HERO Karizma ZMR Owner's manual

PREFACE

Your Authorised Hero MotoCorp dealer will be glad to provide further information or

assistance and is equipped to handle your future service needs.

This booklet is your guide to the basic operation and maintenance of your new

Hero MotoCorp Karizma ZMR. Please take time to read it carefully. As with any fine

machine, proper care and maintenance are essential for trouble-free operation and optimum

performance.

We at Hero MotoCorp, are committed to demonstrate excellence in our environment

performance on a continual basis, as an intrinsic element of our corporate philosophy. To

achieve this we commit ourselves to continue product innovations to improve environment

compatibility, comply with all applicable legislation including environment legislation and

strengthen the green supply chain.

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

Your motorcycle is conforming to latest (Bharat stage-III norms) regulation for emission,

safety & noise levels. We are also using non asbestos brake shoes/pads and engine gaskets

which are environment friendly in nature.

Thank you for selecting a Hero MotoCorp Karizma ZMR. We wish you many miles of

continued riding pleasure in the years ahead.

ALL INFORMATION, ILLUSTRATION, PHOTOGRAPH, DIRECTIONS,

SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS OWNER'S

MANUAL ARE BASED ON THE LATEST PRODUCT INFORMATION

AVAILABLE AT THE TIME OF ITS PRINTING APPROVAL, AND THE

ACCURACY OR CORRECTNESS OF THE SAME IS NOT UNDERTAKEN OR

GUARANTEED. Hero MotoCorp Ltd RESERVES THE RIGHT TO MAKE

CHANGES IN ITS CONTENTS AT ANY TIME WITHOUT NOTICE AND/OR

INCURRING ANY OBLIGATION, WHATSOEVER. NO ONE IS ALLOWED TO

REPRODUCE ANY PART OF THIS PUBLICATION WITHOUT OBTAINING

PRIOR WRITTEN PERMISSION FROM Hero MotoCorp Ltd.

NOTE

Pg. No. Pg. No.

CONTENTS

MOTORCYCLE IDENTIFICATION 1

PRODUCT SPECIFICATION 2

SAFE RIDING TIPS 4

ACCESSORIES & MODIFICATIONS 5

ANTI-THEFT TIPS 5

TIPS FOR HEALTHY ENVIRONMENT 6

MOTORCYCLE VIEWS 7

PARTS FUNCTION 12

PRE-RIDE INSPECTION 27

• Real Time Mileage Indicator (RTMI) 20

• Digital Clock 16

RIDING 29

STARTING THE ENGINE 28

• Steering Lock/Seat lock/Seat removal 22

• Odometer/Tripmeter 17

BRAKING 30

• Instruments & Indicators 12

• Left/Right Handlebar Controls 21

• Seat Installation/Helmet hanger 23

• Fuel Tank 26

• Fuel Gauge 20

• Ignition Switch 14

• Scroll Message 17

TYRES 26

PARKING/TOOL KIT/FIRST AID KIT 31

MAINTENANCE 32

• Safety Precautions 33

• Maintenance Schedule 34

• Brakes 46

• Headlamp Adjustment 51

• Side Stand/Side Stand Switch/Suspension 52

• Air Cleaner 39

• Drive Chain Slider 45

• Clutch/Drive Chain 42

• Throttle Operation/Valve Clearance 41

• Brake Pad Wear 47

• Battery 48

• Centrifugal Oil Filter 37

ENGINE OIL/ENGINE OIL TOP UP PROCESS 36

ENGINE OIL REPLACEMENT PROCESS 36

• Oil Cooler/Spark Plug 38

• Fuse Replacement 50

• Stop Lamp Switch 51

• Washing The Motorcycle 55

• Catalytic Converter 56

WARRANTY DETAILS

INSTALLATION

HERO GEUINE PARTS

• Front Wheel 53

ZONAL/REGIONAL/AREA OFFICES

BASIC TROUBLESHOOTING 57

• Rear Wheel 54

ROAD SIGNS 59

2. For dealing with legal & insurance departments.

VIN and Engine No. may be required:

1. During registration of the motorcycle.

Location: Stamped on the right side of the

steering head tube.

VIN: MBLXXXXEJYZXYYYYY

Location: Stamped on the lower side of the

left crankcase.

MOTORCYCLE IDENTIFICATION

Engine No.: XXXXEGYZXYYYYY

Model: Karizma ZMR

VIN Engine

Variants

XXXXEG Y Z X YYYYY

Engine

Description Year of

Manufacturing Assembly Plant Month of

Manufacturing Serial Number

MBL XXXXEJ Y Z X YYYYY

Manufacturer

code Vehicle

Description Year of

Manufacturing Assembly Plant Month of

Manufacturing Serial Number

Vehicle Identification Number (VIN) Engine No.

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

1

MBLXXXXEJYZXYYYYY

XXXXEGY

ZXYYYYY

SPECIFICATIONSITEM

Dimensions

Overall length

Overall width

Overall height

Wheelbase

Saddle height

Ground clearance

Kerb weight

2100 mm

805 mm

1190 mm

1360 mm

810 mm

145 mm

157kg

Weight

Engine oil

Fuel tank

Hydraulic brake fluid

Front fork oil disassembly

Maximum power

Maximum torque

Bore and stroke

Compression ratio

Displacement

1.35 litres at disassembly and 1.10 litre at draining

15.3 litres (Minimum)

Castrol Q stop-DoT 3 or DoT 4

171±2.5 ml

14.9 kW (20BHP) @ 8000 r/min

19.7 N-m @ 6500 r/min

65.5 x66.2 mm

9.6:1

223 cc

Capacities

Engine

Spark plug gap

Valve clearance (cold)

Idle speed

Front Suspension

Rear Suspension

0.8-0.9 mm

0.10 mm

1400±100 r/min

Telescopic hydraulic shock absorbers

Rectangular swingarm with 5 step adjustable iGRS

system

Intake (cold)

Exhaust (cold)

Chassis and suspension

Fuel metering

Spark plug FI (Fuel Injection)

NGK-DPR 8 EA 9, BOSCH-XR5DE

PRODUCT SPECIFICATION

2

Caster 26°

3

PRODUCT SPECIFICATION SPECIFICATIONSITEM

Trail length 94 mm

Tyre size 80/100x18-47P (Tubeless tyre)

120/80x18-62P (Tubeless tyre)

Front

Rear

Brakes Dia. 276 mm

Dia. 240 mm

Front (Disc type)

Rear (Disc type)

Primary reduction

Final reduction

st

Gear ratio, 1

rd

3th

4

3.0909 (68/22)

3.0769 (40/13)

2.769 (36/13)

1.722 (31/18)

1.263 (24/19)

1.000 (22/22)

Transmission

Cast wheel

Front wheel

Rear wheel

nd

2

Battery 12V-6Ah, *MF Battery

Electricals

*MF stands for Maintenance Free

**MFR stands for Multi-Focal Reflector

12V-0.2W/2.1W LED

Alternator

Starting system

Headlamp (High/Low)

Tail/Stop lamp

Turn signal lamp

Meter illumination

Neutral indicator

Turn signal indicator

Position lamp

Licence plate lamp

Programmed FI Malfunction Indicator (MIL)

Fuse

232W @ 5000 r/min

Electric start

20A, 15A, 7.5 A

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

L.E.D.

12V-5W

12V 1.0W LED (Lamp guide x 2)

L.E.D

12V-1.14W

L.E.D.

12V-10Wx4 nos.-**MFR

th

50.815 (22/27)

Hi beam indicator L.E.D

îDuring night time, dip headlamps of your

motorcycle for oncoming traffic, or when

following another vehicle.

îAlways conduct simple pre-ride inspection

(page 27).

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).

îTo make yourself more visible, wear bright

reflective clothing that fits well.

îTake care of loose/hanging clothes while

solo/pillion riding.

îFor stopping motorcycle, use both brakes

simultaneously, keeping throttle in the close

position.

îGive way to others on the road and signal

before you make a turn.

îGet your motorcycle serviced regularly by

the Authorised Hero MotoCorp workshop.

îRespect road signs and obey traffic rules for

your own safety and that of others on the

road (page 59).

îAvoid sudden acceleration, braking and

turning of your motorcycle.

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.

îNever touch any part of the hot exhaust

system like muffler.

îNever take your hands off the steering

handle while riding.

îNever use cell phone while riding the

motorcycle.

îDo not cross the continuous white/ yellow

line in the center of the road, while

overtaking.

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.

SAFE RIDING TIPS

Do's: Don't:

4

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.

îBe sure electrical equipment does not

exceed the motorcycle's electrical system

capacity (page 3). A blown fuse can cause

a loss of lights.

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.

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.

îFollow all instructions in this owner's manual

regarding accessories and modifications.

îImproper accessories or modifications can

cause a crash in which you can be seriously

hurt or killed.

WARNING

_______________________________________________________

NAME: _____________________________________________

PHONE NO : _____________________________________

ADDRESS: _______________________________________

îMany times stolen motorcycles are identified

by information in the Owner's Manuals that

are still with them.

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.

îPark your motorcycle in a locked garage

whenever possible.

ANTI-THEFT TIPS

îAlways lock the steering and never leave the

key in the ignition switch .

Accessories

5

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.

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 km (with top

up every 3000 kilometres) to keep the engine fit and environment healthy.

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

îNoise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or

defective mufflers, excessive noise will cause headaches and discomfort.

îHealthy engine: The engine is the lifeline of every vehicle. To keep it healthy, it should be

tuned regularly, which will also help reduce pollution and improve vehicle performance &

fuel efficiency.

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.

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.

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.

SOME TIPS FOR HEALTHY ENVIRONMENT

6

5. Headlamp (Lo-beam)

1. Front fender

2. Right position lamp guide

3. Front right turn signal lamp

4. Front visor

63

8

1

2

4

7

6. Front left turn signal lamp

7. Left position lamp guide

8. Headlamp (Hi-beam)

9. Oil cooler

5

9

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

FRONT VIEW MOTORCYCLE VIEWS

7

1. Left rear turn signal lamp

2. Tail/stop lamp 4. Licence plate lamp

3. Right rear turn signal lamp

13

2

4

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

REAR VIEW MOTORCYCLE VIEWS

8

6. Rear view mirror

1. Horn switch

2. Turn signal lamp switch

3. Clutch lever

4. Passing switch

5. Dimmer switch

7. Combination meter console

8. Ignition switch with steering lock

9. Front brake lever

11. Throttle grip

14. Fuel tank cap

10. Dynamic handlebar damper

13. Headlamp switch

12. Electric starter switch

13

3

1

5

4

6

7

11

9

10

14

2

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

FRONT VIEW MOTORCYCLE VIEWS

9

12

8

2

6. Side stand

9. Saree guard with

women pillion step

8. Seat/helmet hanger

7. Pillion foot rest

10. Rear grip

11. Document & tool kit

compartment

12. Fuel pump

13. Fuel injector

1. Starter motor

2. Gearshift pedal

5. Rider foot rest

4. Main stand

3. Side stand switch

1

597 8

11

6

12

13

10

LEFT SIDE VIEW MOTORCYCLE VIEWS

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

34

10

9. Front disc

10. Front master cylinder

7. Throttle body

8. Caliper assembly

11. Battery main fuse

12. Battery compartment

14. Fuse box

15. Rear shock absorber

13. Rear brake fluid reservoir

16. Rear hugger fender

4. Rider foot rest

5. Brake pedal

1. Rear disc

3. Rear master cylinder

6. Oil level dipstick

2. Pillion foot rest

578

1

RIGHT SIDE VIEW MOTORCYCLE VIEWS

11

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

11

10

13 12

14

16

23469

15

Instruments and Indicators

PARTS FUNCTION

The indicators are in the combination meter

console. Their functions are described in the

tables on the followings pages.

Sl. No.

(1) Position Lamp Indicator

(2) Selection Button

(3) Fuel gauge

12

1

2

3

4

56 7

8

9

10

11

12

14

15 13

îTo adjust time (page 16) in the digital clock when pressed

along with the reset button for more than 2 seconds.

îTo register user name (page 16) in the scrolling display.

îTo save mode selection.

îTo select Trip-A, Trip-B on tripmeter or odometer.

Use this button for the following purposes :

Light glows when the headlamp switch is shifted to “ ”.

Position lamp, Tail lamp and Licence plate lamp are functional.

Indicates approximate quantity of fuel available in the form of

digital segments. The fuel gauge digital segments will swing to

the maximum scale on the fuel gauge LCD panel once when

the ignition switch is turned "ON". The approximate amount of

fuel is indicated by the number of segments displayed (pages

20).

Function

Description

(5) Digital clock

(4) Digital speedometer Indicates driving speed.

Indicates hour and minute (pages 16).

(9) Tripmeter Shows the distance traveled during a trip (page 17).

(10) Odometer Shows accumulated mileage

(11) Reset button

(12) Turn signal indicator Flashes when turn signal switch is operated

(13) High beam indiactor Light glows when headlamp is in “Hi” Beam

(14) Neutral indicator Light glows when vehicle is in neutral position

(15) Programmed-FI

lamp (MIL)

malfunction indicator

13

(6) Tachometer

(8) Scroll message display/

message

side stand “ON”

(7) Real time mileage

indicator (RTMI)

Shows engine revolutions per minute. The tachometer digital

segments will swing to the maximum scale on the tachometer

LCD panel once when the ignition switch is turned ''ON".

Indicates the current mileage of the motorcycle in (Km). The

indication will change once in every 10 seconds depending

upon the riding condition (page 20).

Displays a scrolling message as “SIDE STAND IS ON”. When

the side stand is down to alert the customer to lift it up before

riding.

Displays a scrolling Welcome Message when the ignition switch

is turned "ON" (if the side stand is up) and Sign-Off message

when the ignition switch is turned "OFF".

When the ignition switch is turned “ON” the Programmed-FI

MIL glows for few seconds and then should go “OFF”. It

indicates that Programmed FI system is “OK”. If it “flashes”, or

remains “ON” there is an abnormality in the Programmed FI

system, it is recommended to reduce the speed and drive it to

Authorised Hero MotoCorp workshop for check up.

Use this button for the following purposes :

îTo register user name (page 17) in the scrolling display.

îTo select mode selection.

îTo reset Trip-A and Trip-B on tripmeter.

îTo adjust time (page 19) in the digital clock when pressed

along with the select button for more than 2 seconds.

Key Position Function Key Removal

Key cannot be removed

“ON”

(3) Steering lock

(1) Ignition key (2) Ignition switch

îProgrammed-FI Malfunction Indicator lamp

illuminates for few seconds and goes “OFF”.

î“SIDE STAND IS ON” scroll message will be

displayed if the stand is down.

îTurn signal lamps, Horns, Tail/Stop lamp,

Passlamp, Headlamp & Neutral indicator will

be functional.

îThe engine can be started.

îThe combination meter console LCD panel

illuminates & initial display of multifunction

digital segments are displayed.

Engine cannot be started and no electrical

system will be functional. Key can be removed

Key can be removed

“LOCK”

“OFF”

Steering can be locked.

“OFF” Position/

Lock Open

“LOCK” Position

“ON” Position

Ignition switch

1

2

3

14

When the ignition switch is turned "ON" the combination meter console (1) LCD will display

the following digital segments so that you can be sure the LCD display is functioning properly.

1. Combination meter console

4. Real Time Mileage Indicator (RTMI)

2. Digital clock

3. Tachometer

5. Scroll message

8. Fuel gauge

7. Odometer

or

6. Tripmeter

9. Speedometer

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

}

(depending on last selection)

3

1

2

4

56789

15

Digital clock

îTurn the ignition switch "ON".

îPress and hold Select Button (2) and Reset

Button (3) simultaneously for more than 2

seconds. The clock will be set in the adjust

mode with the display blinking.

Digital Clock (1) shows hours and minutes.

To adjust the time, proceed as follows : ·The time is advanced by 1 hour each time

the button is pressed.

îTo set the hour, press Reset Button (3)

until the desired hour is displayed.

îPress the Select Button (2). The minute

display starts blinking.

·The time advances fast when the button is

pressed and held.

SEL RESET

km/h

AM

PM

TOTAL TRIP

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

1

2 3

SEL RESET

km/h

AM

PM

TOTAL TRIP

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

3

SEL RESET

km/h

AM

PM

TOTAL TRIP

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

2

SEL RESET

km/h

AM

PM

TOTAL TRIP

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

3

16

Odometer/Tripmeter

The odometer (1) shows accumulated

distance traveled.

The Tripmeter shows distance traveled per

trip. There are 2 tripmeters, Tripmeter-A (2)

and Tripmeter-B (3).

Push Select button (4) to select the

Odometer, Tripmeter-A or Tripmeter-B.

Tripmeter-A can be displayed from

''9999.9'' Km. Tripmeter-B can be

displayed upto "9999.9" Km. If the

Tripmeter-A or B exceeds "9999.9" Km. it

will return to "0" automatically.

The Odometer can be displayed from "0 to

999999" Km.

îTo set the minute press Reset Button (3)

until the desired minute. The minute display

will return to " " when " " is reached

without affecting the hour display.

·The time advances by 1 minute, each

time the button is pressed.

·The time advances fast when the button is

pressed and held.

îTo end the adjustment press Select Button

(2) or turn the ignition switch "OFF". The

display will stop flashing automatically and

the adjustment will be cancelled if the button

is not pressed for about 30 seconds.

The clock will reset " " if the battery is

disconnected.

NOTE

AM :

km.

TOTAL

km.

A

km.

B

SEL RESET

N

km/h

AM

PM

TOTAL

km.

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

1

2

3

4

The scroll (1) displays a message whenever

the ignition is either turned "ON" (Welcome

Message) (if side stand is up) or "OFF" (Sign-

Off Message).

Scroll message

SEL RESET

km/h

AM

PM

TOTAL TRIP

km/l

Av

0

1

2

34567

8

9

10

x1000r/minx1000r/min

1

îWelcome message: After the ignition is

turned "ON" Welcome Message will be

displayed.

17

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HERO Karizma ZMR Owner's manual

HERO Karizma ZMR Owner's manual

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