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
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
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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