HERO Passion Xpro Owner's manual

PREFACE

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.

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 XPRO. 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.

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

assistance and is equipped to handle your future service needs.

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

Thank you for selecting a Hero MotoCorp Passion XPRO. 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.

STARTING THE ENGINE 22

îIgnition switch 10

PARTS FUNCTION 9

PRE-RIDE INSPECTION 18

TOOL KIT/FIRST AID KIT 20

SAFE RIDING TIPS 4

RIGHT HANDLEBAR CONTROLS 12

HELMET HANGER/FUEL VALVE 13

îInstruments & Indicators 9

îFuel gauge/odometer/trip meter 11

PRODUCT SPECIFICATION 2

LEFT HANDLEBAR CONTROLS 11

îService due indicator 11

STEERING LOCK 13

SEAT LOCK 13

FUEL TANK 14

ENGINE OIL 15

MOTORCYCLE IDENTIFICATION 1

ENGINE OIL TOP UP PROCESS 15

MOTORCYCLE VIEWS 6

ENGINE OIL REPLACEMENT PROCESS 16

TIPS FOR HEALTHY ENVIRONMENT 5

TYRES 16

RIDING/BRAKING 19

PARKING/DOCUMENT COMPARTMENT 20

SAFETY PRECAUTION 21

MAINTENANCE

îMaintenance Schedule 23

îOil filter screen & Centrifugal filter 25

îSpark plug 25

îThrottle operation 27

îCarburetor 29

îAir cleaner 26

î Clutch 29

îDrive chain 30

îFront brake 32

îValve clearance 28

îRear brake 34

îBattery 36

î Stop lamp switch 38

REAR WHEEL REMOVAL 40

îHeadlamp adjustment 38

WASHING THE MOTORCYCLE 41

CATALYTIC CONVERTER 42

SUSPENSION 39

HERO GENUINE PARTS

BASIC TROUBLESHOOTING 43

FRONT WHEEL REMOVAL 39

ROAD SIGNS 45

WARRANTY DETAILS

ZONAL/REGIONAL/AREA OFFICES

AIR SUCTION VALVE 42

MBLXXXXAEYZXYYYYY

XXXXABY

ZXYYYYY

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: MBLXXXXAEYZXYYYYY

Location: Stamped on the lower side of the

left Crankcase.

Engine No.: XXXXABYZXYYYYY

Model: Passion XPRO VIN

AA

AB

Engine

AA

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 XXXXAE Y Z X YYYYY

Manufacturer

code Vehicle

Description Year of

Manufacturing Assembly Plant Month of

Manufacturing Serial Number

Spoke wheel/Electric start/Drum

Cast wheel/Electric start/Drum AC

AD AB

AB

Vehicle Identification Number (VIN) Engine No.

Cast wheel/Electric start/Disc AE AB

MOTORCYCLE IDENTIFICATION

1

SPECIFICATIONSITEM

Dimensions

Overall length

Overall width

Overall height

Wheelbase

Saddle height

Ground clearance

Kerb weight

2005 mm

765 mm

1115 mm

1265 mm

795 mm

170 mm

113 kg (Spoke/Kick), 114 kg (Spoke/Self)

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

1litre at disassembly and 0.85 litre at draining

9.5 litres (Minimum)

2.1 litres (Usable)

167 ml

6.40 kW (8.7 Ps) @ 7500 r/min

9.36 N-m @ 5500 r/min

50.0x55.60 mm

9.0:1

109.1 cc

0.8-0.9 mm

0.10 mm

0.15 mm

1400±100 r/min

Telescopic Hydraulic Shock Absorbers

Swing arm with adjustable Hydraulic Shock

Absorbers

Capacities

Engine

Intake (cold)

Exhaust (cold)

Chassis and suspension

Spark plug

NGK-CPR 7EA 9

PRODUCT SPECIFICATION

115 kg (Caste/Kick), 116 kg (Caste/Self)

2

PRODUCT SPECIFICATION SPECIFICATIONSITEM

*MF stands for Maintenance Free

**MFR stands for Multi-Focal Reflector

Trail length 85 mm

Tyre size 80/100x18-47P (Tubeless for Caste Wheel)

90/90x18-51P (Tubeless for Caste Wheel)

Front

Rear

Primary reduction

Final reduction

st

Gear ratio, 1

rd

3th

4

Battery

3.722 (67/18)

3.0714 (43/14)

3.182 (35/11)

1.765 (30/17)

1.190 (25/21)

0.916 (22/24)

12V-3Ah *MF Battery ETZ-4

Transmission

Electricals

Spoke Wheel/Cast Wheel (Optional)

Front Wheel

Rear Wheel

nd

2

Brakes Dia. 130 mm Internal expanding shoe type

Dia. 240 mm (Optional)

Dia. 130 mm Internal expanding shoe type

Front (Drum type)

Front (Disc type)

Rear (Drum type)

Caster 26°

12V-5/21W-**MFR

Alternator

Starting system

Headlamp (High/Low)

Tail/Stop lamp

Turn signal lamp

Meter illumination

Neutral indicator

Turn signal indicator

Hi Beam indicator

Fuse

140W

Kick/Electric Start (Optional)

10A/15A

12V-35/35W Halogen Bulb-**MFR

L.E.D.

12V-1.2W

L.E.D.

12V-10Wx4 MFR**

3

îTo make yourself more visible, wear bright

reflective clothing that fits well.

îDuring night time, dip headlamps of your

motorcycle for oncoming traffic, or when

following another vehicle.

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).

îAlways conduct simple pre-ride inspection

(page 19).

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.

îRespect road signs and obey traffic rules for

your own safety and that of others on the

road (page 47 & 48).

îTake care of loose/hanging clothes while

solo/pillion riding.

îGet your motorcycle serviced regularly by

the Authorised Hero MotoCorp workshop.

îDo not litter the road.

îAvoid sudden acceleration, braking and

turning of your motorcycle.

îNever touch any part of the hot exhaust

system like muffler.

îDo not cross the continuous white/

yellow line in the center of the road, while

overtaking.

îConcentrate on the road and avoid talking

to the pillion rider or others on the road.

îNever use cell phone while riding the

motorcycle.

îNever shift gears without disengaging the

clutch and closing the throttle.

îNever ride under the influence of alcohol or

drugs.

îNever take your hands off the steering

handle while riding.

îDo not attach large or heavy items to the

handlebars, front forks, or fenders.

SAFE RIDING TIPS

Do's: Don't:

4

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.

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.

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.

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

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 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 km) to keep the engine fit and environment healthy.

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

5

(6) Pass lamp switch

(7) Headlamp dimmer switch

(8) High beam indicator

(9) Neutral indicator

(2) Turn signal switch

(5) Rear view mirror

(10) Speedometer

(4) Headlamp switch

(1) Horn switch

(3) Clutch lever

(15) Front brake lever

(17) Electric starter switch (Optional)

(11) Turn Signal Indicator lamp

(18) Ignition switch with steering lock

(12) LCD panel

(14) Master cylinder (Optional)

(16) Throttle grip

(19) Fuel tank cap

(13) Reset button

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

10

16

17

18

19

15

5

4

3

2

1

697 811 12 14

13

10

MOTORCYCLE VIEWS

TOP VIEW

6

(1) Air suction valve

(3) Fuel valve

(2) Leg guard (Optional)

(5) Gear shift pedal

(6) Rider foot rest

(4) Carburetor

(12) Saree guard

(8) Side stand

(7) Main stand

(11) Seat lock/Helmet hanger

(10) Women pillion step

(9) Side cover left

(13) Rear turn signal lamp

(14) Reflex reflector

(15) Tail/Stop lamp

(16) Rear grip

(17) Front turn signal lamp

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

1

MOTORCYCLE VIEWS

LEFT SIDE VIEW

43

2

19

8

57

612

11

10

17

16

15

14

13

7

(5) Oil level dipstick

(1) Pillion foot rest

(2) Battery compartment (inside)

(3) Kick starter pedal

(4) Rider foot rest

(7) Starter motor (Optional)

(9) Front disc (Optional)

(10) Front suspension

(8) Caliper (Optional)

(6) Rear brake pedal (11) Headlamp

(12) Visor

(13) Document

compartment

(14) Rear suspension

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

13

MOTORCYCLE VIEWS

RIGHT SIDE VIEW

46

5

13

29

8

7

12

11

10

14

8

Sl. No. Description Function

(1) High beam indicator Light glows when Headlamp is in Hi Beam

(2) Neutral Indicator Light glows when vehicle is in neutral

(3) Speedometer Indicates driving speed

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

Indicates approximate fuel quantity in the form of digital

(5) Fuel gauge 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".

(6) Tripmeter Shows the distance traveled during a trip

(7) Service due indicator Displays when a service is due (page-11).

(8) Odometer Shows accumulated distance traveled

(9) Reset button To reset the tripmeter to zero before starting a new trip

The indicators are in the speedometer panel

above the headlamp. The functions are as

below.

Instruments and Indicators

PARTS FUNCTION 6

4

8

5

91

7

1 3

9

“OFF” Position/

Lock Open

“LOCK” Position

“ON” Position

Ignition switch

2

3

1

(1) Ignition switch

(2) Ignition key

(3) Steering lock position

The engine can be started, Turn signal indicator,

Horn, Tail/Stop lamp 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

10

Fuel gauge

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.

Tripmeter

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).

The Service Due Indicator (1) is to indicate to

an user to bring the vehicle to an Authorised

Hero MotoCorp workshop for service.

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.

Service due indicator

The Service Due Indicator can be reset at an

Authorised Hero MotoCorp workshop.

The indicator shall start blinking when the vehicle

covers 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.

(1) Fuel gauge (2) Segments

2

1

(1) Fuel gauge (2) Segments

5

3

6

4

7

(6) Reset button (7) Service reminder indicator

(3) Segment (4) Odometer (5) Tripmeter

LEFT HANDLEBAR CONTROLS

4

7

1

2

3

1. Passing switch

Gives an indication for passing ahead.

11

2. Headlamp switch

Functions in DC when the passing switch

knob is pressed in the following condition.

The switch has three positions.

îHeadlamp switch is “OFF”.

îHeadlamp switch is “ON” but on low beam.

Position

Action

Headlamp “ON”

“Following is “ON”

• Tail/Stop lamp

• Position lamp

“OFF”

marked by white dot.and

3. Headlamp dimmer switch

Select “ ” for high beam and “ ” for low beam.

Select “ ” to put the position lamp to “ON”.

4. Position lamp switch

5. Turn signal lamp switch

Shift the turn signal knob sideways for

right/left indications and leave it to come back

to its normal position on its own.

5

6

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.

6. Horn switch

IMPORTANT: To switch “OFF” the turn

signal after completing the turn, gently push

inside.

RIGHT HANDLEBAR CONTROLS

Starter Switch (For electric start model)

Press the switch to operate the horn.

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.

1

(1) Electric starter switch

Never hold starter switch continuously for

more than 5 seconds as continuously cranking

of engine will drain the battery.

CAUTION

12

SEAT LOCK/HELMET HANGER

Location: On the rear left side of the seat,

below the rear cowl.

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.

STEERING LOCK

1

(1) Ignition key

(1) Seat Lock (2) Knob (3) Helmet Hanger

1

2 3

Operation: Insert the key and turn it

clockwise. Pull the knob 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

clicks.

The helmet can be hung and locked on the

hook provided with the seat lock by rotating

the key.

FUEL VALVE

“OFF” Position

At “OFF” position, fuel cannot flow from the

tank to the carburetor. Turn the valve “OFF”

whenever the motorcycle is not in use.

The three way fuel valve is on the left side of

the carburetor.

At “ON” position, fuel will flow from fuel tank

to the carburetor.

“ON” Position

(1) “OFF” Position

1

13

2

“RES” Position

At "RES", 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 usable reserve fuel supply is 1.0

litre.

3

(2) “ON” Position

(3) “RESERVE” Position

îTo remove the fuel tank cap (1), open the

key hole cover (2) and insert the ignition

key (3), turn it clockwise and remove the

fuel tank cap.

FUEL TANK

Fuel tank capacity is 9.5 litres (minimum)

including a reserve supply of 2.1 litres

(usable).

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

11 2

(1) Fuel tank cap (2) Key hole cover

(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

2

14

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

motorcycle is refilled or where petrol is stored.

WARNING

Use hero genuine engine oil or recommended

grade oil.

îSavita Oil Technologies Limited.

îBharat Petroleum Corporation Limited.

îTide Water Oil Co. (India) Ltd.

ENGINE OIL

Manufactured by:

OIL CAPACITY: 1 litre

GRADE: SAE 10W 30 SL Grade

(JASO MA2).

BRAND: Hero 4T plus

Engine Oil Level Check

Check engine oil level each day before

operating the motorcycle.

Do top up if oil level reaches towards the lower

level mark or every 3000 km whichever is

earlier.

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.

ENGINE OIL TOP UP PROCESS

îPark the motorcycle on its main stand.

îStart the engine & let it idle for 3-5 minutes.

(1) Oil level dipstick (2) Upper level mark

(3) Lower level mark

UPPER

LOWER

3

2

1

3

îStop the engine & place the motorcycle on its

main stand on level ground, remove the oil

level dipstick and wipe it clean.

îIf required, add the specified oil up to the

upper level mark. Do not overfill.

îReinsert the oil level dipstick without

screwing it in and check the oil level.

15

î Reinstall the oil level dipstick and check for

oil leaks.

ENGINE OIL REPLACEMENT PROCESS

Drain engine oil with the engine warm and the

motorcycle on its main stand.

îTo drain the oil, remove the oil level dipstick

and drain plug (1).

îAfter the oil has completely drained, make

sure that the sealing washer is in good

condition and reinstall the drain plug.

îStart the engine and allow it to idle for few

minutes.

îFill the crankcase through the filler hole with

approximately 0.85 litre of the recommended

grade oil at draining.

îReinstall the oil level dipstick.

(1) Drain plug (2) Sealing washer

2

1

mark of the oil level dipstick with the

motorcycle in an upright position and that

there are no oil leaks.

îEngine oil is a major factor affecting the

performance and service life of the engine.

Non-detergent, vegetable or castor based

racing oils are not recommended.

îRunning the engine with insufficient

oil can cause serious engine damage.

îRunning the engine with excessive oil can

cause spark plug fouling & loss in

performance.

CAUTION

The tyres that are fitted on your motorcycle are

designed to match the performance capabilities

of your motorcycle and provide the best

combination of handling, braking, durability

and comfort.

TYRES

To safely operate your motorcycle, the tyres

must be of recommended type and size, in

good condition with adequate tread, and

correctly inflated. The recommended tyres

size is:

Front

Rear

18/100x18-47P

90/90x18-51P

Properly inflated tyres provide the best

combination of handling, tread life, and riding

Air Pressure

comfort. Generally, under inflated tyres wear

unevenly, adversely affect handling, and are

îStop the engine.

îMake sure that oil level is at the “UPPER”

level

16

more likely to fail from being overheated.

Under inflated tyres can also cause wheel

damage in rocky terrain. Over inflated tyres

make your motorcycle ride more harshly, are

more prone to damage from surface hazards

and wear unevenly.

1

(1) Air pressure gauge

Front

Rear

2

1.75 kgf/cm (25 psi)

2

2.00 kgf/cm (29 psi)

2

1.75 kgf/cm (25 psi)

2

2.25 kgf/cm (33 psi)

Rider only Rider and Pillion

The recommended “cold” tyre pressure are:

If necessary, install a new cap.

Make sure the valve stem caps are secure.

Over inflation/Under inflation will affect the

performance.

CAUTION

Whenever you check the tyre pressure, you

should also examine tyre treads & side walls

for wear, damage & foreign objects:

Inspection

îCuts, splits or cracks in the tyre. Replace the

tyre if you can see fabric or cord.

Replace tyres immediately when the wear

indicator (1) appears on the tyre. The tread

limits are:

MINIMUM TREAD DEPTH:

îBumps or bulges in the side of the tyre or the tread.

Replace the tyre if you find any bumps or bulges.

Look for:

Front:1.0 mm Rear: 1.0 mm

Also, if you hit a pothole or hard object, pull to

the side of the road as soon as you safely can

and carefully inspect the tyres for damage.

Check the tread wear indicator (1) for tyre wear.

îExcessive tread wear.

Tread Wear

Unidirectional Tyres

Ensure the arrow mark (2) on the tyre is in

the same direction as that of forward

rotation of the wheel, whenever the tyre is

removed and put back in case of puncture.

(1) Tread wear indicator (2) Arrow mark

2

17

1

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HERO Passion Xpro Owner's manual

HERO Passion Xpro Owner's manual

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