HERO Passion Pro Owner's manual

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PREFACE
Thank you for selecting a Hero MotoCorp Passion Pro. We wish you many miles of
continued riding pleasure in the years ahead.
Your Authorised Hero MotoCorp dealer will be glad to provide further information or
assistance and is equipped to handle your future service needs.
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.
This booklet is your guide to the basic operation and maintenance of your new
Hero MotoCorp Passion Pro. Please take time to read it carefully. As with any fine machine,
proper care and maintenance are essential for trouble-free operation and optimum
performance.
We at Hero MotoCorp, are committed to demonstrate excellence in our environment
performance on a continual basis, as an intrinsic element of our corporate philosophy. To
achieve this we commit ourselves to continue product innovations to improve environment
compatibility, comply with all applicable legislation including environment legislation and
strengthen the green supply chain.
Let us make this world a safer, healthier and more environment friendly place.
ALL INFORMATION, ILLUSTRATION, PHOTOGRAPH, DIRECTIONS,
SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS OWNER'S
MANUAL ARE BASED ON THE LATEST PRODUCT INFORMATION
AVAILABLE AT THE TIME OF ITS PRINTING APPROVAL, AND THE
ACCURACY OR CORRECTNESS OF THE SAME IS NOT UNDERTAKEN OR
GUARANTEED. Hero MotoCorp Ltd RESERVES THE RIGHT TO MAKE
CHANGES IN ITS CONTENTS AT ANY TIME WITHOUT NOTICE AND/OR
INCURRING ANY OBLIGATION, WHATSOEVER. NO ONE IS ALLOWED TO
REPRODUCE ANY PART OF THIS PUBLICATION WITHOUT OBTAINING
PRIOR WRITTEN PERMISSION FROM Hero MotoCorp Ltd.
NOTE
Pg. No.
CONTENTS
MOTORCYCLE IDENTIFICATION 1
PRODUCT SPECIFICATION 2
SAFE RIDING TIPS 4
ACCESSORIES & MODIFICATIONS 5
MOTORCYCLE VIEWS 7
PARTS FUNCTION 10
îInstruments & Indicators
îIgnition switch
îFuel gauge/odometer/trip meter
îService reminder indicator
LEFT HANDLEBAR CONTROLS
RIGHT HANDLEBAR CONTROLS
STEERING LOCK
SEAT LOCK
HELMET HANGER
SIDE STAND INDICATOR/SIDE STAND SWITCH
FUEL VALVE
FUEL TANK
10
11
12
13
14
ENGINE OIL 16
ENGINE OIL LEVEL CHECK/TOP UP PROCESS 17
ENGINE OIL REPLACEMENT PROCESS 17
16
TYRES 18
PRE-RIDE INSPECTION 19
STARTING THE ENGINE 23
RIDING 20
BRAKING/PARKING 21
12
12
14
14
14
15
21TOOL KIT/FIRST AID KIT 22SAFETY PRECAUTION
ANTI-THEFT TIPS 5
TIPS FOR HEALTHY ENVIRONMENT 6
MAINTENANCE
ROAD SIGNS
24
26
26
27
29
30
31
31
31
32
34
36
37
38
39
40
40
41
41
42
43
44
44
45
47
îSpark plug
îAir cleaner
îFuse replacement
îMaintenance Schedule
îOil screen filter & Centrifugal filter
îThrottle operation
îCarburetor
îThrottle controlled ignition system
îValve clearance
îClutch
îDrive chain
îFront brake
îRear brake
îBrake wear indicators
îBattery
îStop lamp switch
îSide Stand
îHeadlamp adjustment
SUSPENSION
FRONT WHEEL
REAR WHEEL
WASHING THE MOTORCYCLE
CATALYTIC CONVERTER
BASIC TROUBLESHOOTING
WARRANTY DETAILS
HERO GENUINE PARTS
ZONAL/REGIONAL OFFICES
Pg. No.
VIN and Engine No. may be required:
2. For dealing with Legal & Insurance Departments.
1. During registration of the motorcycle.
Location: Stamped on the right side of the
steering head tube.
VIN: MBLXXXXBUYZXYYYYY
Location: Stamped on the lower side of the
left Crankcase.
MOTORCYCLE IDENTIFICATION
Engine No.: XXXXEVYZXYYYYY
Model: Passion Pro VIN
BP
BR
Engine
EU
EU
Cast wheel/Kick start/Drum
Spoke wheel/Kick start/Drum
Variants
XXXXEV Y Z X YYYYY
Engine
Description Year of
Manufacturing Assembly Plant Month of
Manufacturing Serial Number
MBL XXXXBU Y Z X YYYYY
Manufacturer
code Vehicle
Description Year of
Manufacturing Assembly Plant Month of
Manufacturing Serial Number
Cast wheel/Electric start/Drum
Spoke wheel/Electric start/Drum BT
BS EV
EV
Vehicle Identification Number (VIN)
MBLXXXXBUYZXYYYYY
Engine No.
XXXXEVY
ZXYYYYY
Cast wheel/Electric start/Disc BU EV
1
SPECIFICATIONSITEM
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Saddle height
Ground clearance
Kerb weight
1980 mm
765 mm
1075 mm
1235 mm
795 mm
165 mm
112 kg (Kick Start/Drum)
Weight
Engine oil
Fuel tank
Fuel reserve capacity
Front fork oil disassembly
Maximum power
Maximum torque
Bore and stroke
Compression ratio
Displacement
Spark plug gap
Valve clearance (cold)
Idle speed
Front Suspension
Rear Suspension
1.05 litres at disassembly and 0.85 litre at draining
12.5 litres (Minimum)
1.0 litre (Usable)
162-165 ml
6.15 kW (8.36 Ps) @ 8000 r/min
0.82 kgf-m (8.05 N-m) @ 5000 r/min
50.0x49.5 mm
9.9:1
97.2 cc
0.6-0.7 mm
0.10 mm
0.10 mm
1400±100 r/min
Telescopic Hydraulic Shock Absorbers
Swingarm with 5 step adjustable Hydraulic
Shock Absorbers
Capacities
Engine
Intake (cold)
Exhaust (cold)
Chassis and suspension
Spark plug NGK-CR7HSA, BOSCH-UR4AC,
Champion-P-RZ9HC (Federal Mogul)
PRODUCT SPECIFICATION
115 kg (Electric Start/Drum)
116 kg (Electric Start/Disc)
2
PRODUCT SPECIFICATION SPECIFICATIONSITEM
*MFR stands for Multi-Focal Reflector
**MF stands for Maintenance Free
3
12V-5/21W-MFR*
Trail length 85 mm
Tyre size 2.75x18-4PR/42P
3.00x18-6PR/52P
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
Side stand indicator
Fuse
3.722 (67/18)
3.071 (43/14)
3.181 (35/11)
1.706 (29/17)
1.238 (26/21)
0.958 (23/24)
**MF Battery, MF-3:12V-3Ah (Kick Start),
**MF-4:12V-3Ah (Electric Start)
115 W
Kick/Electric Start (Optional)
7A/10A (Kick start), 10A/15A ( Electric start)
Transmission
Electricals
Spoke Wheel/Cast Wheel (Optional)
Spoke Wheel/Cast Wheel (Optional)
Front Wheel
Rear Wheel
nd
2
Brakes Dia. 240 mm (Optional)
Dia. 130 mm
Dia. 130 mm
Front (Disc type)
Front (Drum type)
Rear (Drum type)
12V-35/35W Trapezoidal Halogen Bulb-MFR*
L.E.D.
L.E.D.
12V-3.0W
L.E.D.
12V-1.12W
L.E.D.
12V-10Wx4 (Amber bulb) with clear lens-MFR*
Caster 26°
îAlways conduct simple pre-ride inspection
(page 19).
îAlways wear a helmet (ISI marked) with
chin strap securely fastened and insist on a
helmet for your pillion rider.
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.
îRespect road signs and obey traffic rules for
your own safety and that of others on the
road (page 47 & 48).
îDuring night time, dip headlamps of your
motorcycle for oncoming traffic, or when
following another vehicle.
îGive way to others on the road and signal
before you make a turn.
îTo make yourself more visible, wear bright
reflective clothing that fits well.
îTake care of loose/hanging clothes while
solo/pillion riding.
îGet your motorcycle serviced regularly by
the Authorised Hero MotoCorp workshop.
îAvoid sudden acceleration, braking and
turning of your motorcycle.
îNever use cell phone while riding the
motorcycle.
îNever touch any part of the hot exhaust
system like muffler.
îNever ride under the influence of alcohol or
drugs.
îConcentrate on the road and avoid talking
to the pillion rider or others on the road.
îDo not litter the road.
îDo not attach large or heavy items to the
handlebars, front forks, or fenders.
îNever shift gears without disengaging the
clutch and closing the throttle.
îDo not cross the continuous white/
yellow line in the center of the road, while
overtaking.
îNever take your hands off the steering
handle while riding.
SAFE RIDING TIPS
4
Do's: Don't:
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.
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.
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 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.
îImproper accessories or modifications can
cause a crash in which you can be seriously
hurt or killed.
îFollow all instructions in this owner's manual
regarding accessories and modifications.
WARNING
îMany times stolen motorcycles are identified
by information in the Owner's Manuals that
are still with them.
ANTI-THEFT TIPS
ADDRESS: _______________________________________
îPut your name, address and phone number
in this Owner's Manual and keep it in your
motorcycle at all times.
îUse an additional anti-theft device of good
quality.
NAME: _____________________________________________
îPark your motorcycle in a locked garage
whenever possible.
________________________________________________________
________________________________________________________
_____________________________________________________
PHONE NO : _____________________________________
îAlways lock the steering and never leave the
key in the ignition switch .
5
Accessories
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.
îThe following tips shall ensure a healthy motorcycle, healthy environment, and a healthy you.
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.
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.
îNoise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or
defective mufflers, excessive noise will cause headaches and discomfort.
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.
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.
SOME TIPS FOR HEALTHY ENVIRONMENT
6
(3) Clutch lever
(11)Speedometer
(10)High beam indicator
(5) Passing switch
(9) Neutral indicator
(8) Side stand indicator
(1) Horn switch
(4) Headlamp switch
(7) Dimmer switch
(2) Turn signal switch
(6) Rear view mirror
(12) Turn signal indicator
(19) Ignition switch with steering lock
(20) Fuel tank cap
(13) LCD panel
(18) Electric starter switch (optional)
(15) Master cylinder (optional)
(17) Throttle grip
(14) Reset button
(21) Leg guard
(16) Front brake lever
16
17
18
19
20
21
15
711 14
13
12
8910
1
6
3
2
4
5
TOP VIEW MOTORCYCLE VIEWS
*Accessories and features shown may not be part of standard fitment.
7
(2) Carburetor
(3) Gear shift pedal
(4) Rider foot rest
(5) Main stand
(6) Side stand
(1) Fuel valve (7) Left side cover
(8) Saree guard with women
pillion step
(10) Reflex reflector
(9) Rear turn signal lamp
(11) Tail/Stop lamp
(13) Seat lock/Helmet hanger
(15) Front turn signal lamp
(12) Rear grip
(14) Side stand switch
15
10
11
LEFT SIDE VIEW MOTORCYCLE VIEWS
*Accessories and features shown may not be part of standard fitment.
12
13
14
124567 9
8
3
8
(3) Kick starter pedal
(4) Rider foot rest
(5) Starter motor (optional)
(1) Pillion foot rest
(2) Battery compartment (inside) (8) Caliper (optional)
(6) Rear brake pedal
(9) Front disc (optional)
(7) Oil level dipstick (11) Headlamp
(10) Front suspension
(12) Front visor
(13) Rear suspension
MOTORCYCLE VIEWS
RIGHT SIDE VIEW
13
10
11
12
123456788 9
*Accessories and features shown may not be part of standard fitment.
9
5
3
7
PARTS FUNCTION
The indicators are in the speedometer panel
above the headlamp. The functions are as
below.
Instruments and Indicators
4
89
6
10
1 2
Sl. No. Description Function
(6) Odometer Shows accumulated distance traveled
Indicates approximate fuel quantity in the
form of digital segments. The fuel gauge segments will
swing to the maximum scale on the fuel gauge LCD
panel once when the ignition switch it turned "ON".
(9) Side stand indicator Light glows when the vehicle is parked on the side stand
(10) High beam indicator Light glows when headlamp is in “Hi” Beam
(1) Neutral indicator Light glows when vehicle is in neutral
(2) Speedometer Indicates driving speed
(3) Turn signal indicator Flashes when turn signal switch is operated
(8) Reset button To reset the tripmeter to zero before starting a new trip
(7) Service reminder indicator Displays when the next service is due (page 12)
(5) Tripmeter Shows the distance traveled during a trip
(4) Fuel gauge
10
“OFF” Position/
Lock Open
“LOCK” Position
“ON” Position
Ignition switch
2
1
3
(1) Ignition switch
(2) Ignition key
(3) Steering lock position
The engine can be started, Turn signal lamps,
Horn, Tail/Stoplamp and Passing Switch can be
operated. Fuel Gauge, Odometer and Tripmeter
reading 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
11
The fuel gauge (1) is of a Liquid Crystal
Display (LCD) type.
The approximate amount of fuel quantity
available in the fuel tank is indicated by the
number of segments (2) in the display.
Fuel gauge
If only one segment (3) is displayed and
blinks, this indicates that the fuel quantity is
low and is in reserve. The fuel tank should be
refilled as soon as possible.
Odometer
The Odometer (4) shows accumulated
distance traveled.
The Tripmeter (5) shows distanced traveled per
trip. The Tripmeter can be reset to zero by
pressing the RESET button (6).
Service reminder indicator
The Service Reminder Indicator (1) is to indicate
user to bring the vehicle to an Authorised Hero
MotoCorp workshop for service. The indicator
shall start blinking when the vehicle covers
Tripmeter
kilometers as specified in the maintenance
schedule. The indicator will keep on blinking
throughout the kilometer interval for a
particular service and will stay ‘‘ON’ thereafter.
The Service Reminder Indicator can be reset at an
Authorised Hero MotoCorp workshop.
SERVICE REMINDER
TRIP
km
km
2
1
SERVICE REMINDER
TRIP
km
km
536
4
7
After getting the vehicle serviced, make sure that
the Service Reminder Indicator has been reset.
NOTE
LEFT HANDLEBAR CONTROLS
3
6
1
2
12
(1) Fuel gauge (2) Segments
(3) Segment (4) Odometer (5) Tripmeter
(6) Reset button (7) Service reminder indicator
SERVICE REMINDER
TRIP
km
km
2
1
(1) Fuel gauge (2) Segments
îHeadlamp switch is “OFF”.
Functions in DC when the passing switch
knob is pressed in the following condition.
îHeadlamp switch is ON” but on low beam.
2. Headlamp switch
Gives an indication for passing ahead.
1. Passing switch
The switch has three positions.
Position
Action
Headlamp “ON”
“Following is “ON”
Tail/Stop lamp
Position lamp
“OFF”
Speedometer L.E.D.
marked by white dot.and
Press the switch to operate the horn.
5. Horn switch
IMPORTANT: To switch “OFF” the turn
signal after completing the turn, gently push
inside.
3. Dimmer switch
Select for high beam and for low beam.
Shift the turn signal knob sideways for
right/left indications and leave it to come back
to its normal position on its own.
4. Turn signal lamp switch
6. Clutch Switch (For electric start model)
There is a clutch switch provided for the safety
of the rider. The motorcycle cannot be started
by electric starter switch until the clutch lever is
operated when the vehicle is engaged in gear.
RIGHT HANDLEBAR CONTROLS
Ensure starter switch (1) is operated when the
vehicle is in neutral gear. If the vehicle is
engaged in gear press the clutch lever before
operating the starter switch. Release starter
switch after the engine has started.
Starter Switch (For electric start model)
1
4
5
13
(1) Electric starter switch
Never hold starter switch continuously for
more than 5 seconds as continuously cranking
of engine will drain the battery.
CAUTION
Location: On the rear left side of the seat,
below the rear cowl.
SEAT LOCK
STEERING LOCK
Steering lock with Ignition switch, turn the
ignition 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
(1) Ignition key
(1) Seat Lock (2) Knob (3) Helmet Hanger
The helmet can be hung and locked on the
hook provided with the seat lock (1) by
rotating the key.
HELMET HANGER
When the vehicle is parked on side stand
(Ignition Switch “ON”), an indicator lamp
glows in the speedometer panel.
Operation: Insert the key and turn it
clockwise. Pull the knob (2) downwards to
release the seat. To install, engage the hook
on the underside of the seat with the frame
and push on the top rear side of the seat until
the lock (1) clicks.
SIDE STAND INDICATOR
For the safety of the customer a side stand
indicator (1) is provided.
1
1
(1) Side stand indicator
SIDE STAND SWITCH
A side stand switch (1) is provided in the side stand,
when the vehicle is parked on side stand (Ignition
Switch ON), the switch enables the side stand
indicator lamp to glow on the speedometer panel.
3 2
14
At “ON” position (2), fuel will flow from fuel
tank to the carburetor
“ON” Position
“OFF” Position
The three way fuel valve is on the left side of the
carburetor.
At “OFF” position (1), fuel cannot flow from
the tank to the carburetor. Turn the valve
“OFF” whenever the motorcycle is not in use.
FUEL VALVE
2
At “RES” position (3), 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 “RES”. The reserve fuel
supply is 1.0 litre (usable).
“RES” Position
3
15
(1) Side stand switch (2) “ON” Position
(3) “RES” Position
(1) “OFF” Position
1
1
RES
ON
OFF
CHOKE
OFF
ON
CHOKE
OFF
ON
RES
ON
OFF
CHOKE
OFF
ON
RES
ON
OFF
FUEL TANK
Fuel tank capacity is 12.8 litres (minimum)
including a reserve supply of 1.0 litre (usable).
îTo remove the fuel tank cap (2), open the key
hole cover (1) and insert the ignition key (3)
turn it clockwise and remove the cap.
îDo not overfill the tank. There should be no
fuel (3) in the filler neck (4).
îFor locking, position the cap back on the
opening and press gently. The key springs
back to the normal position and the cap gets
locked.
3
1
2
(1) Key hole cover (2) Fuel tank cap
(3) Ignition key
îDo not operate the motorcycle with the fuel
valve in the “RES” 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 5
4
(4) Filler Neck (5) Fuel
Do not park the motorcycle under direct
sunlight as it causes evaporation of petrol due
to heat and deterioration of paint gloss due to
ultra violet rays.
CAUTION
Petrol is extremely flammable and is explosive
under certain conditions. Refill in a well ventilated
area with the engine stopped. Do not smoke or
allow flames or sparks in the area where the petrol
is refilled or where petrol is stored.
WARNING
îOIL CAPACITY: 1.05 litres
Use hero genuine engine oil or recommended
grade oil.
Manufactured by:
îTide Water Oil Co. (India) Ltd.
îSavita Oil Technologies Limited.
ENGINE OIL
îBharat Petroleum Corporation Limited.
GRADE: SAE 10W 30 SL Grade
(JASO MA2).
BRAND: Hero 4T plus
16
(1) Oil level dipstick (2) Upper level mark
(3) Lower level mark
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.
îStart the engine & let it idle for 3-5 minutes.
îRemove the oil level dipstick, wipe it clean
and insert without screwing it in.
îQuantity of oil to be filled is 0.85 litre
(approx.) during oil change when right
crankcase cover is not removed.
îReinstall the oil level dipstick with a new O-ring.
îTo drain the oil, remove the oil level dipstick
and drain plug (1).
îFill the crankcase through the oil filler hole
with approximately 0.85 litre of the
recommended grade oil.
îAfter the oil has completely drained, reinstall
the drain plug with a new sealing washer (2).
îStop the engine and let the engine oil settle down.
îReinstall the oil level dipstick and check for
oil leaks.
Drain engine oil with the engine warm and the
motorcycle on its main stand.
îMake sure that oil level is at the UPPER
level mark of the oil level dipstick with the
motorcycle in an upright position and that
there are no oil leaks.
îRecheck the oil level.
ENGINE OIL REPLACEMENT PROCESS
îStart the engine and allow it to idle for few
minutes.
(1) Drain plug (2) Sealing washer
2
1
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.
TOP UP PROCESS
Do top up if oil level reaches towards the lower
level mark or every 3000 kms. whichever is earlier.
Check engine oil level each day before
operating the motorcycle.
ENGINE OIL LEVEL CHECK/
UPPER
LOWER 3
2
1
17
/