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
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)
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.
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
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
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