeless Tyre) operation and if necessary, adjust free play.
Important Safety Reminders î Rear brake (Disc type)-Check for
î Do not install a tube inside a tubeless tyre correct brake fluid level in the reservoir
on this motorcycle. Excessive heat buildup (page 43).
can cause the tube to burst. î Tyres-Check condition and pressure
î Use only tubeless tyres on this motorcycle. (page 20).
The rims are designed for tubeless tyres, î Clutch-Check for smooth operation.
and during hard acceleration or braking, a Adjust free play (page 39).
tube-type tyre could slip on the rim and î Drive Chain-Check condition and
cause the tyre to rapidly deflate. slackness (page 40). Adjust and lubricate if
PRE-RIDE INSPECTION necessary.
You should conduct pre-ride inspection î Throttle-Check for smooth opening and
before riding the motorcycle to enhance riding closing in all steering positions (page 37).
comfort and safety. î Lamps and Horn-Check that headlamp,
Clean your motorcycle regularly. It protects tail/stop lamp, turn signal lamps and horn
the surface finish. Avoid cleaning with function properly.
products that are not specifically designed for î Rear View Mirror-Ensure that the rear
motorcycle surfaces. Inspect your motorcycle view mirror gives a good rear view when
very day before you start the engine. The you are sitting on the motorcycle.
items listed here î Air Suction Valve-Make sure all tube
will only take a few minutes, and in the long connections are secured properly (page 53).
run they can save time, expense and possibly î Fitting & Fasteners-Check & tighten if
your life. Please follow the tips as given below: necessary.
î Engine Oil Level-Check and top up î Steering-Check for smooth action for
engine oil if required (page 32). Check for easy maneuverability.
leaks. î Side stand indicator-Make sure the side
î Fuel Level-Ensure sufficient fuel is stand is up. If it is in down position the side
available in your fuel tank for journey stand indicator (page 17) will glow on
(page 19). Check for leaks. speedometer panel.
23
STARTING THE ENGINE
1. Turn the ignition 4. Pull the Bystarter lever
switch “ON”. downwards as indicated
(Use Bystarter during
cold conditions)

2. Turn the fuel valve 5. Press the starter switch.

ON
“ON”. (Alternatively, kick start
pedal can be used for
OFF
starting).
RES

3. Find neutral position & 6. Push the Bystarter lever

check N indicator upwards, ( ) position as
glows on instrument indicated, after the engine
cluster with ignition gets sufficiently warmed up
“ON”. to have a stable throttle
response.

NOTE
î To start the engine in any gear position, press the clutch lever and press the starter
switch/kick start the engine.
î Do not accelerate while starting when the Bystarter lever is "ON".
î Never 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.
WARNING
Never run the engine in a closed area, the exhaust contains poisonous gases.
24
Flooded Engine î When the motorcycle attains a moderate
If the engine fails to start after repeated speed, close the throttle, press the clutch lever
attempts, it may be flooded with excess fuel. To and shift to 2nd gear by lifting the gear pedal
clear a flooded engine, turn the ignition switch upwards using the toe the gearshift pedal.
“OFF” and move Bystarter lever fully upwards î The sequence is repeated progressively to
“OFF” position ( ). Close the throttle fully and shift 3rd, 4th and 5th gear.
crank the engine several times with the kick
starter. Turn the ignition switch “ON” and start
the engine without using Bystarter.
Running In 5
Helps to assure your motorcycle's future
reliability and performance by paying extra 4
attention to how you ride during the first 500 3
km. 2
During this period, avoid full-throttle starts N
and rapid acceleration. 1
RIDING CAUTION
î After the engine has been warmed up, the Do not shift gears without operating clutch
motorcycle is ready for riding. and without closing the throttle otherwise
î While the engine is idling, press the clutch this would lead to damage of gears.
lever and depress the gearshift pedal BRAKING
downwards using the toe to shift into 1st î For normal braking, close the throttle and
(low) gear. gradually apply both front and rear brakes
î Slowly release the clutch lever and at the simultaneously while shifting down gears to
same time, gradually increase engine speed suit your road speed.
by opening the throttle. Coordination of the î For maximum deceleration/quick stopping,
throttle and clutch lever will assure a smooth close the throttle and apply the front and
positive start. rear brakes simultaneously.

25
 WARNING CAUTION
î Independent use of only the front or rear î Park the motorcycle on firm level ground to
brake increases stopping distance. prevent overturning.
î Extreme braking may cause wheel locking î While parking vehicle on side stand engage
and reduce control over the motorcycle. the first gear.
î Wherever possible, reduce speed or apply
brake before entering a turn, closing the TOOL KIT
throttle or braking in mid turn may cause The tool kit (1) is located below the seat in the
wheel slip. Wheel slip will reduce control rear. Some emergency repairs, minor
over the motorcycle. adjustments and parts replacement can be
î When riding in wet or rainy conditions, or on performed with the tools contained in the kit.
loose surfaces the ability to stop the Kit consists of following tool:
motorcycle reduces.
î All your actions should be smooth under î Tool Bag,
these conditions. Sudden acceleration, î +, - No. 2 Driver,
braking or turning may cause loss of î Grip
control. For your safety, exercise extreme î Box wrench P16x14
caution when braking, accelerating or î Pin Spanner
turning.
î When descending a long steep slope use î No. 3 cross point screw driver
engine braking (power) by changing to
lower gears, with intermittent use of both
brakes. Continuous brake application can
overheat the brakes and reduce their
effectiveness.
PARKING
After stopping the motorcycle, shift the
transmission into neutral, turn the fuel valve
“OFF”, turn the ignition switch “OFF”, park
the motorcycle on main stand, lock the 1
steering and remove the key.
(1) Tool kit

26
ANTI-THEFT TIPS MAINTENANCE
î Always lock the steering and never leave the Importance of Maintenance
key in the ignition switch. This sounds A well-maintained motorcycle is essential for
simple but people do forgets. safe economical and trouble-free riding. It will
î Be sure the registration information for your also help reduce air pollution.
motorcycle is accurate and correct. To help you, take proper care of your
î Park your motorcycle in a locked garage motorcycle, the following pages include a
whenever possible. Maintenance Schedule and a Maintenance
î Use an additional anti-theft device of good Record for regular scheduled maintenance.
quality. These instructions are based on the
î Never park your motorcycle in an isolated assumption that the motorcycle will be used
area. Park as for as possible in a designated exclusively for its designed purpose. Sustained
area. high speed operation or operation in
î Enter your name, address and phone unusually wet or dusty conditions will require
number in this Owner's Manual and keep it more frequent service than specified in the
in your motorcycle at all times. Many times Maintenance Schedule.
stolen motorcycles are identified by Consult your Authorised Distributor/Dealer
information in the Owner's Manuals that are for recommendation applicable to your
still with them. individual needs and use.
NAME: _____________________________________________
ADDRESS: _______________________________________ WARNING
_______________________________________________________ Improperly maintained motorcycle or failing
_______________________________________________________ î to correct a problem before you ride can
_______________________________________________________ cause a crash in which you can be seriously
_______________________________________________________ hurt.
_______________________________________________________
_______________________________________________________ î Always follow the inspection and maintenance
_______________________________________________________ recommendations and schedules in this
PHONE NO : _____________________________________ owner’s manual.

27
MAINTENANCE SAFETY SAFETY PRECAUTION
This section includes instructions on some î Make sure the engine is “OFF” before you
important maintenance tasks. You can begin any maintenance or repair. This will
perform some of these tasks with the tools help to eliminate several potential hazards:
* Carbon monoxide poisoning from
provided (if you have basic mechanical skills).
Other tasks that are more difficult and require engine exhaust.
special tools are best performed by Be sure there is adequate ventilation
professionals. Wheel removal should normally whenever you operate the engine.
* Burns from hot parts.
be handled only by a Hero MotoCorp skilled Let the engine and exhaust system cool
technician or other qualified technician; before touching.
instructions are included in this manual only to
* Injury from moving parts.
assist in emergency service. Do not run the engine unless instructed to
You will come across some of the most do so.
important safety precautions in the following î Read the instruction before you begin and
make sure you have the tools and skills
pages of this manual. required.
However, we cannot warn you of every î To help prevent the motorcycle from
conceivable hazard that can arise in falling over, park it on a firm, level surface
performing maintenance. Only you can decide on the main stand.
î To reduce the possibility of a fire or explosion,
whether or not you should perform a given be careful when working around petrol or
task. batteries. Use only nonflammable solvent, not
WARNING petrol, to clean parts. Keep cigarettes, sparks
î and flames away from the battery and all fuel-
Failure to follow maintenance instructions related
and precautions properly can seriously R e m e mparts.
ber that your Authorised
injure you. Distributor/Dealer knows your motorcycle best
î Always follow the procedures and and is fully equipped to maintain and repair it.
precautions in this owner's manual. To ensure best quality and reliability, use
only new Hero MotoCorp Genuine Parts for
repair and replacement.
28
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 Hero MotoCorp by properly trained and equipped
technicians. Your Authorised Distributor/Dealer 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 Distributor/Dealer 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 Distributor/Dealer.
* 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 rpm/idle CO adjustment (if required).
@ Visit Authorised Distributor/Dealer 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-2: Service more frequently when riding in rain or at full throttle.
Note-3: Replace front fork oil once in a every 2 years or 20000 km, whichever is earlier.
Note-4: Inspect the bearings free play, replace if necessary.
Note-5: Inspect for any play in the mounting bushes, replace if necessary.

29
MAINTENANCE MAINTENANCE SCHEDULE
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.
ITEMS SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
DAYS 1st 60 Next
90
Next Next
90 90
Next
90
Next
90
Next
90
Next
90
Next Next Next
90 90 90
500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000-
KM NOTE-1 750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500 30000-

Fuel Line I I I I I I I I I I I
Throttle Operation I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Bystarter I I I I I I I I I I I
Operation
Engine Idle Speed C,A A C,A A C,A A C,A A C,A A C,A
/Carburetor
Air Cleaner Do not open air cleaner element unless R R
element* there is a drivability problem
Air cleaner drain NOTE-2 I,C I,C I,C I,C I,C I,C I,C I,C I,C I,C I,C
tube
Spark Plug I,C,A I,C,A I,C,A I,C,A R I,C,A I,C,A I,C,A R I,C,A I,C,A
Valve Clearance I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Engine Oil** O I,T O I,T O I,T O I,T O I,T O
Engine Oil C C C C C C
Strainer Screen
Engine Oil C C C C C C
Centrifugal Filter
Electric Starter I I I I I I I I I I I
Oil Circulation I I I I I I I I I I I
Drive Chain@ I,C,L,A at every 2000 km I,C,L,A at every 2000 km

30
 ITEMS SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
DAYS 1st 60 Next
90
Next Next
90 90
Next
90
Next
90
Next
90
Next
90
Next
90
Next
90
Next
90
KM NOTE-1 500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000- 30000-
750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500
Drive Chain I I I I I I I I I I
Slider
Battery Voltage I I I I I I I I I I I
Brake Shoe/ I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Pad Wear
Brake Fluid**** I I I I I I I I I I I
Brake System
(Brake Cam & C,L C,L C,L C,L C,L
Brake Pedal)
Stop Lamp I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Switch
Headlamp Focus I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Clutch I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A I,A
Side Stand/ L L L L L L L L L L L
Main Stand
Side Stand I,C I,C I,C I,C I,C I,C I,C I,C I,C I,C I,C
Switch
Nuts, Bolts & I I I I I I I I I I I
Fasteners***
Wheel Bearings NOTE-4 I I I I I I I I I I I
Wheels/Tyres I I I I I I I I I I I
Steering Head I I,A I I,A I,L,A I I,A I I,L,A I I,A
Bearing
Front Suspension/ NOTE-3 I I I I I I I I I I I
Oil****
Rear Suspension NOTE-5 I I I I I I I I I I I
Secondary Air I I I I I
Injection
Muffler (Catalytic I,E I,E I,E I,E I,E
Converter)•
29
31
ENGINE OIL Engine oil top up process
Use only Hero Genuine Engine Oil. î Park the motorcycle on its main stand.
BRAND: Hero 4T plus î Start the engine & let it idle for 3-5
GRADE: SAE 10W 30 SJ Grade minutes.
(JASO MA). î Stop the engine and wait for 2-3 minutes.
Manufactured by: î Remove the oil level dipstick, wipe it clean
î Tide Water Oil Co. (India) Ltd. and insert without screwing it in.
î Savita Oil Technologies Limited. î Remove the oil level dipstick and check the
î Bharat Petroleum Corporation Limited. oil level.
OIL CAPACITY :1.2 litres at disassembly î If required, add the specified oil up to the
:1 liter at draining “UPPER” level mark. Do not overfill.
Engine oil level check î Reinstall the oil level dipstick with new
Check engine oil level each day before O-ring and check for oil leaks.
operating the motorcycle. Engine oil replacement process
The oil level dipstick (1) is on the right Replace engine oil once in every 6000 km/
crankcase cover for measuring oil level. Oil level
6 months whichever is earlier.
must be maintained between the upper (2) andDrain engine oil with the engine warm and the
lower (3) level marks on the oil level dipstick.
motorcycle on its main stand.
Do top up if oil level reaches towards the lower
î To drain the oil, remove the oil level dipstick,
level mark or every 3000 km. whichever is earlier.
drain bolt (1) and sealing washer (2).
î After the oil has completely drained, reinstall
the drain bolt with a new sealing washer.
î Fill 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.
î Reinstall the oil level dipstick with a new O-ring.
UPPER î Start the engine and allow it to idle for few
minutes.
LOWER 3 2 1 î Stop the engine and let the engine oil settle down.
(1) Oil level dipstick (2) Upper level mark î Make sure that oil level is at the “UPPER”
(3) Lower level mark level mark of the oil level dipstick with the
32
 motorcycle in an upright position and that î Reinstall the filter screen with the tapered
there are no oil leaks. end facing in.
2 1

2
4

3
1
(1) Drain bolt (2) Sealing washer (1) Clutch cable (2) Kick start pedal
CAUTION (3) Kick stopper (4) Right crankcase cover
î Running the engine with insufficient oil can î Remove centrifugal filter cover (6) & clean
cause serious engine damage. the centrifugal filter (7) with non flammable
î Running the engine with excessive oil can or high flash point solvent (kerosene).
cause spark plug fouling & loss in 6
performance.
î Engine oil is a major factor affecting the
performance and service life of the engine.
Non-detergent, vegetable, or castor based
racing oils are not recommended.
OIL FILTER SCREEN & CENTRIFUGAL 5
FILTER
î Drain the engine oil throughly (page 32).
î Disconnect the clutch cable (1), remove the
kick start pedal (2) and kick stopper (3) 7
remove right crankcase cover (4). (5) Oil Filter Screen (6) Centrifugal Filter Cover
î Remove the oil filter screen (5) and wash it (7) Centrifugal Filter
in clean non flammable or high flash point î Reinstall the centrifugal filter cover, right
solvent (kerosene). crankcase cover and connect the clutch cable.
33
 Install kick stopper and kick start pedal.
of spark plug box wrench provided in the
tool bag.
î Fill the crankcase with clean engine oil as
per specification. î Visually inspect the spark plug electrodes
NOTE for wear. The center electrode should have
î Clean filters as specified in the square edges and the side electrode should
maintenance schedule. not be eroded. Discard the spark plug if
î Ensure to replace gasket once removed. there is apparent wear or if the insulator is
cracked or chipped.
SPARK PLUG î Make sure that the spark plug gap is
0.8-0.9 mm using a wire-type feeler
gauge. If adjustment is necessary, bend the
side electrode carefully. Make sure the plug
washer is in good conditions.
1
2 0.8-0.9 mm

(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 î With the plug washer attached, thread the
extended periods at high speeds or near spark plug in by hand to prevent cross-
maximum power in hot climates, the spark threading.
plug should be changed to a cold heat range Tighten a new spark plug 1/2 turn after
number, consult Authorised Distributor/Dealer î plug seats, with spark plug box wrench to
workshop on this if required. compress the washer. If you are reusing a
î Clean dirt around the spark plug base. plug, it should only take 1/8-1/4 turn
î Disconnect the noise suppressor cap (1) after the plug seats.
and remove the spark plug (2) with the help
34
AIR CLEANER 3
The air cleaner is viscous type paper filter
which enhances filtering efficiency. The air
cleaner should be replaced at regular
intervals (page 30). When riding in dusty 4
areas, more frequent replacement may be
necessary.
î Remove the seat assembly (page 20).
î Remove the side cover (1) by removing
side cover screws (2). (3) Air cleaner cover screws/washers
1 (4) Air cleaner cover
î Remove the element air cleaner screws/
washers (5) and remove the element air
cleaner (6).
5

2
(1) Side cover (2) Side cover screws
î Remove the air cleaner cover screws
washers (3) and the cover (4). 6
(5) Element air cleaner screws/washers
(6) Element air cleaner
î Remove the air cleaner element (6)
from housing (7).
î Clean the air cleaner housing (7) using a
shop towel.
35
7

(6) Element air cleaner AIR CLEANER DRAIN TUBE

(7) Air cleaner housing Remove the drain tube (1) from the air cleaner
assembly (2) and drain the deposit into a
î Install a new air cleaner element in the suitable container. Reinstall the drain tube.
reverse order of removal. Follow the above process more frequently
CAUTION when riding in rain or at full throttle.
î Never wash or clean the viscous filter. NOTE
Replace filter element once in every 15000 Always ensure to reinstall the drain tube after
km.
î Replace it earlier if it becomes very dirty, draining the deposit.
damage on surface or on the sealing area.

(1) Drain tube (2) Air cleaner assembly

36
THROTTLE OPERATION
Cable Inspection
Check for smooth rotation of the throttle grip
from the fully open to the fully closed position.
Check at full left and full right steering
positions. Inspect the condition of the throttle
cable from the throttle grip down to the A
carburetor. If the cable is kinked, chafed or 2 3
improperly routed, it should be replaced or B
rerouted. Standard throttle grip free play (1)
is approximately 2-6 mm of grip rotation. 4
(2) Boot (3) Lock nut (4) Adjuster
(A) Decrease free play (B) Increase free play
1 Valve clearance
Excessive valve clearance will cause noise, and
little or no clearance will prevent the valve
from closing and cause valve damage and
power loss. Check valve clearance at the
specified intervals (page 30).

(1) Free play 2-6 mm 2

Free play adjustment
To adjust free play slide the boot (2), loosen
the lock nut (3). Turn the adjuster(4) to 4
adjust free play. After adjustment, tighten the
lock nut and slide the boot on the adjuster and
locknut securely. 1 3
Direction A - to decrease the free play (1) Crankshaft hole cap (2) Timing hole cap
Direction B - to increase the free play (3) 'T' mark (4) Index mark
37
 NOTE î Check the clearance by inserting the feeler
The checking or adjusting of valve clearance gauge (7) between the adjusting screw (5)
should be performed while the engine is cold. and valve stem.
The clearance will change as the engine
temperature rises.
î Remove the crankshaft hole cap (1) and
timing hole cap (2)
î Remove the cylinder head cover.
î Rotate 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 7
piston is at Top Dead Center and both the (7) Feeler gauge
inlet and exhaust valves are closed.
This condition can be determined by Standard clearance (Cold condition)
moving the rocker arms. If they are free, it is Intake:0.08 mm; Exhaust: 0.12 mm
an indication that the valves are closed and If adjustment is required, adjust by loosening
the piston is in compression stroke. If they the lock nut (6) and turning the adjusting
are tight the valves are open, rotate the screw (5) until there is a slight drag on the
flywheel 360° anticlockwise and re-align
the“T” mark with the index mark. feeler gauge (7).
After tighten the lock nut (6), check the
clearance again.
î Install the parts in the reverse order of
disassembly.
5 NOTE
Before inserting the feeler gauge, smear a bit
6 of engine oil on the feeler gauage to avoid
damage to the feeler gauge.

(5) Adjusting screw (6) Lock nut

38
CARBURETOR CLUTCH
Idle speed Clutch adjustment may be required if the
motorcycle stalls when shifting into gear or
The carburetor is factory pre-set in order to
achieve optimum performance and meet tends to creep or if the clutch slips, causing
emission standards. acceleration to lag behind engine speed.
However in case of specific requirement of Normal clutch lever free play (1) is 10-20
tuning due to engine stalling in idle speed,mm at the lever (2).
î To adjust the free play, loosen the lock nut
please follow the instructions given hereunder:
î Warm up the engine and rest the (3). Turn the adjusting nut (4) to obtain the
motorcycle on the main stand. specified free play. Tighten the lock nut and
î Adjust idle speed with the throttle stop check the adjustment.
screw (1). î Start the engine, press the clutch lever and
IDLE SPEED: 1400±100 RPM shift into gear. Make sure the engine does
not stall, and the motorcycle does not creep.
CAUTION Gradually release the clutch lever and open
Do not attempt to compensate for faults in the throttle. The motorcycle should start
other systems by adjusting idle speed. Visit smoothly and accelerate.
your Authorised Distributor/Dealer for 2
scheduled carburetor adjustment.
1
1

1
A B
(1) Free play 10-20 mm (2) Clutch lever
(1) Throttle stop screw
NOTE
(A) Increase rpm If proper adustment cannot be obtained or the
(B) Decrease rpm clutch does not work correctly, visit your
Authorised Distributor/Dealer.
39
 3 4 Inspection
î Turn the engine “OFF”, park the motorcycle
A on its main stand and shift the transmission to
neutral. Remove hole cap (2).
B î Drive 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
(1) Lock nut (2) Clutch cable adjuster nut another, some links are kinked and binding.
(A) Decrease free play (B) Increase free play Binding can be eliminated by frequent
Other Checks lubrication.
î Check the clutch cable for kinks or signs of 1
wear that could cause sticking or failure.
î Check for clutch cable model. Use genuine
clutch cables.
î Check that the clutch cable routing is
correct. 3 30 mm
DRIVE CHAIN
The service life of the drive chain depends
upon proper lubrication and adjustment.
Poor maintenance can cause premature wear 2
or damage to the drive chain and sprockets. (1) Drive chain (2) Hole cap
The drive chain (1) should be checked and (3) Drive chain slack 30 mm
lubricated as part of the Pre-ride Inspection î Turn the chain to view chain lock plate (4)
(page 23). Under severe usage, or when the inside the hole. Ensure that the chain lock
motorcycle is ridden in unusually dusty areas. plate open end (5) is installed in the
more frequent maintenance will be necessary. opposite direction of the chain rotation.

40
î Inspect the sprocket teeth for wear or î Loosen the rear axle nut (1) and sleeve
damage. nut (2).
î Loosen the drive chain lock nut (3).
î Turn both the adjusting nuts (4) in an equal
4 number of turns until the correct drive chain
slack is obtained. Turn the adjusting nut
5 clockwise to decrease the slack or
anticlockwise to increase the slack of the
chain.
î Align the chain adjuster index mark (5) with
the corresponding scale graduations (6) on
both the sides of the swing arm equally.
î If the drive chain slack is excessive when the
(4) Chain lock plate (5) Open end rear axle is moved to the farthest limit of
î If the drive chain or sprockets are adjustment, the drive chain is worn and
excessively worn or damaged, they should must be replaced.
be replaced. Never use a new chain with î Tighten the rear axle nut and sleeve nut.
worn out sprockets since this will result in - Rear axle nut torque 6.8 kgf-m.
rapid chain wear. - Sleeve nut torque 5.9 kgf-m.
Worn Sprocket Teeth î Check the drive chain slack again.
1

Damaged Normal
Sprocket Teeth Sprocket Teeth
Adjustment
î Park the motorcycle on its main stand with
the transmission in neutral and the ignition (1) Rear axle nut
switch in "OFF" position.
41
 3 Drive Chain Slider
(Refer to “Maintenance Schedule” on
(page 30).
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
Distributor/Dealer.
2

2 5 6 4
(2) Sleeve nut (3) Drive chain lock nut
(4) Drive chain adjusting nut (5) Index mark CUTOUT
(6) Scale graduation
î Rear 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). 1
Lubrication (1) Chain slider (2) Wear limit
î Turn the engine “OFF”, park the FRONT BRAKE
motorcycle on its main stand and shift the Refer to the safety precautions on (page 28).
transmission into neutral. Master cylinder (1)
î Lubricate the drive chain by applying liberal Location: Right handlebar.
amount of SAE#90 oil or chain lubricant. Brake fluid recommended: Castrol Q Stop-
CAUTION DoT 3 or DoT 4
Regular adjustment and lubrication as per the Fluid level- Ensure that the brake fluid level
maintenance schedule would ensure high does not fall below "MIN'' mark (2) on front
performance and longer life. brake master cylinder parallel to the ground.
NOTE The level decreases gradually due to piston
Visit Authorised Distributor/Deale r movement to compensate pad wear. If the
for inspection, cleaning, lubrication and level decreases abruptly, check for the
adjustment of drive chain at every 2000 km. leakages in the brake system and consult your
Authorised Distributor/Dealer.
42
 Brake Pad Wear
Brake pad wear depends upon the severity of
usage, the type of riding & road conditions.
Generally, the pads will wear faster on wet &
1 dirty roads. Inspect the pads at each regular
maintenance interval.
2 1 1

(1) Master cylinder (2) “MIN” mark

NOTE
î Clean the dirt and mud accumulation
between the brake pads (3) caliper (4) and
the disc (5) by using a water jet.
î Always contact your Authorised
Distributor/Dealer for refilling of master (1) Wear Indicator Grooves
cylinder when necessary. Do not mix DoT 3 î Check the brake pads for wear by
and DoT 4 brake fluid. examining the wear limit groove on each
pad.
î If either pad is worn to the bottom of the
grooves replace both pads as a set. Visit
your Authorised Distributor/Dealer for this
4 service.
WARNING
Always apply front and rear brakes
simultaneously to avoid skidding of vehicle.
REAR BRAKE
3 5 Disc type
Refer to the safety precautions on (page 28).
(3) Brake pads (4) Caliper (5) Disc Rear: Reservoir (1)
43
Location: Inside right side cover next to the battery. Rear Caliper
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 3
decreases gradually due to piston movement 4
to compensate pad wear. If the level decreases
abruptly, check for the leakages in the brake
system and consult your Authorised 5
Distributor/Dealer.
Reservoir (3) Rear caliper (4) Brake (5) Disc
Check the wear indicator grooves (6) in each
1 pad.
If either pad is worn to the bottom of the
2 grooves, replace both as a set. Visit your
Authorised Distributor/Dealer for this service.

(1) Reservoir (2) Lower mark

NOTE
î Clean the dirt and mud accumulation
between the brake pads (3) caliper (4) and
the disc (5) by using a water jet.
î Always contact your Authorised 6
Distributor/Dealer for refilling of master
cylinder when necessary. Do not mix DoT 3 (6) Wear indicator grooves
and DoT 4 brake fluid.
44
REAR BRAKE Make sure that the cut-out on the adjusting
Drum Type nut is seated on the brake arm pin (4) after
î Park the motorcycle on its main stand. the final adjustment has been made.
î Measure the distance of brake pedal (1)
moves before the brake starts to take hold.
Free play (2) should be 20-30 mm.

3 4 3 4
20-30 mm (A) Cut-out not seated (B) Cut-out seated
(3) Adjusting nut (4) Brake joint pin
î Apply the brake serveral times and check
1 2 for free wheel rotation when released.
(1) Rear brake pedal (2) Free play 20-30 mm
î If adjustment is necessary, turn the real NOTE
brake adjusting nut (3). If proper adjustment cannot be obtained by
this method, visit your Authorised
Distributor/Dealer.
BRAKE WEAR INDICATORS
When the brake is applied, an arrow (1), fixed
to the brake arm (2), moves towards a
B reference mark (3) on the brake panel (4). If
the arrow aligns with the reference mark on
3 A full application of the brake, the brake shoes
4 must be replaced.
(3) Adjusting nut (4) Brake arm pin
(A) Decrease free play (Clockwise)
(B) Increase free play (Counter clockwise)
45
REAR BRAKE WEAR INDICATION Specification
4 MF Battery,12V-4 Ah ETZ 5
It is not necessary to check the battery
1 electrolyte
3
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 Distributor/Dealer.
2 NOTE
This symbol on the battery means that
(1) Arrow (2) Brake arm (3) Reference mark this product must not be treated as
(4) Brake penal household waste.
This symbol on the battery means the
old battery must be returned to your
BATTERY Authorised Distributor/Dealer as it
must be treated as recyclable material.
î Battery is a Maintenance-Free (sealed) type
and can be permanently damaged if the
sealing strip is removed.
î An improperly disposed battery can be
harmful to the environment and human
health. Always confirm local regulations for
battery disposal.
WARNING
11 î The battery gives off explosive hydrogen gas
(1) Battery during normal operation.
î A spark or flame can cause the battery to
Refer to the safety precautions on (page 28). explode with enough force to seriously hurt you.
Location î Wear protective clothing and a face shield,
The battery (1) is located behind the right side or have skilled technician do the battery
cover. maintenance.
46
Battery charging 1
Always visit your Authorised Distributor/Dealer
if you see any symptom of battery discharge as
earliest as possible to get the battery charged.
The battery has a tendency to discharge rapidly
if additional electrical accessories are fitted on
the motorcycle.
Battery storage
î If in case your motorcycle is not used for more
then a month remove the battery, fully charge 2
and store in a cool and dry place. (1) Right side cover screws (2) Side cover
î If the battery is expected to be stored for
more then two months, ensure to fully 5 6
charge the battery once in a month.
î Always ensure the battery is fully charged
before installation.
î Ensure the battery leads are properly
connected to the battery terminals during
installation.
Battery removal
î Make sure the ignition switch is "O FF"
î Remove the seat (page 20). 4 3
î Remove the right side cover screws (1) and (3) Bolt (4) Band battery (5) Negative (-)ve
remove the side cover (2). terminal (6) Positive (+)ve terminal
î Remove the battery clamp bolt (3) and the Battery installation
battery clamp (4). î Reinstall in the reverse order of removal. Be
î Disconnect the negative (-)ve terminal lead sure to connect the positive (+)ve terminal
from the battery first, then disconnect the first, then the negative (-)ve terminal.
positive (+)ve terminal lead (6). î Check all fasteners are secure.
î Pullout the battery from the battery box.

47
FUSE REPLACEMENT WARNING
Refer to the safety precautions on (page 28). î Never use a fuse with a different rating from
Fuse Box (A) Location : Below the seat that specified. It may lead to serious damage
Fuse Type: Blade fuse to the electrical system or a fire due to short
2 1 circuit.
î Battery gives off explosive gases. Keep
sparks, flames & cigarettes away.
CAUTION
Do not attempt to start or ride the motorcycle
î
without a charged battery, it can cause fusing
of the bulbs and permanent damage to
certain electrical components.
A î Turn the ignition switch "OFF" before checking
or replacing the fuse to prevent accidental
short-circuiting.
(1) In circuit fuse 15A, 10A STOP LAMP SWITCH
(2) Spare fuse 15A, 10A The stop lamp switch (1) must be adjusted so
Start Mag. Switch (B) that stop lamp will glow when rear brake is
Location: Inside right side cover applied. Rear brake free play (page 45) should
Fuse Type: Blade fuse be adjusted before performing stop lamp switch
Location: Below start mag switch. adjustment. The procedure for adjusting stop
1 lamp switch is as follows:
î Turn the ignition switch to the “ON”
position.
î Turn the adjusting nut (2) to position stop
lamp switch at a point where the stop lamp
B 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
2 switch timing.
(1) In circuit fuse 20A (2) Spare fuse 20A
48
 2 î Park the motorcycle on level ground.
î Adjust the headlamp beam by loosening the
bolt (1) and moving the headlamp unit
forward and backward for correct focus
A adjustment.
î Tighten the bolt after adjustment.
B WARNING
An improperly adjusted headlamp may blind
oncoming rider/driver or it may fail to light the
1 road for a safe distance.
(1) Stop lamp switch (A) Advamce SUSPENSION
(2) Adjusting nut (B) Retard Inspection
î Check the front forks by locking the front
HEADLAMP ADJUSTMENT brake and pumping the front fork up and
î Headlamp is preset. However in case of down vigorously. The suspension action
adjustment required, please follow the steps should be smooth and there should be no oil
as given below: leakage.
î Headlamp adjustment is done by the î Check the rear shock absorber by pushing
loosening the bolt (1) located below the hard downwards on rear grip while the
headlamp. motorcycle is not parked on stand. The
motorcycle action should be smooth and
there should be no oil leakage.
Front Rear

1
ON

FLOW
GY
LE
TUMBNOLO
NCED TECH
RES
TION
ADVA
INDUC

(1) Bolt
49
Rear shock absorber adjustment
Rear shock absorber adjustment can made
according to the load/road conditions.
î In direction A stiffer
î In direction B softer
NOTE 2
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 1
(1) Axle nut (2) Speed sensor
CAUTION
Do not operate front brake lever when the
wheel is removed.
FRONT WHEEL INSTALLATION
A î Install the side collar (1) to the right side of
the wheel hub and then install the speed
B sensor (2) on the left side of the wheel hub.
(1) Shock absorber adjustment tool
FRONT WHEEL REMOVAL
Refer to the safety precautions on (page 28).
î Support the motorcycle securely on the 1
main stand and raise the front wheel off the
ground.
î Remove the front axle nut (1) remove the
speed sensor (2), axle and wheel.
î Remove the side collar from the wheel. 2
(1) Side collar (2) Speed sensor
50
î Position 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 5
between the brake pads to avoid damage to
the pads. Insert the axle from the right side 1
through the fork legs and wheel hub.
î Tighten the front axle nut to the specified
torque. 3
TORQUE : 5.9 kgf-m 4 2
î Install the stay and speed sensor cable stay
bolt (1) on the left fork leg. (1) Rear axle nut (2) Washer (3) Axle (4) Right
î After installing the wheel apply the brake side collar (5) Caliper assembly
several times and then check if the wheel
rotates freely. Recheck the wheel if the REAR WHEEL INSTALLATION
brake drags or if the wheel does not rotate î Install the side collar (1) to the right side of
freely. the wheel hub.
REAR WHEEL REMOVAL î Tilt the motorcycle and position the rear
Disc type wheel between the swingarm.
î Refer safety precautions on (page 28). î Insert the disc (2) between the pads in the
î Support the motorcycle securely on the caliper assembly. When installing the wheel,
main stand and raise the rear wheel off the carefully fit the brake disc between the
ground. brake pads to avoid damage to the pads.
î Remove the rear axle nut (1) and washer
(2). î Align the rear caliper holder (3) with the
î Remove the axle (3) and the right side swingarm (4).
collar (4). î Insert the axle (5) from the left side through
î Move the caliper assembly (5) upwards. the swingarm, wheel hub, collar and rear
î Slide the wheel out from left side. caliper holder .

51
 4 î Raise the rear wheel off the ground.
î Remove the rear brake adjusting nut (1) and
5 disconnect the brake rod (2) from the brake
arm (3) by pushing down the brake pedal.
Disconnect the brake stopper arm (4) from
7 the brake panel (5) by removing split pin (6)
3 and lock nut (7).
2 5 î Remove the axle nut (8) and pull out the
axle (9). Remove the wheel.
1 6 Installation
î Reverse the removal procedure
(1) Side Collar (2) Disc (3) Rear caliper holder î Axle nut torque : 6.8 kgf-m
(4) Swingarm (5) Axle (6) Washer (7) Axle nut Brake stopper arm nut torque:2.2 kgf-m
î Install the washer (6) and tighten the rear î Adjust the brake (page 45).
axle nut (7) to the specified torque. î After installing the wheel, apply the brake
TORQUE : 6.8 kgf-m several times and check for free wheel
REAR WHEEL REMOVAL rotation when released.
Drum type CAUTION
8 Always replace used split pins with new ones.
WASHING THE MOTORCYCLE
Follow the below mentioned steps for washing
9 the motorcycle.
2 î Wet the motorcycle with light water spray.
Avoid directing water to muffler outlets and
electrical parts.
3 î Clean the headlamp lens and other plastic
parts using a cloth or sponge dampened
1 5 6 7 4 with a solution of mild detergent and water.
(1) Rear brake adjusting nut (2) Rear brake
Rub the soiled area gently rinsing it frequently
rod (3) Brake arm (4) Brake stopper arm (5)
with fresh water.
î After cleaning spray water thoroughly.
Brake panel (6) Split pin (7) Lock nut (8) Axle î Dry the motorcycle by wiping with dry soft
nut (9) Axle cloth.
52
 NOTE AIR SUCTION VALVE
î We at dealership take all above mentioned 1
precautions like recommended detergents
and usage of muffler caps/plugs during wash to
ensure quality wash.
î Do 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.
î Do not use high pressure water (or air). It
can damage certain parts of the motorcycle.
CATALYTIC CONVERTER
This motorcycle is equipped with a catalytic (1) Air suction valve
converter in the muffler to meet the emission Further to meet emission standards this
norms . The catalytic converter contains noble motorcycle is provided with the air suction
metals that serve as catalyst, promoting valve.
chemical reactions to convert CO and HC in Air Suction Valve (1) supplies fresh air from
the exhaust to CO2 and H2O (water vapour). the air filter to the exhaust manifold to convert
A defective catalytic converter contributes to carbon monoxide to carbon dioxide. This
air pollution and can impair your engine’s reduces the CO% in the vehicles exhaust.
performance.
Follow these guidelines to protect your
motorcycle’s catalytic converter.
î Always use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
converter ineffective.
î Keep the engine tuned up.

53
 BASIC TROUBLESHOOTING
1. STARTING TROUBLE - ENGINE DOES NOT START
A. Fuel System
Check fuel valve position “OFF” Turn to “ON” position
“ON” Position
Check fuel in Fuel Tank No Fuel Refill
OK
Check fuel Lines Leakage/Air Lock Rectify
OK
Consult Authorised Distributor/Dealer

B. Electric Starter Not Working

Check Fuse Fuse Replace Fuse (ref. page 48)
OK
Inspect Battery Weak Consult Authorised Distributor/Dealer
OK
Check connections, Ignition switch/starter switch Loose Secure connections
OK
Consult Authorised Distributor/Dealer

C. No Spark At Spark Plug

Check Ignition Switch “OFF” Turn ignition switch “ON”
OK
Check Spark Plug for Fouling/ Replace Spark Plug/Adjust
Improper Electrode Gap No Spark Spark Plug Gap (0.8-0.9 mm)
OK
Check for Poorly Connected Secure Properly
or Loose Spark Plug Wire LooseContact
OK
Consult Authorised Distributor/Dealer
54
 BASIC TROUBLESHOOTING
2. ENGINE STARTS BUT STALLS
Check Bystarter lever position “ON” Turn to “OFF” position
“OFF” Position
Check Air Cleaner element Dirty/Clogged Replace
OK
Consult Authorised Distributor/Dealer
3. POOR PICK UP
Spark Plug Loose in Cylinder Head Loose Tighten the Spark Plug
OK
Check Air Cleaner element Clogged Replace
OK
Improper functioning (Disc Type)
Check Brake Binding Consult Authorised Distributor/Dealer
Readjust free play of rear Brake brake pedal
OK Improper Adjustment (Drum Type)
Check Tyre Inflation Pressure Under Inflated Correct Tyre Pressure
OK
Consult Authorised Distributor/Dealer
4. ELECTRICAL SYSTEM
Feeble Horn Sound or No Light
Check Fuse Fuse Replace Fuse
OK
Inspect Battery Weak Consult Authorised Distributor/Dealer
OK
Check Bulbs Fuse/Wrong Wattage Replace Bulbs
OK
Check Connections Loose Secure Connections
OK
Consult Authorised Distributor/Dealer
55
 CU
ST
OM
ER
Hero MotoCorp Ltd.

’S
CO
PY
DELIVERY CERTIFICATE
No.: IBQD

I certify having taken delivery of one Hero MotoCorp HUNK

Motorcycle bearing the following particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.

Customer’s Copy
 Hero MotoCorp Ltd.
Alongwith the motorcycle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool Kit -
Tool Bag, +, -No. 2 Driver, Grip, Box Wrench 16 x 14, Pin Spanner, No.
3 cross point screw driver
 DIS
TR
IBU AU
TO THO
R/ RI
DE SE
Hero MotoCorp Ltd. AL D
ER
C OP
Y

DELIVERY CERTIFICATE
No.: IBQD

I certify having taken delivery of one Hero MotoCorp HUNK motorcycle

bearing the following particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.

Authorised Distributor/Dealer copy

 Hero MotoCorp Ltd.
Alongwith the motorcycle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool Kit -
Tool Bag, +, -No. 2 Driver, Grip, Box Wrench 16 x 14, Pin Spanner, No.
3 cross point screw driver
WHAT ARE THE BENEFITS OF Hero MotoCorp GENUINE SPARE PARTS ?
î Assures long life
î Ensures economy for a long time
î Safety of vehicle and rider
î Peace of mind
î Value for money
î Assured quality
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
î Material used is inferior
î Damages other parts of clutch like, clutch center and
Clutch Plate outer clutch
î Affects fuel efficiency
î Poor acceleration

Cam Chain Kit î Poor performance

î Reduced life
î Improper sealing
î
Gasket Cylinder Head î Engine knocking
Leads to leakage and smoky exhaust
î Higher emission level
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
î Improper air filtration resulting in premature engine failure
Element Air Cleaner î Affects fuel efficiency
î Poor engine performance
î Frequent stalling of engine
Spark Plug î Higher emission level
î Poor engine performance
î Affects fuel efficiency
î Poor braking efficiency
Brake Pads/Shoes î Rider safety-an issue
î Discs/Drum wear out, resulting in subsequent repair cost

Chain Sprocket Kit î Noisy Operation

î Failure of chain can cause fatal accident
 Hero MotoCorp Ltd.
JOBS APPLICABLE TO PERIODIC SERVICES
î Wash the vehicle, blow dry with air.
î Inspect fuel line at every service.
î Inspect throttle free play and operation at every service, adjust if necessary.
î Inspect Bi-starter operation at every service.
î Clean carburetor at first service then every 6000 kms., adjust if necessary.
î Replace air cleaner element at every 15000 kms.
î Inspect and clean air cleaner drain tube at every service, if required.
î Inspect, clean spark plug at every service, adjust if necessary (replace at every 12000 kms).
î Inspect the valve clearance at every service, adjust if necessary.
î Replace engine oil or top up as per the maintenance schedule.
î Clean engine oil strainer screen at first service then at every 6000 kms.
î Clean engine oil centrifugal filter at first service then at every 6000 kms.
î Inspect oil circulation at every service.
î Inspect electric starter operation at every service.
î Inspect, clean, lubricate and adjust the drive chain at every 2000 kms.
î Inspect battery voltage at every service and charge if required.
î Inspect brake shoe wear at every service, adjust if necessary.
î Clean and lubricate brake cam at second service, then at every 6000 kms.
î Inspect brake pads, disc wear and brake fluid level at every service. Top-up if necessary. Replace brake
fluid once in every two years or 30000 kms. whichever is earlier.
î Inspect all lamps, horn and switches at every service, adjust if necessary.
î Inspect headlamp focus at every service, adjust if necessary.
î Inspect clutch free play at every service, adjust if necessary.
î Lubricate the side stand and main stand at every service.
î Inspect and clean the side stand switch at every service.
î Inspect all the fasteners and tighten to the specified torque (if required).
î Inspect wheels, wheel bearings and tyre pressure at every service.
î Inspect steering for smooth operation, adjust in every alternate service and lubricate at every 12000 kms.
î Inspect rear suspension at every service.
î Inspect front suspension at every service, replace oil once in every 2 year or 30000 kms whichever is earlier.
î Inspect secondary air injection system at every 6000 kms.
î Polish entire motorcycle.
 SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km. Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
I 500 - 750
II 3000 - 3500
III 6000 - 6500
IV 9000 - 9500
V 12000 - 12500
VI 15000 - 15500
VII 18000 - 18500
VIII 21000 - 21500
IX 24000 - 24500
X 27000 - 27500
XI 30000 - 30500
XII 33000 - 33500
XIII 36000 - 36500
XIV 39000 - 39500
XV 42000 - 42500
XVI 45000 - 45500
XVII 48000 - 48500
NOTE
It is mandatory to avail all free and paid services as per the recommended schedule to be eligible for the warranty
benefits. Please ensure that each paid service is availed within 90 days from the date of previous service or as per
the recommended schedule, whichever is earlier.
 SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km. Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
XVIII 51000 - 51500
XIX 54000 - 54500
XX 57000 - 57500
XXI 60000 - 60500
XXII 63000 - 63500
XXIII 66000 - 66500
XXIV 69000 - 69500
XXV 72000 - 72500
REMARKS (IF ANY)
 SERVICE ADVICE SHEET
Normal wear and tear components replacement advice
Kms Authorised Completion Dt.
Date Advice Distributor/Dealer
Job Card No. (Sig. & Stamp) Job Card No.
 Hero MotoCorp Ltd.
OWNERSHIP RECORD AND DATA

VIN

AUTHORISED DISTRIBUTOR/DEALER NAME

ADDRESS

AUTHORISED DISTRIBUTOR/DEALER
STAMP AND SIGNATURE