PREFACE No : IB14D

Thank you for selecting a HMCL Niloy Bangladesh Ltd. Passion XPRO. We wish you many
miles of continued riding pleasure in the years ahead.
We at HMCL Niloy Bangladesh Ltd., 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 environment legislation and strengthen
the green supply chain.
This booklet is your guide to the basic operation and maintenance of your new
HMCL Niloy Bangladesh Ltd. 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.
Authorised Distributor or the authorised dealer(s) of the Distributor ("Dealer") will be glad
to provide further information or assistance and to handle your future service needs.
Let us make this world a safer, healthier and more environment friendly place.
 NOTE
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.
HMCL Niloy Bangladesh 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 HMCL Niloy Bangladesh Ltd.
 CONTENTS
Pg. No. Pg. No.
VEHICLE IDENTIFICATION 1 SPARK PLUG INSPECTION 37
VEHICLE VIEWS 2 ENGINE OIL 37
VEHICLE SPECIFICATION 5 OIL FILTER SCREEN & CENTRIFUGAL FILTER 39
ACCESSORIES & MODIFICATIONS 7 AIR CLEANER 40
ANTI-THEFT TIPS 7 CARBURETOR 42
VEHICLE SAFETY 8 VALVE CLEARANCE ADJUSTMENT 42
Ÿ Important safety information 8 CLUTCH LEVER FREE PLAY 44
Ÿ Protective apparel 9 THROTTLE OPERATION 45
SAFE RIDING TIPS 10 DRIVE CHAIN SLACKNESS 46
TIPS FOR HEALTHY ENVIRONMENT 11 DRIVE CHAIN SLIDER INSPECTION 48
PARTS FUNCTION 12 BRAKES 48
Ÿ Ignition switch 12 SUSPENSION 51
Ÿ Instruments and Indicators 13 WHEEL 52
LCD panel 15 MAIN/SIDE STAND LUBRICATION 54
FEATURES 16 TUBELESS TYRES 54
HANDLEBAR SWITCHES CONTROL 21 NUTS, BOLTS & FASTENERS 57
i3s (IDLE STOP START SYSTEM) 22 BATTERY 57
SIDE STAND INDICATOR/SWITCH 24 FUSE REPLACEMENT 59
FUEL TANK 24 STOP LAMP SWITCH 60
FUEL VALVE 25 HEADLAMP FOCUS ADJUSTMENT 61
USB CHARGER 26 CATALYTIC CONVERTER 61
SEAT LOCK/HELMET HANGER 27 AIR SUCTION VALVE (ASV) 61
PRE-RIDE INSPECTION 28 EVAPORATIVE EMISSION CONTROL SYSTEM 62
STARTING THE ENGINE 29 POLISHING OF VEHICLE 62
RIDING 30 BASIC TROUBLESHOOTING 63
BRAKING 30 DELIVERY CERTIFICATE
PARKING 31 GENUINE PARTS
TOOL KIT 31 JOBS APPLICABLE TO PERIODIC SERVICES
CLEANING AND WASHING OF VEHICLE 32 SERVICE RECORD SHEET
MAINTENANCE 32 SERVICE ADVICE SHEET
SAFETY PRECAUTIONS 33 OWNERSHIP RECORD AND DATA
MAINTENANCE SCHEDULE 34
 VEHICLE IDENTIFICATION

PS1J
JA06EC#

AW2
#######

3###
####
##
Vehicle Identification Number (VIN) Engine No.
Location: Stamped on the right side of the Location: Stamped on the lower side of the
steering head tube. left crankcase.
VIN: PS1JAW23#########
PS1 JAW23 # # # # #####
Manufacturer Vehicle Check Model Year Plant Month of Production
code Description Digit Code Manufacturing Serial Number
Engine No.: JA06EC########
JA06EC # # # #####
Engine Year of Assembly Plant Month of Serial Number
Description Manufacturing Manufacturing
Model: Passion XPRO
Variants VIN Engine
Cast wheel/Electric start/Disc/IBS JAW23 JA06EC
VIN and Engine No. may be required:
1. During registration of the vehicle.
2. For dealing with legal & insurance departments.
1
 VEHICLE VIEWS
TOP VIEW 8 9 10 11 12 13 14 15 16

6 17
5
18
4
19
3
20
2
21
1 22

(1) Fuel tank cap (11) Side stand indicator

(2) USB charger (12) Turn signal indicator
(3) Dimmer switch (13) High beam indicator
(4) Horn switch (14) i3s indicator
(5) Turn signal switch (15) Master cylinder/Reservoir
(6) Clutch lever (16) i3s switch
(7) Rear view mirror (17) Front brake lever
(8) Pass lamp switch (18) Throttle grip
(9) Mode button (19) Electric starter switch
(10) LCD panel of Meter console. (20) Neutral indicator
Refer instruments and indicators (21) Ignition switch with steering lock
(page 15) for fuel gauge, (22) Leg guard
speedometer and other features
of console
*Accessories and features shown may not be part of standard fitment.
2
LEFT SIDE VIEW
17 16 15

18
14
13
12

11

11 2 3 4 5 6 7 8 9 10
(1) Air suction valve (inside) (8) Side stand (13) Licence plate lamp
(2) Fuel valve (9) Saree guard with women (14) Tail/Stop lamp
(3) Carburetor pillion step (15) Rear grip
(4) Gearshift pedal (10) Seat lock/Helmet hanger (16) Seat
(5) Rider footrest (11) Reflex reflector (17) Left side cover
(6) Side stand switch (12) Rear turn signal lamp (18) Front turn signal lamp
(7) Main stand
*Accessories and features shown may not be part of standard fitment.
3
RIGHT SIDE VIEW
16

15

14

13

17

1 2 23 4 5 6 7 8 9 10 11 12
(1) Exhaust muffler (6) Rider footrest (12) Side reflex reflector
(2) Pillion footrest (7) Starter motor (13) Front suspension
(3) Rear master cylinder (8) Rear brake pedal (14) Headlamp
(inside) (9) Oil level dipstick (15) Front visor
(4) Brake fluid reservoir (10) Caliper assembly (16) Battery compartment (inside)
(inside) (11) Front disc (17) Rear shock absorber
(5) Kick starter pedal
*Accessories and features shown may not be part of standard fitment.
4
VEHICLE SPECIFICATION
ITEM SPECIFICATIONS
Dimensions
Overall length 1967 mm
Overall width 768 mm
Overall height 1075mm
Wheelbase 1249 mm
Saddle height 798 mm
Ground clearance 165 mm
Weight
Kerb weight 121 kg (Self/Cast/Disc)
Payload 130kg (Rider 75Kg+ Pillion 55Kg)
Capacities
Engine oil 1.25 liters at disassembly and 1.1 liters at draining
Fuel tank 9.2 litres (Minimum)
Fuel reserve capacity 1.3 litre (Usable)
Front fork oil disassembly 163±1.75 ml
Engine
Maximum power 6.70 kW (9.11 Ps) @ 7500 rpm
Maximum torque 0.92 kgf-m (9.0 N-m) @ 5500 rpm
Bore and stroke 50.3x49.5 mm
Compression ratio 10:1
Displacement 109.15 cc
Spark plug NGK-CR7HSA, BOSCH-UR4AC
Spark plug gap 0.6-0.7 mm
Valve clearance (cold) Intake (cold) 0.10 mm
Exhaust (cold) 0.12 mm
Idle speed 1400±100 rpm
Chassis and suspension
Front suspension Telescopic hydraulic shock absorbers
Rear suspension Swingarm with 5 step adjustable hydraulic
shock absorbers
Caster angle 26°
Trail length 90.3 mm
5
VEHICLE SPECIFICATION
ITEM SPECIFICATIONS
Tyre size Front 80/100-18 M/C 47P (Tubeless Tyre)
Rear 90/90-18 M/C 51P (Tubeless Tyre)
Front (Disc variant) Dia. 240 mm
Brakes Rear (Drum variant) Dia. 130 mm (Internal Expanding Shoe Type)
(Integrated Braking System)
Front wheel Cast wheel
Rear wheel Cast wheel
Transmission
Primary reduction 3.722 (67/18)
Final reduction 2.857 (40/14)
Gear ratio,1stnd 3.182 (35/11)
2 1.706 (29/17)
3rdth 1.238 (26/21)
4 0.958 (23/24)
Electricals
Battery *MF Battery 12V-3Ah/ETZ4
Alternator 120 W @ 5000 rpm
Headlamp (High/Low) LED
Tail/Stop lamp LED
Turn signal lamp 12V-10Wx4 Nos.(Amber bulb) with clear lens-**MFR
Meter illumination LED
Neutral indicator LED
Turn signal indicator LED
Hi beam indicator LED
Licence plate lamp 12V-5.0W
i3s indicator LED
Side stand indicator LED
Fuse 20A,15Ax2
*MF stands for Maintenance Free
**MFR stands for Multi-Focal Reflector

6
ACCESSORIES & MODIFICATIONS operation. Such changes could seriously
Modifying your vehicle or using non-genuine impair your vehicle's handling, stability and
accessories can make your vehicle unsafe. braking, making it unsafe to ride. Removing or
Before you consider making any modifications modifying your lamps, mufflers, emission
or adding an accessory, be sure to read the control system or other equipment can also
following information. make your vehicle illegal.
! WARNING
ANTI-THEFT TIPS
• Always lock the steering and never leave the
• Improper accessories or modifications can key in the ignition switch. This sounds
cause a crash in which you can be seriously simple but people do forgets.
hurt or killed. • Be sure the registration information for your
• Follow all instructions in this owner's manual vehicle is accurate and correct.
regarding accessories and modifications. • Park your vehicle in a locked garage
Accessories whenever possible.
• Make sure that the accessory does not • Use an additional anti-theft device of good
obscure any lamps, reduce ground quality.
clearance, limit suspension travel or steering • Never park your vehicle in an isolated area.
travel, affect your riding position or interfere Park as for as possible in a designated area.
with operating any controls. • Enter your name, address and phone
• Be sure electrical equipment does not number in this Owner's Manual and keep it
exceed the vehicle's electrical system in your vehicle at all times. Many times
capacity (page 6). A blown fuse can cause a stolen vehicles are identified by information
loss of lights. in the Owner's Manuals that are still with
• Do not pull a trailer or sidecar with your them.
vehicle. This vehicle was not designed for
these attachments, and their use can NAME: _____________________________________________
seriously impair your vehicle's handling. ADDRESS: _______________________________________
Modifications _______________________________________________________
We strongly advise you not to remove any _______________________________________________________
original equipment or modify your vehicle in _______________________________________________________
any way that would change its design or
PHONE NO : _____________________________________

7
VEHICLE SAFETY
IMPORTANT SAFETY INFORMATION
Your vehicle can provide many years of
service and pleasure if you take responsibility
for your own safety and understand the
challenges you can meet on the road.
There is much that you can do to protect
yourself when you ride. You will find many
helpful recommendations through out this
manual. Following are a few that we consider
most important.
Always wear a helmet
It is a proven fact, Helmet significantly reduces
the number and severity of head injuries. So
always wear a helmet and make sure your
pillion rider does the same. We also
recommend that you wear eye protection,
sturdy boots, gloves and other protective gear.
Before riding your vehicle
Make sure that you are physically fit, mentally
focused and free of alcohol and drugs. Check
that you and your pillion are both wearing an
approved vehicle helmet and protective
apparel. Instruct your pillion on holding onto
the grab rail or your waist, leaning with you in
turns, and keeping their feet on the footrest,
even when the vehicle is stopped.
Take time to learn & practice your
vehicle
Even if you have ridden other vehicles,
practice riding in a safe area to become
familiar with how this vehicle works and
handles, and to become accustomed to the
vehicle's size and weight.
Ride defensively
Always pay due attention to other vehicles
around you, and do not assume that other
drivers see you. Be prepared to stop quickly or
perform an evasive maneuver.
Make yourself easily visible
Some drivers do not see vehicles because they
are not looking for them. To make yourself more
visible, wear bright reflective clothing, position
yourself so that others can see you, signal before
turning or changing lanes, and use horn which
will help others to notice you.
Ride within your limits
Pushing the limits is another major cause of
vehicle accidents. Never ride beyond your
personal abilities or faster than conditions
demand. Remember that fatigue and
negligence can significantly reduce your ability
to make good judgements and ride safely.
Do not drink and ride
Riding under the influence of alcohol or drugs
is dangerous. Alcohol can reduce your ability
to respond to changing conditions and reduce
the reaction time. Do not drink and ride.
Keep your vehicle in safe condition
For safe riding, its important to inspect your
vehicle before every ride and perform all
recommended maintenance. Never exceed
load limits, and only use accessories that have
been approved by HMCL Niloy Bangladesh
Ltd. for this vehicle.
8
If you are involved in a crash
Personal safety is your first priority. If you or
anyone else has been injured, take time to
assess the severity of the injuries and whether
it is safe to continue riding. Call for emergency
assistance if needed. Also follow applicable
laws and regulations if another person or
vehicle is involved in the crash.
If you decide to continue riding, first evaluate
the condition of your vehicle. If the engine is
still running, turn it off. Inspect for fluid leaks,
check the tightness of critical nuts and bolts,
and check the handlebar, brake levers, brakes,
and wheels. Ride slowly and cautiously. Your
vehicle may have suffered damage that is not
immediately apparent. Have your vehicle
thoroughly checked at a qualified service
facility as soon as possible.
PROTECTIVE APPAREL
For your safety, we strongly recommend that
you always wear a helmet which should
conform as per your country standards, in
addition to eye protection, boots, gloves, long
pants and a long sleeve shirt or jacket
whenever you ride. Take care of loose/
hanging clothes while solo/pillion riding.
Although complete protection is not possible,
wearing proper gear can reduce the chance of
injury when you ride.
Following are suggestions to help you choose
proper riding gear.
! WARNING
• Not wearing a helmet increases the chance of
serious injury or death in a crash.
• Be sure you and your pillion always wear a
helmet, eye protection and other protective
apparel when you ride.
Helmets and eye protection
Your helmet is your most important piece of
riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and securely.
A bright coloured helmet can make you more
noticeable in traffic, as can reflective strips.
An open-face helmet offers some protection,
but a full-face helmet offers more. Always
were face shield or goggles to protect your
eyes and help your vision.
Additional riding gear
In addition to a helmet and eye protection, we
also recommend:
• Sturdy boots with non-slip soles to help
protect your feet and ankles.
• Leather gloves to keep your hands warm
and help prevent blisters, cuts, burns, and
bruises.
• A two wheeler riding suit or jacket for
comfort as well as protection. Bright
coloured reflective clothing can help make
you more noticeable in traffic. Be sure to
avoid loose clothes that could get caught on
any part of your vehicle.
9
 SAFE RIDING TIPS
Do's: Don't
• Always conduct simple pre-ride inspection • Never use cell phone while riding the
(page 28). vehicle.
• Always wear a helmet with chinstrap
Avoid sudden acceleration, braking and
securely fastened and insist on a helmet for • turning
your pillion rider. Helmet should conform as of your vehicle.
per safety standards applicable in your • Never shift gears without disengaging the
country. clutch and closing the throttle.
• While riding, sit in a comfortable position •
with your legs close to fuel tank. Never touch any part of the hot exhaust
• Ride defensively and at a steady speed system like muffler.
(between 40-50 km/hr). • Never ride under the influence of alcohol or
• To stop the vehicle (in IBS), press the rear drugs.
brake pedal for the application of front and
rear brakes simultaneously. However, for • Concentrate on the road and avoid talking
more effective braking, it is advised to apply , • to the pillion rider or others on the road.
both brakes simultaneously, keeping the Do not litter the road.
throttle in the close position. • Do not cross the continuous white/yellow
• During night time, dip headlamps of your line in the center of the road, while
vehicle for oncoming traffic, or when overtaking.
following another vehicle.
• Give way to others on the road and signal • Do not attach large or heavy items to the
before you make a turn. handlebars, front forks, or fenders.
• To make yourself more visible, wear bright • Never take your hands off the steering
reflective clothing that fits well. handle while riding.
• Tightly wrap loose/hanging clothes & avoid
entangling with moving parts.
• Get your vehicle serviced regularly by the
Authorised Distributor/ Dealer.
• Before riding make sure in which mode you
are riding whether with i3s switch “ON’ or
“OFF”.
10
TIPS FOR HEALTHY ENVIRONMENT
The following tips shall ensure a healthy vehicle, healthy environment, and a healthy you.
• Healthy 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.
• Regular servicing: Get your vehicle serviced at an Authorised Distributor/Dealer, as per
the service schedule, for an optimum performance and keep the emission level under check.
• Genuine spares: Always insist on genuine parts as spurious or incompatible spares and
accessories can upset or deteriorate your vehicle’s running condition.
• Genuine engine oil: Hero 4T Plus SAE 10W 30 SL grade (JASO MA2) engine oil
recommended by HMCL Niloy Bangladesh Ltd. and make sure you change it every 6000
kms. (with top up every 3000 kilometres) to keep the engine fit and environment healthy.
• Noise pollution : Noise beyond a certain decibel is pollution. Whether it is from horns or
defective mufflers, excessive noise will cause headaches and discomfort.
• Fuel 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.

11
PARTS FUNCTION 3
Ignition switch “ON” ( )
position

“OFF”( )
position/
Lock open
1 2
(1) Steering lock position
(2) Ignition switch
“LOCK” position (3) Ignition key

Key position Function Key removal

The LCD panel illuminates & initial display of multi
function digital segments are displayed. The fuel
gauge segment will swing to the maximum scale
once and back to its normal position. The
speedometer and odometer will go to their
maximum values and will come back to its their
“ON” ( ) normal readings. Scroll message will appear in LCD Key cannot be removed
panel. The engine can be started. Turn signal lamp,
horn, tail/stop lamp, fuel gauge, passing switch &
neutral indicator will be functional.
“OFF”( ) Engine cannot be started and no electrical system Key can be removed
will be functional.
“LOCK” Steering can be locked. Key can be removed

12
Instruments and Indicators 1 2 3 456 7 8
The indicators are in the speedometer panel
above the headlamp. The functions are as
below. 17
16 TRIP
AB
km/h
odo
km
9
15 MODE
10
HERO MOTOCORP

MODE 14 13 12 11
Sl. No. Description Function
1 Service reminder
indicator Displays when the next service is due (page 16).
If your smartphone is paired with the meter console of your
2 Incoming call alert vehicle via bluetooth (page 17), then you will get all the
incoming call alert on the meter console (page 19).
If your smartphone is paired with the meter console of your
3 Missed call alert vehicle via bluetooth (page 17), then you will get all the
missed call alert on the meter console (page 20).
If your smartphone (android) is paired with the meter
4 Message alert console of your vehicle via bluetooth (page 17), then you
will get all the message alert on the meter console (page 20).
Indicates approximate fuel available in the form of
5 Fuel gauge digital segments. The digital segments will swing to
maximum scale on the meter console once the ignition
switch is turned “ON” ( ) (page 15).
6 Side stand indicator Light glows when the vehicle is parked on the side stand.
7 Turn signal indicators Flashes when turn signal switch is operated.
8 High beam indicator Light glows when headlamp is in “Hi” beam.
13
Sl. No. Description Function
9 i3s indicator Indicator glows for 2 seconds and turns “OFF” indicating
that i3s system is functional.
10 Neutral indicator Light glows when vehicle is in neutral position.
11 Bluetooth On pairing (page 17), meter console display bluetooth
symbol in bluetooth connected.
If your smartphone is paired with the meter console of your
12 Phone battery status vehicle via bluetooth (page 17), then it will display battery
status of smartphone on the meter console (page 20).
13 Odometer Shows accumulated distance travelled (page 15).
14 Mode button Switches display between odometer, tripmeter-A & B,
and bluetooth connectivity.
15 Scroll display Displays a scrolling “HELLO HERO MOTOCORP” message for few
seconds when the ignition key is turned “ON” (page 16).
16 Tripmeter Shows the distance travelled during a trip after setting to
zero (page 15).
17 Speedometer Indicates driving speed.

14
LCD PANEL
(a) Odometer
The odometer (1) shows accumulated
distance travelled. The odometer can be
selected by pressing the mode button (2). 1 TRIP
AB
km/h
odo
km

MODE

2
TRIP
AB
km/h
odo
km
(1) Tripmeter (2) Mode button
(c) Fuel gauge
2 MODE
The fuel gauge (1) indicates approximate fuel
available in the form of digital segments.
1 The digital segments (2) will swing to
(1) Odometer maximum scale on the meter console once the
(2) Mode button ignition switch is turned “ON” ( ). If all the
(b) Tripmeter segments are displayed it means fuel quantity
The tripmeter (1) shows distance travelled in the fuel tank is 10 litres.
per trip. The tripmeter can be reset to zero by 2
pressing the mode button (2) for more than 2
seconds. The tripmeter can be selected by
pressing the mode button.
The tripmeter (1) shows distance travelled
since trip meter was reset last time. There are
two tripmeters, “Trip-A” and “Trip-B”.
Push the mode button (2) to select “Trip-A”
and “Trip-B”. “Trip-A” and “Trip-B” can be
displayed upto "999.9" km. 1
If the tripmeter exceeds "999.9" km it will (1) Fuel gauge (2) Segments
return to "0.0" km automatically.
15
(d) Scroll message NOTE
The scroll (1) display a message “HELLO HERO After getting the vehicle
MOTOCORP” after for few seconds whenever the that the service reminderserviced, make sure
indicator has been
ignition is turned “ON”. reset.
NOTE 1
If the user name “VIJAY” is assigned in hero
ride guide application (page 18) then user
name will come as “HELLO VIJAY“, instead of
“HELLO HERO MOTOCORP“

km/h
odo
HERO MOTOCORP km
(1) Service reminder indicator
MODE
FEATURES
(a) Steering lock
1 Steering lock with ignition switch, turn the
(1) Scroll message ignition key (1) to “OFF” ( ) position & turn
(e) Service reminder indicator 1
The service reminder indicator (1) is to
indicate user to bring the vehicle to an
Authorised Distributor/Dealer for service. 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. The service reminder
indicator can be reset at an Authorised (1) Ignition key
Distributor/Dealer.
16
the handlebar towards left or right & push the
key downwards & turn towards “LOCK”
position. After locking take out the ignition
key.
(b) Hero ride guide
Application:
Hero ride guide is available in the google play
store (for androids) or App Store (for iOS),
which can be installed in your device to access
bluetooth, incoming calls alerts, missed call 1
alerts, mobile battery status and message alert. (1) Access for incoming call information on
NOTE digital cluster
• Compatibility and performance of hero ride • For first time pairing, allow the application
guide application may vary based on your to access:
device and software version.
• Application needs GPS signal, internet and a. Contacts
bluetooth connectivity to perform the c. b. Make & manage phone calls
desired functionality. Phone call logs on your device
d. Device’s location if GPS is not enabled in
Bluetooth: your device
Your vehicle is equipped with bluetooth
connectivity feature by which you can pair a b
your smartphone with the meter console of
your Passion XPRO vehicle through hero
ride guide application. ALLOW
To connect your device proceed as follows:
• Turn the ignition switch “ON”.
• Open hero ride guide application on your
smartphone.
• Give access to show incoming call
information on digital cluster (1).

17
c d 3

ALLOW

4
(3) Select your vehicle
(4) Battery optimization
• The application searches for a while and
displays all compatible nearby devices.
Select the device with your name (5).
• Update your name (6) (if required) and
select either save and connect (7) or
connect (8) to proceed.
2
(2) Accept terms of use
• Then the application will automatically start. Xyz
• Application also asks you to accept (2) the Xyz

terms of use to proceed.

• Now select your vehicle (3).
• Now application asks the user to turn the
battery optimization off (4). It can be done
by following the steps which are mentioned 5 6 7 8
in the application or the user can ignore this (5) Select your device (6) Update your name
step. (7) Save and connect (8) Connect
18
• Now application will send paring request
notification (9). Click on the notification.
• Now meter console will display paring pin
(10) in place of odometer reading.
• Enter the pin in application screen and
select “OK” (11). km/h
10 odo
km

12
km/h
XXXXXX

(12) Bluetooth symbol

Autopairing
Your vehicle is equipped with autopairing
feature by which if you turn ''OFF'' vehicle's
ignition switch after successful pairing with
hero ride guide application, it will reconnect
9 11 automatically
''ON''.
once ignition switch is turned
(9) Pairing request notification
(10) Pin (11) “OK” NOTE
• On pairing, meter console displays • vehicle Always keep your smartphone close to your
bluetooth symbol (12) which indicates that autopairing. during the course of pairing,
bluetooth is connected . • Application need to be running in the
• If any error occurs during the course of background.
pairing process, then meter console will not
display bluetooth symbol. Repeat the above Incoming call alert
steps and keep your smartphone closer to If your smartphone is paired with the meter
the vehicle to reconnect. console of your vehicle via bluetooth (page
17), then you will get all the incoming calls
alerts (1) on the meter console.
19
 1 Message alert:
If your smartphone (android) is paired with
the meter console of your vehicle via bluetooth
(page 17), then you will get all the message
alerts (1) on the meter console.
km/h
1
odo
km

(1) Incoming call alert km/h

odo
km
Missed call alert:
If your smartphone is paired with the meter
console of your vehicle via bluetooth (page
17), then you will get all the missed calls alerts
(1) on the meter console. (1) Message alert
1 Phone battery status:
If your smartphone is paired with the meter
console of your vehicle via bluetooth
(page 17), then it will display phone battery
status (1) of your smartphone on the meter
km/h console.
TRIP
AB
odo
km 4 bar display – 80-100%
3 bar display – 60-79%
2 bar display – 40-59%
1 bar display – 20-39%
(1) Missed call alert 1 bar blinks with outer line display – 1-19%.

20
 2. Passing switch
80-100%
Gives an indication for passing ahead.
Press passing lamp switch (2) to operate the
60-79% passing lamp.
km/h
40-59% 3. Dimmer switch
odo
km
20-39% Select “ ” for high beam and “ ” for
1-19% (Blink)
low beam.
4. Turn signal lamp switch ( )
1 Shift the turn signal lamp switch (4) sideways
(1) Phone battery status for right/left indications and leave it to come
HANDLEBAR SWITCHES CONTROL IMPORTANT: back to its normal position on its own.
Left handlebar controls To switch “OFF” the turn
signal after completing the turn, gently push
1. Clutch switch inside.
There is a clutch switch (1) provided for the 5. Horn switch ( )
safety of the rider. The vehicle cannot be Press the horn switch (5) to operate the horn.
started by electric starter switch until the clutch
lever is operated when the vehicle is engaged
in gear.
2 1

4
5
3
(4) Turn signal lamp switch
(5) Horn switch
(1) Clutch switch (2) Passing switch
(3) Dimmer switch
17
21
Right handlebar controls 2. i3s switch
1. Electric starter switch ( ) There is an i3s switch (2) provided to enable
Ensure starter switch (1) is operated when the the rider for turning i3s mode “ON” or “OFF”
vehicle is in neutral gear. If the vehicle is based on the traffic conditions.
engaged in gear press the clutch lever before i3s (IDLE STOP START SYSTEM)
operating the starter switch. Release starter Starting & Warm up the engine:
switch after the engine has started. Keep the i3s switch (1) to “OFF” position.
! CAUTION Turn the ignition key to “ON” ( ) position. the
• Never hold electric starter switch continuously i3s indicator (2) will glow on the speedometer
more than 5 seconds as continuous cranking console for 2 seconds and turn “OFF”. Start the
of engine will drain the battery. engine and let it idle for 2-3 minutes.
• During electric or clutch start, the engine
will cut-off if engine reaches 900 rpm if the NOTE
relay is engaged for more than 5 seconds. • The engine will stall if the i3s switch is in
2 “ON” position during warmup.
• Use choke during cold conditions.
1

1
(1) Electric starter switch (2) i3s switch
(1) i3s switch

22

2 vehicles and no special functions will be
(2) i3s indicator
Initial Activation of the i3s system:
Keep the i3s switch (1) to “ON” position.
Turn the Ignition key to “ON” ( ) position.
The i3s indicator (2) on the speedometer
console will glow for 2 seconds and turn
“OFF”. Start the vehicle and allow the engine
transmission to run in neutral with the rpm less
than 2000 rpm. The engine will cut off in
30 secs. After the first stop start every
subsequent stop will be in 5 secs.
In this condition, the engine can be restarted
either with kick or electric start only.
Driving with i3s Switch in “ON”
position:
While driving, if the engine is kept idling (while
waiting in a traffic signal), the engine will cut
off in 5 secs. (The vehicle should be in neutral
at less then 2000 rpm with clutch
lever/throttle is in released position). By
pressing the clutch lever, the engine will start
23
again and gear can be engaged to move the
vehicle.
Driving with i3s Switch in “OFF”
position:
While driving in a traffic jam/or very dense
traffic where the vehicle has to encounter a
stop and go situation, the i3s switch can be
changed to “OFF” position. Once this is done,
the i3s system will not work and the vehicle
will be in normal operating conditions as other
performed.
NOTE
• If the battery voltage is low, the i3s system
will not work. The i3s indicator on the
speedometer console will start to blink, if the
rpm is less than 2000 rpm and the i3s
indicator goes off if the rpm is more than
2000 rpm. The vehicle will be in normal
operating conditions as other vehicles and
no special functions will be performed.
• If the vehicle is driven without battery or with
the dead battery, the i3s system will not
work. The i3s indicator on the speedometer
console will start to glow continuously. The
vehicle will be in normal operating
conditions as other vehicles and no special
functions will be performed.
• During electric or clutch start, the engine will
cut-off
• if engine reaches 900 rpm
• if the relay is engaged for more than 5
seconds.
SIDE STAND INDICATOR/SWITCH FUEL TANK
For the safety of the customer a side stand Fuel tank capacity is 9.2 litres including
indicator (1) is provided. reserve supply of 1.3 litres (usable reserve).
1 • To remove the fuel tank cap (1), open the
key hole cover (2) and insert the ignition key
(3) turn it clockwise and remove the cap.
3

2 1
(1) Side stand indicator
A side stand switch (2) 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 (1) Fuel tank cap (2) Key hole cover
speedometer panel. (3) Ignition key
4 5

(2) Side stand switch (4) Filler Neck (5) Fuel

24
• Do not overfill the tank, there should be no
fuel in the filler neck (4). Fill the tank with
fuel (5) as shown.
• For locking, position the cap back on the
opening and press gently. The key springs
back to the normal position and the cap gets 1
locked.
! CAUTION
Do not park the vehicle under direct sunlight
as it causes evaporation of petrol due to heat
and deterioration of paint gloss due to ultra (1) “OFF” ( ) position
violet rays.
! WARNING “ON” ( ) position
Petrol is extremely flammable and is explosive At “ON” position (2), fuel will flow from the
under certain conditions. Refill in a well tank to the carburetor.
ventilated area with the engine stopped. Do
not smoke or allow flames or sparks in the
area where the vehicle is refilled or where
petrol is stored.

FUEL VALVE
The three way fuel valve is on the left side of 2
the carburetor.
“OFF” ( ) position
At “OFF” position (1), fuel cannot flow from
the tank to the carburetor. Turn the valve (2) “ON” ( ) position
“OFF” whenever the vehicle is not in use.

25
“RES” ( ) position Use of non-standard USB cable may cause
At "RES" position (3), fuel will flow from the damage to the mobile phones.
reserve fuel supply to the carburetor.
Use the reserve fuel only when the main 3 2
supply is exhausted. Refill the tank as soon as
possible after switching to "RES". The reserve
fuel supply is 1.3 litres (usable reserve).

3
1
(1) USB charger (2) Cap (3) Front cowl
To connect a mobile phone to the charger,
first open the cap from the USB charger and
then plug in the charger cable to it. HMCL
(3) “RES” ( ) Position Niloy Bangladesh Ltd. will not be responsible
for damages caused due to use of non
NOTE standard USB cable.
• Do not operate the vehicle with the fuel valve
in the “RES” ( ) position after refilling. You ! CAUTION
may run out of fuel, with no reserve.
• • Always place the device in a soft clean
Do not keep the fuel valve between “ON” ( ) cloth/towel to avoid any damage due to
and “OFF” ( ) position while driving, since road shocks while riding.
this may drain reserve fuel from the tank. • Multiple charging of USB devices has to be
USB CHARGER avoided, simultaneous charging may lead to
A USB charger (1) with a cap (2) located on • slow or no charging.
the left side of the front cowl (3) near meter USB port is for charging compatible USB
console to charge your mobile phone safely devices.
while riding.
26
• Do not leave the USB device and USB cable SEAT LOCK/HELMET HANGER
in the fuel tank cover when the vehicle is Location: On the rear left side of the seat,
parked. below the rear cowl.
• Charge your device when the engine is Operation: Insert the key (1) and turn it
operational/while riding. clockwise. Pull the knob (2) downwards to
• USB charger will not be covered under
warranty in case of USB charger cap release the seat. To install, engage the hook on
damage. the underside of the seat with the frame and
push on the top rear side of the seat until the
NOTE lock clicks.
• Do not apply any soap solution, oil or 1
grease inside the USB charger.
• Any personal belongings have to be
removed before water washing to avoid
damage.
• Always keep the USB port cap closed after
use to prevent dust or water entry during
rains/water wash.
• Do not direct water jet towards the port
even with cap closed to avoid any short
circuit. Always dry the area using a dry cloth
or moisture free compressed air before use. 2 3
• Press the cap slightly for proper locking of (1) Key (2) Knob (3) Helmet Hanger
USB charger cap.
• The charging time of mobile may vary, The helmet can be hung and locked in the
depending on the mobile's battery state of helmet hanger (3) provided with the seat lock
the charge, mobile make and conditions. by rotating the key.

27
PRE-RIDE INSPECTION
You should conduct pre-ride inspection
before riding the vehicle to enhance riding
comfort and safety.
Clean your vehicle regularly. It protects the
surface finish. Avoid cleaning with products
that are not specifically designed for vehicle
surfaces. Inspect your vehicle very day before
you start the engine.
The items listed here will only take a few
minutes, and in the long run they can save
time, expense and possibly your life. Please
follow the tips as given below:
• Engine oil level-Check and top up engine
oil if required (page 38). Check for leaks.
• Fuel level-Ensure sufficient fuel is available
in your fuel tank for journey (page 24).
Check for leaks.
• Front brake (Disc variant)-Check for
correct brake fluid level in the master
cylinder (page 48).
• Rear brakes (For IBS): Check for correct
brake fluid level in the reservoir (page49).
• Tyres-Check condition and pressure
(page 54).
• Clutch-Check for smooth operation.
Adjust free play (page 44).
28
• Drive chain-Check condition and
slackness (page 46). Adjust and lubricate if
necessary.
• Throttle-Check for smooth opening and
closing in all steering positions (page 45).
• Lamps and Horn-Check that headlamp,
tail/stop lamp, turn signal lamps and horn
function properly.
• Rear view mirror-Ensure that the rear
view mirror gives a good rear view when you
are sitting on the vehicle.
• i3s switch-Make sure whether the i3s
switch is in “ON” or “OFF” position
(page 22).
• i3s system-Make sure that i3s system is
functional properly (page 22).
• Fitting & Fasteners-Check & tighten if
necessary.
• Steering-Check for smooth action for easy
maneuverability.
• Side stand indicator-Make sure that the
side stand is up. If it is in down position the
side stand indicator (page24) will glow on
the speedometer panel.
• Air suction valve (ASV)-make sure all
tube connections are secured properly
(page 61).
STARTING THE ENGINE
5. Push the choke lever
downward to “ON”
position as indicated
(Use choke during
ON
cold conditions).
1. Turn the ignition 3. Select neutral position
switch “ON” ( ). & check N indicator 6. Open the throttle
glows on instrument slightly & press the
cluster with ignition starter switch.
“ON” ( ). (Alternatively kick
pedal can be used for
starting).
7. Pull the choke lever
OFF
upward to "OFF"
position as indicated,
after the engine gets
2. Turn the fuel valve4. Make sure whether sufficiently warmed-up
“ON” ( ). the i3s switch is to have a stable throttle
in “ON” or “OFF” response.
position.
! WARNING
Never run the engine in a closed area, the exhaust contains poisonous gases.
NOTE
• To start the engine in any gear position using the electric starter, press the clutch lever and
push the starter switch.
• Kick starting will not be possible when the transmission gears are engaged. Shift the
transmission into neutral before kick starting.
• Never attempt to kick start while vehicle is moving forward or backward. This may lead to
damage to the product and is not safe as well.

29
Flooded engine 4
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel. To 3
clear a flooded engine, turn the ignition switch 2
“OFF” ( ) and turn the choke lever to “OFF”.
Close the throttle fully and crank the engine 1
several times with the kick starter. Turn the
ignition switch “ON” ( ) and start the engine N
without using choke.
Running in
During first 1000 km, do not operate the
vehicle at more than 60 km/hr speed in top Recommended max. operating speed in
gear, 45 km/hr in third gear, 30 km/hr in each gear.
second gear and 15 km/hr in first gear. 1ndst 20 km/hr 3rdth 70 km/hr
Avoid full throttle operation. 2 45 km/hr 4 100 km/hr
During initial running in, newly machined CAUTION
surfaces will be in contact with each other and !
these surfaces will wear in quickly. Running in Do not shift gears without operation of clutch
precautions till 1000 km will reduce initial and without closing the throttle otherwise this
wear of engine components and increase its would lead to damage of gears.
service life. BRAKING
RIDING • For normal braking, close the throttle and
• After the engine has been warmed up, the
vehicle is ready for riding. gradually apply both front and rear brakes
• While the engine is idling, press the clutch simultaneously while shifting down gears to
lever and depress the gearshift pedal to shift suit your road speed.
into 1st (low) gear. • For sudden deceleration/quick stopping,
• Slowly release the clutch lever and at the close the throttle and apply the front and
same time, gradually increase engine speed rear brakes simultaneously.
by opening the throttle. Coordination of the For integrated braking system (IBS)
throttle and clutch lever will assure a smooth To stop the vehicle, press the rear brake pedal
positive start. for the application of front and rear brakes
• When the vehicle attains a moderate speed, closend simultaneously. However, for more effective
the throttle, press the clutch lever and shift to 2 braking, it is advised to apply front and rear
gear by depressing the gearshift pedal. brake simultaneously, keeping the throttle in
• The sequence is repeated progressively to
shift 3rdand 4th (top gear). closed position.
30
 ! WARNING ! CAUTION
• When riding in wet or rainy conditions, or on • Park the vehicle on firm level ground to
loose surfaces, apply front brake carefully prevent overturning.
after applying rear brake to avoid wheel slip. • While parking vehicle on side stand engage
• Extreme braking may cause wheel locking the first gear.
and reduce control over the vehicle.
• Wherever possible, reduce speed or apply TOOL KIT
brake before entering a turn, closing the The tool kit (1) is located below the seat in the
throttle or braking in mid turn may cause rear. Some emergency repairs, minor
wheel slip. Wheel slip will reduce control adjustments and parts replacement can be
over the vehicle. performed with the tools contained in the kit.
• When riding in wet or rainy conditions, or on Kit consists of following tool:
loose surfaces the ability to stop the vehicle • Tool Bag
reduces. • +, - No. 2 driver
• All your actions should be smooth under these • Grip
conditions. Sudden acceleration, braking or
turning may cause loss of control. For your • Box wrench P 16 X 14
safety, exercise extreme caution when • Pin spanner
braking, accelerating or turning.
• When descending a long steep slope use
engine braking (power) by changing to lower
gears, with intermittent use of both brakes.
Continuous brake application can overheat
the brakes and reduce their effectiveness.
PARKING
After stopping the vehicle, shift the
transmission to neutral, turn the fuel valve
“OFF”, turn the ignition switch “OFF”, park 1
the vehicle on main stand, lock the steering (1) Tool kit
and remove the key.

31
CLEANING AND WASHING OF VEHICLE
• Follow the below mentioned steps for
washing the vehicle.
• Wet the vehicle with light water spray. Avoid
directing water to muffler outlets and
electrical parts.
• Clean the headlamp lens and other plastic
parts using a cloth or sponge dampened
with a solution of mild detergent and water.
• Rub the soiled area gently rinsing it
frequently with fresh water.
• After cleaning spray water thoroughly.
• Dry the vehicle by wiping with dry soft cloth.
NOTE
• We at Authorised Distributor/Dealer take all • Always follow the inspection and
above mentioned precautions like
recommended detergents and usage of
muffler caps/plugs during wash to ensure
quality wash.
• Do not use high pressure water (or air). It can This section includes instructions on some
damage certain parts of the vehicle.
MAINTENANCE
The importance of maintenance
A well-maintained vehicle is essential for safe
economical and trouble-free riding. It will also
help reduce pollution.
To help you, take proper care of your
vehicle, the following pages include a
maintenance schedule and a maintenance
record for regular scheduled maintenance.
32
These instructions are based on the
assumption that the vehicle will be used
exclusively for its designed purpose.
Sustained high speed operation or operation
in unusually wet or dusty conditions will
require more frequent service than specified in
the maintenance schedule.
Consult your Authorised Distributor/
Dealer for recommendation applicable to
your individual needs and use.
! WARNING
•Improperly maintaining this vehicle or
failing to correct a problem before you ride
can cause a crash in which you can be
seriously hurt or killed.
maintenance recommendations and
schedules in this owner's manual.
Maintenance safety
important maintenance tasks. You can
perform some of these tasks with the tools
provided (if you have basic mechanical skills).
Other tasks that are more difficult and require
special tools are best performed by
professionals. Wheel removal should normally
be handled only by a Authorised Distributor/
Dealer skilled technician or other qualified
technician; instructions are included in this
manual only to assist in emergency service.
You will come across some of the most SAFETY PRECAUTIONS
important safety precautions in the following Make sure the engine is “OFF” before you
•
pages of this manual. begin any maintenance or repair. This will
However, we cannot warn you of every help to eliminate several potential hazards:
conceivable hazard that can arise in • Carbon monoxide poisoning from
performing maintenance. Only you can decide
whether or not you should perform a given engine exhaust.
task. Be sure there is adequate ventilation
whenever you operate the engine.
! WARNING • Burns from hot parts.
• Failure to follow maintenance instructions Let the engine and exhaust system cool
and precautions properly can seriously before touching.
injure you. • Injury from moving parts.
• Always follow the procedures and Do not run the engine unless instructed
precautions in this owner's manual. to do so.
• Read the instruction before you begin and
make sure you have the tools and skills
required.
• To help prevent the vehicle from falling
over, park it on a firm, level surface on the
main stand.
• To reduce the possibility of a fire or
explosion, be careful when working around
petrol or batteries. Use only nonflammable
solvent, not petrol, to clean parts. Keep
cigarettes, sparks and flames away from the
battery and all fuel-related parts.
Remember that your Authorised Distributor/
Dealer knows your vehicle best and is fully
equipped to maintain and repair it.
To ensure best quality and reliability, use only
new genuine Parts for repair and replacement.

33
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection (page 28) at each scheduled maintenance period.
I: INSPECT C: CLEAN R: REPLACE A: ADJUST O: OIL CHANGE
L: LUBRICATE T: TOP UP E: EMISSION CHECK
The following maintenance schedule specifies all maintenance required to keep your vehicle in
peak operating condition. Maintenance work should be performed in accordance with
standards and specifications of HMCL Niloy Bangladesh Ltd. by properly trained and
equipped technicians. Your Authorised Distributor/Dealer meets all of these requirements.
Ensure that each paid service is availed within 90 days or 3000 km from the date of previous
service, whichever is earlier.
To be serviced by your Authorised Distributor/Dealer unless the owner has the
relevant tools, technical information and is technically qualified.
In the interest of safety, we recommend that these jobs are carried out only by your
Authorised Distributor/Dealer.
Note-1 : At higher odometer readings, repeat the frequency interval established here.
Note-2 : Replace air cleaner element once in every 15000 km or early replacement may
be required when riding in dusty areas.
Note-3 : Replace engine oil once in every 6000 km. Top up once in every 3000 km.
Note-4 : Visit Authorised Distributor/Dealer for inspection, cleaning, lubrication and
adjustment of drive chain at every 2000 km.
Note-5 : Replace once in a every 2 years or 30000 km, whichever is earlier.
Note-6 : Inspect & maintain specified torque.
Note-7 : Inspect the wheel bearings free play, replace if necessary.
Note-8 : Replace front fork oil once in a every 2 years or 30000 km, whichever is earlier.
Note-9 : Inspect for any play in the mounting bushes, replace if necessary.
Note-10: Check idle CO emission along with idle rpm/idle CO adjustment (if required).
Note-11: Inspect the canister hoses for deterioration, damage or loose connections and
canister for cracks or other damages.
Note: Always wipe the water from the vehicle after washing. Use clean soft cloth or
pressurized air for completely drying the water.
34
 MAINTENANCE SCHEDULE
Dear Customer,
We would strongly recommend the following schedule, to keep your vehicle in
perfect running condition and healthy environment. Vehicle subjected to severe use or ridden
in dusty area will require more frequent servicing.
SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
DAYS 1st 60 90Next Next Next Next Next Next Next Next Next Next
ITEMS 90 90 90 90 90 90 90 90 90
Km Note-1 500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000- 30000-
750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500
Fuel Line I I I I I I I I I I I
Throttle Operation I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Carburetor/Engine C, A A C, A A C, A A C, A A C, A A C, A
Idle Speed
Air Cleaner Element Note-2 Do not open air cleaner element unless R R
there is a drivability problem
Spark Plug I, C, A I, C, A I, C, A I, C, A R I, C, A I, C, A I, C, A I, C, A R I, C, A
Valve Clearance I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Engine Oil Note-3 O I, T O I, T O I, T O I, T O I, T O
Engine Oil Strainer C C C C C C
Screen
Engine Oil C C C C C C
Centrifugal Filter
Electric Starter I I I I I I I I I I I
Starter Reduction I, L I, L I, L I, L I, L
Gear Shaft
Oil Circulation I I I I I I I I I I I
Drive Chain Note-4 I,C,L,A at every 2000 km I,C,L,A at every 2000 km
Drive Chain Slider I I I I I I I I I I
Battery Voltage I I I I I I I I I I I
Brake Shoe I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A

35
 SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
DAYS 1st 60 90Next Next Next Next Next Next Next Next Next Next
ITEMS 90 90 90 90 90 90 90 90 90
500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000-
Km Note-1 750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500 30000-

Disc Wear/Pad Wear I I I I I I I I I I I

(For disc and IBS)
Brake Fluid Note-5 I, T I, T I, T I, T I, T I, T I, T I, T I, T I, T I, T
(For disc and IBS)
Brake System (Brake C, L C, L C, L C, L C, L
Cam & Brake Pedal)
Stop Lamp Switch I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Headlamp Focus I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Clutch Lever Free Play I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Side Stand/Main Stand L L L L L L L L L L L
Side Stand Switch I, C I, C I, C I, C I, C I, C I, C I, C I, C I, C I, C
i3s System I I I I I I I I I I I
Nut, Bolts & Fasteners Note-6 I I I I I I I I I I I
Wheels Bearings Note-7 I I I I I I I I I I I
Wheels/Tyres I I I I I I I I I I I
Steering Head Bearing I I, A I I, A I, L, A I I, A I I, L, A I I, A
Front Suspension/Oil Note-8 I I I I I I I I I I R
Leakage
Rear Suspension Note-9 I I I I I I I I I I I
Secondary Air Injection I I I I I
Muffler
(Catalytic Converter) Note-10 I, E I, E I, E I, E I, E
Evaporative Emission Note-11 I I I I I I I I I I I
Control System

36
SPARK PLUG INSPECTION
Recommended spark plugs:
NGK-CR7HSA, BOSCH-UR4AC
For most riding conditions this spark plug heat
range number is satisfactory. However, if the
vehicle is going to be operated for extended
periods at high speeds or near maximum
power in hot climates, the spark plug should
be changed to a cold heat range number,
consult Authorised Distributor/Dealer on this
if required.
• Clean any dirt around the spark plug base.
• Disconnect the noise suppressor cap (1)
and remove the spark plug (2) with the help
of spark plug box wrench provided in the
tool bag.
1 • With the plug washer attached, thread the
2 BRAND: Hero 4T plus
(1) Noise suppressor cap (2) Spark plug
• Visually inspect the spark plug electrodes for
wear. The center electrode should have
square edges and the side electrode should
not be eroded. Discard the spark plug if
there is apparent wear or if the insulator is
cracked or chipped.
37
0.6-0.7 mm
• Make sure that the spark plug gap is
0.6-0.7 mm using a wire-type feeler
gauge. If adjustment is necessary, bend the
side electrode carefully. Make sure the plug
washer is in good conditions.
spark plug in by hand to prevent cross-
threading.
• Tighten a new spark plug 1/2 turn with
spark plug wrench to compress the washer.
If you are reusing a plug, it should only take
1/8-1/4 turn after the plug seats.
ENGINE OIL
Use only genuine engine oil.
GRADE: SAE 10W 30 SL Grade
(JASO MA2).
Manufactured by:
• Tide Water Oil Co. (India) Ltd.
• Savita Oil Technologies Limited.
• Bharat Petroleum Corporation Limited.
OIL CAPACITY: 1.25 liters
Engine oil level inspection/Top up
process
Check engine oil level each day before
operating the vehicle.
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.
Do top up if oil level reaches towards the lower
level mark or every 3000 km whichever is
earlier.
1 and drain bolt (1).
2 O-ring.
UPPER
LOWER
3 • Remove the tappet inspection cover. Slowly
(1) Oil level dipstick (2) Upper level mark
(3) Lower level mark
• Park the vehicle on its main stand.
• Start the engine & let it idle for 3-5
minutes.
• Stop the engine and wait for 2-3 minutes.
• Remove the oil level dipstick, wipe it clean
and insert without screwing it in.
• Remove the oil level dipstick and check the
oil level.
38
• If required, add the specified oil up to the
upper level mark. Do not overfill.
• Quantity of oil to be filled is 1.1 liters
(approx.) during oil change when right
crankcase cover is not removed.
• Reinstall the oil level dipstick and check for
oil leaks.
Engine oil replacement process/
Oil circulation inspection
Drain engine oil with the engine warm and the
vehicle on its main stand.
• To drain the oil, remove the oil level dipstick
• After the oil has completely drained, reinstall
the drain bolt with a new sealing washer (2).
• Fill the crankcase through the oil filler
hole with 1.25 liters (approximately) of the
recommended grade oil.
• Reinstall the oil level dipstick with a new
• Start the engine and allow it to idle for few
minutes.
accelerate and check the engine oil entry
into the cylinder head, engine oil will splash
out from the tappet inspection cover
opening.
• After checking the oil circulation, install the
tappet inspection cover.
• Stop the engine, let the engine oil settle
down and recheck the oil level.
• Make sure that oil level is at the “UPPER”
level mark of the oil level dipstick with the
vehicle in an upright position and that there 1
are no oil leaks.
2
5
2 3
4
1
(1) Kick starter pedal (2) Clutch cable
(3) Muffler (4) Rider foot rest
(5) Right crankcase cover
(1) Drain bolt (2) Sealing washer Ÿ Remove the gasket (6) and dowel pins (7).
7 9
! CAUTION 8
• Running the engine with insufficient oil can
cause serious engine damage.
• Running the engine with excessive oil can
cause spark plug fouling & loss in
performance.
• Engine 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. 6
OIL FILTER SCREEN & CENTRIFUGAL (6) Gasket (7) Dowel pins
FILTER (8) Oil filter screen (9) Centrifugal filter cover
• Drain the engine oil thoroughly. • Remove the oil filter screen (8) and wash it
• Remove the kick starter pedal (1), in clean non flammable or high flash point
disconnect the clutch cable (2), remove the solvent (kerosene).
muffler (3), remove the right side rider • Reinstall the oil filter screen with the sharp
footrest (4) and remove the right crankcase edged side facing inwards.
cover (5).
39
• Remove centrifugal filter cover (9) & clean • Remove the seat (page 27).
the centrifugal filter (10) with non flammable • Remove the left side cover (1) by removing
or high flash point solvent (kerosene). side cover screws (2).
10 1

2
(10) Centrifugal filter (1) Side cover (2) Side cover screws
• Reinstall the dowel pins and gasket.
• Reinstall the centrifugal filter cover, right • Remove
and the
the air cleaner cover screws (3)
cover (4).
crankcase cover, kick start pedal & clutch
cable.
• Fill the crankcase with clean engine oil as
per specification. 3
NOTE
• Clean filters as specified in the maintenance 4
schedule.
• Ensure to replace gasket with new one once
removed.
AIR CLEANER
Air cleaner element inspection
The air cleaner element is viscous type, it (3) Air cleaner cover screws
should be replaced at regular intervals (page (4) Air cleaner cover
34). Early replacement may be required • Remove the air cleaner element (5)
when riding in unusually wet or dusty area. from air cleaner housing (6).
40
 • Clean the air cleaner housing using a shop
towel.
• Install the new air cleaner element
• Install the air cleaner element cover.
• Install the left side cover.
• Install the seat.
! CAUTION
• Never wash or clean the viscous filter.
6 5 Replace filter element once in every 15000
(5) Air cleaner element (6) Air cleaner housing • km.
Replace it earlier if it becomes very dirty,
damage on surface or on the sealing area.
Air cleaner drain tube cleaning
Drain the deposit into a suitable container.
Follow the above process more frequently
when riding in rain or at full throttle. Always
ensure to reinstall the drain tube after draining
the deposit.

(1) Drain tube

41
CARBURETOR
Idle speed adjustment
The carburetor is factory pre-set in order to
achieve optimum performance and meet
emission standards.
However in case of specific requirement of
tuning due to engine stalling in idle speed,
please follow the instructions given here
under:
Warm up the engine and park the vehicle on
the main stand.
Adjust idle speed with the throttle stop screw
(1).
IDLE SPEED: 1400 ± 100 RPM
3 specified intervals (page 34).
A B
! CAUTION
Never adjust air screw (2). Air screw
adjustment is to be done only by Authorised
Distributor/Dealer.
If air screw is tampered it affects the overall
performance characteristics of the vehicle.
Throttle position sensor switch (3) alters the
ignition timing as per the throttle operation
and ensures optimum driving performance.
VALVE CLEARANCE ADJUSTMENT
Excessive valve clearance will cause noise, and
little or no clearance will prevent the valve
from closing and cause valve damage and
power loss. Check valve clearance at the
• Remove the tappet covers (1) and cylinder
head left side cover (3) with gasket (2) by
removing the bolt/sealing washer.

2 1 1
2
(1) Throttle stop screw (A) Decrease rpm
(2) Air screw (B) Increase rpm 3
(3) Throttle position sensor switch
NOTE
Always adjust the idle speed in i3s switch (1) Tappet covers (2) Gasket
“OFF” position. (3) Cylinder head left side cover

42
 NOTE 7
The checking or adjusting of valve clearance
should be performed while the engine is cold.
The clearance will change as the engine
temperature rises. 8
• Remove the timing hole cap (4) and tappet
covers. Rotate the cam sprocket (7)
clockwise using the special tool (8) until the
‘T’ mark (5) on the flywheel coincides with
the index mark (6) on the left crankcase
cover. In this position, the piston will either (7) Cam sprocket (8) Special tool
be on the compression or exhaust stroke.
The adjustment must be made when the
piston is at top dead center and both the inlet
and exhaust valves are closed.
4 This condition can be determined by moving
the rocker arms. If they are free, it is an
indication that the valves are closed and the
piston is in compression stroke. If they are
tight, the valves are open, rotate the cam
6 sprocket (7) 360O clockwise and realign the
5
'T' mark with the index mark.
• Check the clearance by inserting the feeler
(4) Timing hole cap (5) 'T' mark gauge (9) between the adjusting screw
(6) Index mark (10) and valve stem.
Standard clearance (cold condition)
Intake : 0.10 mm
Exhaust: 0.12 mm

43
 10 2

1
11
9

(9) Feeler gauge (10) Adjusting screw (1) Free play:10-20 mm (2) Clutch lever
(11) Lock nut • To adjust the free play, loosen the lock nut
• Adjust by loosening the lock nut (11) and (3). Turn the adjusting nut (4) to obtain the
turning the adjusting screw (10) until there specified free play. Tighten the lock nut and
is a slight drag on the feeler gauge (9). After check the adjustment.
tightening the lock nut, check again the
clearance.
• Install all parts in the reverse order of
disassembly.
NOTE 3 4
B
Before inserting the feeler gauge, smear a bit
of engine oil on the feeler gauge to avoid A
damage to the feeler gauge.
CLUTCH LEVER FREE PLAY
Adjustment
Clutch adjustment may be required if the (3) Lock nut (4) Clutch cable adjusting nut
vehicle stalls when shifting into gear or tends (A) Decrease free play (B) Increase free play
to creep or if the clutch slips, causing
acceleration to lag behind engine speed.
Normal clutch lever free play (1) is 10-20
mm at the lever (2).
44
• Start the engine, press the clutch lever and improperly routed, it should be replaced or
shift into gear. Make sure the engine does rerouted. Standard throttle grip free play (1)
not stall, and vehicle does not creep. is approximately 2-6 mm of grip rotation.
Gradually release the clutch lever and open
the throttle. The vehicle should start
smoothly and accelerate specified free play. 1
Tighten the lock nut and check the
adjustment.
• Start the engine, press the clutch lever and
shift into gear. Make sure the engine does
not stall, and vehicle does not creep.
Gradually release the clutch lever and open
the throttle. The vehicle should start
smoothly and accelerate.
Other checks (1) Free play: 2-6 mm
• Check the clutch cable for kinks or signs of
wear that could cause sticking or failure. Free play adjustment
• Check for clutch cable model. Use genuine Slide the boot (2), loosen the lock nut (3) and
clutch cables. turn the adjuster (4).
• Check for clutch cable routing.
NOTE
If proper adjustment cannot be obtained or the
clutch does not work correctly, visit your
Authorised Distributor/Dealer. A
3
THROTTLE OPERATION
Cable inspection B
Check for smooth rotation of the throttle grip
from the fully open to the fully closed position.
Check at full left and full right steering 2 4
positions. Inspect the condition of the throttle (2) Boot (A) Decrease free play
cable from the throttle grip down to the (3) Lock nut (B) Increase free play
carburetor. If the cable is kinked, chafed or (4) Adjuster
45
DRIVE CHAIN SLACKNESS If the chain is slack in one section and tight in
The service life of the drive chain depends another, some links are kinked and binding.
upon proper lubrication and adjustment. Binding can be eliminated by frequent
Poor maintenance can cause premature wear lubrication.
or damage to the drive chain and sprockets.
The drive chain (1) should be checked and
lubricated as part of the Pre-ride Inspection 4
(page 28). Under severe usage, or when the
vehicle is ridden in unusually dusty areas more
frequent maintenance will be necessary. 5
Inspection
• Turn the engine “OFF”, park the vehicle on
its main stand and shift the transmission to
neutral. Remove hole cap (2).
• Drive chain slack (3) should be adjusted to
allow approximately 30 mm vertical (4) Chain lock plate (5) Open end
movement by hand. • Turn the chain to view chain lock plate (4)
2 inside the hole. Ensure that the chain lock
plate open end (5) is installed in the
opposite direction of the chain rotation.
3 Sprocket Teeth
orn
W

Da
maged Sprock

th
e
Te
1

et
tT ck
(1) Drive chain (2) Hole cap

e
eet p ro
h
(3) Drive chain slack: 30 mm N o r m al S

Rotate the wheel and check drive chain slack

as the wheel rotates. Drive chain slack should
remain constant as the wheel rotates.
46
• Inspect the sprocket teeth for wear or 56 3
damage.
• If the drive chain or sprockets are
excessively worn or damaged, they should
be replaced. Never use a new chain with
worn out sprockets since this will result in
rapid chain wear.
Adjustment
• Park the vehicle on its main stand with the
transmission in neutral and the ignition
switch in "OFF" position. 2 4
• Loosen the rear axle nut (1) and sleeve nut (2) Sleeve nut (3) Drive chain lock nut
(2). Loosen both the drive chain lock nuts (4) Drive chain adjusting nut (5) Index mark
(3). (6) Scale graduation
• Align the chain adjuster index mark (5) with
the corresponding scale graduations (6) on
both the sides of the swing arm equally.
• If the drive chain slack is excessive when the
rear axle is moved to the farthest limit of
adjustment, the drive chain is worn and must
be replaced. Tighten the rear axle nut and
sleeve nut.
- Rear axle nut torque: 5.0-6.0 kgf-m
- Sleeve nut torque : 4.5-5.0 kgf-m
1 • Check the drive chain slack again.
(1) Rear axle nut • Rear brake pedal free play and stop lamp
switch free play are affected when
• Turn both the adjusting nuts (4) in an equal repositioning the rear wheel to adjust drive
number of turns until the correct drive chain chain slack. Check rear brake pedal free
slack is obtained. Turn the adjusting nut play and adjust as necessary (page 50).
clockwise to decrease the slack or Lubrication
anticlockwise to increase the slack of the • Turn the engine “OFF”, park the vehicle on
chain. its main stand and shift the transmission into
neutral.
47
• Lubricate the drive chain by applying liberal
amount of SAE#90 oil.
! CAUTION
Regular adjustment and lubrication as per the
maintenance schedule would ensure high
performance and longer life.
NOTE
Visit Authorised Distributor/Dealer
for inspection, cleaning, lubrication and
adjustment of drive chain at every 2000 km.
DRIVE CHAIN SLIDER INSPECTION
(Refer to “Maintenance Schedule” on
(page 34).
Check the drive chain slider (1) for wear, the
chain slider must be replaced if it is worn to the
bottom of the cutout or wear limit (2) is
reached. For replacement, visit your
Authorised Distributor/Dealer.
2 1
CUTOUT
1
(1) Drive chain slider (2) Wear limit (1) "MIN" mark
48
BRAKES
Brakes (Integrated braking system)
Brakes are items of personal safety and
should always be maintained with proper
adjustments.
When one applies the Integrated/Rear brake
pedal, front & rear brakes activate jointly.
(a) Front brake inspection (Disc variant)
Master Cylinder/Reservoir
Location: Right handlebar
Brake fluid recommended: DoT 3 or DoT 4
Fluid level-Ensure that the brake fluid level
does not fall below “MIN” mark (1) on the
master cylinder, when checked with the
master cylinder parallel to the ground. The
level decreases gradually due to piston
movement to compensate pad wear. If the
level decreases abruptly, check for leakage in
the brake system and contact your Authorised
Distributor/Dealer.
 NOTE abruptly, check for the leakages in the brake
• Clean the dirt and mud accumulation system and consult your Authorised
between the brake pads (2), caliper (3) and Distributor/Dealer
the disc (4) by using a water jet. 1
• Always contact your Authorised
Distributor/Dealer for refilling of master
cylinder when necessary. Do not mix DoT 3
and DoT 4 brake fluid.
2
3 MIN

4 usage, the type of riding & road conditions.
(2) Brake pads (3) Caliper (4) Brake disc
(B) Rear brake fluid (For IBS)
Refer to the safety precautions on (page 33).
Reservoir (1)
Location : Near the right side pillion footrest.
Brake fluid recommended :
DoT-4/DoT-3.
Fluid level - Ensure that the brake fluid level
does not fall below "MIN" mark (2) on the
reservoir parallel to the ground. The level
decreases gradually due to piston movement to
compensate pad wear. If the level decreases.
49
2
(1) Reservoir (2) "MIN" mark
(c) Brake pad wear (Disc variant)
Brake pad wear depends upon the severity of
Generally, the pads will wear faster on wet &
dirty roads. Inspect the pads at each regular
maintenance interval.
Inspection
Check the wear indicator grooves (1) on each
pad.
Check the brake pads for wear by examining
the wear limit grooves on each pad.
Replace the pads if worn out to the bottom of
the groove.
Always replace both the pads as a set.
Visit your Authorised Distributor/Dealer for
the brake pad replacement.

1
(1) Wear indicator groove
! WARNING
Always apply front and rear brakes
simultaneously to avoid skidding of vehicle.
(d) Rear brake inspection
Adjustment
• Park the vehicle on its main stand.
• Measure the brake pedal free play (1)
moves before the brake starts to take hold.
Free play (2) should be 20-30 mm.
• If adjustment is necessary, turn the rear
brake adjusting nut (3).
• Make sure that the cut-out on the adjusting
nut is seated on the brake joint pin (4) after
the final adjustment has been made.
3 (A) Decrease free play (CW)
B
A
4 (B) Increase free play (ACW)
(3) Adjusting nut (4) Brake joint pin

X ü
2

3 4 3 4
1 (A) Cut-out not seated (B) Cut-out seated
(1) Rear brake pedal (2) Free play:20-30 mm (3) Adjusting nut (4) Brake joint pin
CW- Clockwise, ACW- Anticlockwise
50
• Apply the brake several times and check forSUSPENSION
free wheel rotation when released. Front and rear suspension inspection
• Check the front forks by locking the front
NOTE brake and pumping the front fork up and
If proper adjustment cannot be obtained by down vigorously. The suspension action
this method, visit your Authorised Distributor should be smooth and there should be no
/Dealer. oil leakage.
(e) Brake wear indicators Front Rear
When the brake is applied, an arrow (1),
fixed to the brake arm (2), moves towards a
reference mark (3) on the brake panel (4). If
the arrow aligns with the reference mark on
full application of the brake, the brake shoes
must be replaced.
Rear brake wear indication
4

3 1 • Check the rear shock absorber by pushing

hard downwards on rear grip while the
vehicle is not parked on stand. The
suspension action should be smooth and
there should be no oil leakage.
2 Rear shock absorber adjustment
Rear shock absorber adjustment can be made
(1) Arrow (2) Brake arm
according to the load/road conditions.
(4) Brake panel • In
• direction A: Stiffer
(3) Reference mark In direction B: Softer

51
 1 5 3 1

A
B

2 4 2
(1) Pin spanner (2) Rear shock absorber (1) Speedometer cable (2) Tab (3) Axle nut
(A) Stiffer (B) Softer (4) Axle (5) Side collar
NOTE ! CAUTION
Always adjust both the rear shock absorbers to Do not operate front brake lever when the
the same position. To adjust the rear shock wheel is removed.
absorber (2), use the rear shock absorber
adjustment tool (Pin spanner) (1) available in Installation
the tool kit. • Install the side collar (1) to the right side of
WHEEL the wheel hub and then install the
speedometer drive gear (2) on the left side
(a) Front wheel of the wheel hub.
Removal • Position the front wheel between the fork
• Support the vehicle securely on the main legs by aligning the slot on the speedometer
stand and raise the front wheel off the gear box with the lug on the fork leg and the
ground. disc between the brake pads to avoid
• Remove the speedometer cable (1) by damage to the pads. Insert the axle from the
pressing the tab (2) & pulling cable out right side through the fork legs and wheel
from the speedometer gearbox. hub.
• Remove the front axle nut (3). • Tighten the front axle nut to the specified
• Remove the axle (4) and the wheel. torque.
• Remove the side collar (5) from the wheel. TORQUE : 5.0-6.0 kgf-m
52
 1 2 5 2

1 7 6 4
(1) Side collar (2) Speedometer drive gear (1) Rear brake adjusting nut (2) Brake rod
• After installing the wheel apply the brake (3) Brake arm (4) Brake stopper arm
several times and then check if the wheel (5) Brake panel (6) Split pin (7) Lock nut
rotates freely. Recheck the wheel if the • Remove the rear axle nut (8).
brake drags or if the wheel does not rotate • Pull out the axle (9) and collar (10).
freely. • Remove the wheel.
(b) Rear wheel 10
Removal
• Support the vehicle securely on the main
stand and raise the rear wheel off the
ground.
• Remove the rear brake adjusting nut (1)
and disconnect the brake rod (2) from the 9
brake arm (3) by pushing down the brake
pedal. Disconnect the brake stopper arm
(4) from the brake panel (5) by removing
split pin (6) and lock nut (7). 8
(8) Axle nut (9) Axle (10) Collar

53
Installation 2
• Reverse the removal procedure
Axle nut torque: 5.4 kgf-m
Brake stopper arm nut torque:
1.8-2.5 kgf-m
• Adjust the rear brake free play (page 50)
and drive chain slackness (page 46).
• After installing the wheel, apply the brake
several times and check for free wheel
rotation when released. 1
(1) Main stand (2) Side stand
! CAUTION TUBELESS TYRES
Always replace used split pins with new ones. The tyres fitted on your vehicle are of
MAIN/SIDE STAND LUBRICATION TUBELESS type.
• Park the vehicle on the level surface. To safely operate your vehicle, your tyres must
• Check the main/side stand return spring for be of the proper type and size, in good
damage or loss of tension. condition with adequate tread, and correctly
• Check the main stand (1)/side stand (2) inflated for the load you are carrying.
for freedom of movement. The following pages give more detailed
• Lubricate the side stand pivot if necessary. information on how and when to check the air
• Make sure the side/main stand is not bent. pressure, how to inspect your tyres for
damage, and what to do when your tyres need
to be repaired or replaced.
Front 80/100-18 M/C 47P (Tubeless tyre)
Rear 90/90-18 M/C 51P (Tubeless tyre)
! WARNING
• Using tyres that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or killed.
• Follow all instructions in this owner's
manual regarding tyres inflation and
maintenance.
54
Air pressure Rider only Rider and Pillion
Keeping your tyres properly inflated provides 2 2
Front 1.75 kgf/cm (25 psi) 1.75 kgf/cm (25 psi)
the best combination of handling, tread life
and riding comfort. 2 2
Rear 2.00 kgf/cm (29 psi) 2.25 kgf/cm (33 psi)
Generally, under-inflated tyres wear unevenly, 1
adversely affect handling and are more likely
to fail from being overheated.
Under inflated tyres can also cause wheel
damage in rocky terrain.
Over-inflated tyres make your vehicle ride
harshly, are more prone to damage from road
hazards, and wear unevenly.
We recommend that you visually check your
tyres before every ride and use a gauge to
measure air pressure at least once a month or
any time you think the tyres pressure might be (1) Air pressure gauge
low. Tubeless tyres have some self-sealing
ability if they are punctured. However, ! CAUTION
because leakage is often very slow, you should Over inflation/Under inflation will affect the
look closely for punctures whenever a tyre is performance.
not fully inflated.
Always check air pressure when your tyres are Inspection
"cold"-when the vehicle has been parked for Whenever you check the tyre pressure, you
at least three hours. If you check air pressure should also examine tyre treads & side walls
when your tyres are "warm"-when the vehicle for wear, damage & foreign objects.
has been ridden for even a few km-the Look for:
readings will be higher than if the tyres were • Bumps or bulges in the side of the tyre or
"cold". This is normal, so do not let air out of the tread. Replace the tyre if you find any
the tyres to match the recommended cold air bumps or bulges.
pressures given below. If you do, the tyres will • Cuts, splits or cracks in the tyre. Replace the
be under-inflated. tyre if you can see fabric or cord.
The recommended “cold” tyre pressures are:
55
 MINIMUM TREAD DEPTH:
Front: 0.8 mm Rear: 0.8 mm
Check the tread wear indicator for tyre wear.
1

2
• Excessive tread wear.
(1) Wear indicator (2) Arrow mark
Unidirectional tyres
Whenever the tyre is removed and put back in
case of puncture, ensure the arrow mark (2)
on the tyre is in the same direction as that of
forward rotation of wheel.
Tyre repair
If a tyre is punctured or damaged, you should
replace it, not repair it. As mentioned below, a
• Carefully inspect the tyres for any damage, tyre that is repaired either temporarily or
permanently, will have lower speed and
if the vehicle hits a pothole or hard object. performance
Tread wear limits than a new tyre.
A temporarily
Replace tyres immediately when the tread tubeless tyre plug, repaired, such as an external
may not be safe for normal
wear indicator (1) appears on the tyre. The speeds and riding conditions.
tread limits are: If a temporary or
emergency repair is made to a tyre, you should
ride slowly cautiously to your Authorised
Distributor/Dealer and have the tyre replaced.
If possible you should not carry a pillion or
load until a new tyre is installed.
56
Even if a tyre is professionally repaired with a
permanent internal patch plug, it will not be as
good as a new tyre.
You should not exceed 70 km/hour for the
1st 24 hours or 105 km/hour at any time
thereafter. In addition you may not be able to
safely carry as much load as with a new tyre.
Therefore, we strongly recommend that you
replace a damaged tyre.
If you decide to have a tyre replace be sure the
wheel is balanced before you ride.
Tyre replacement
The tyres that were installed on your vehicle
were designed to match the performance
capabilities of your vehicle and provide the
best combination of handling, braking,
durability and comfort.
! WARNING
• Operation with excessively worn tyres is
hazardous and will adversely affect traction
and handling.
• Under-inflation may result in the tyre
slipping on or tyre coming off the rim.
• Always use the size and type of tyres
recommended in this owner's manual.
NOTE
For repair and replacement of tyre it is advised BATTERY
to visit your Authorised Distributor/Dealer.
57
Important safety reminders
• Do not install a tube inside a tubeless tyre on
this vehicle. Excessive heat buildup can
cause the tube to burst.
• Use only tubeless tyres on this vehicle. The
rims are designed for tubeless tyres, and
during hard acceleration or braking, a tube-
type tyre could slip on the rim and cause the
tyre to rapidly deflate.
NUTS, BOLTS & FASTENERS
• Tighten bolts and nuts at regular interval
shown in the maintenance schedule.
• Check that all chassis nuts and bolts are
tightened to correct torque values.
• Check that all cotter pins, safety clips, hose
clamps and cable stays are in place.
Location
The battery is located behind the right side
cover.
Specification
*MF Battery: 12V-3Ah/ETZ4
53
It is not necessary to check the battery • If the battery is expected to be stored for
electrolyte level or add distilled water as the more then two months, ensure to fully
battery is a Maintenance Free (sealed) type. charge the battery once in a month.
If your battery seems weak and electrolyte is • Always ensure the battery is fully charged
leaking (causing hard starting or other before installation.
electrical troubles), contact your Authorised • Ensure the battery leads are properly
Distributor/Dealer. connected to the battery terminals during
NOTE installation.
This symbol on the battery means that Battery removal
this product must not be treated as • Make sure the ignition switch is “OFF”
household waste. position ( ).
This symbol on the battery means the • Remove the seat (pages 27).
old battery must be returned to your • Remove the right side cover screws (1)
Authorised Distributor/Dealer as it and remove the side cover (2).
must be treated as recyclable material. 2
• Battery is a Maintenance-Free (sealed) type
and can be permanently damaged if the
sealing strip is removed.
• An improperly disposed battery can be
harmful to the environment and human
health. Always confirm local regulations for
battery disposal.
Battery charging
Always visit your Authorised Distributor/
Dealer if you see any symptom of battery
discharge as earliest as possible to get the (1) Screws 1 (2) Side cover
battery charged. The battery has a tendency to • Remove the fuse box A and fuse box B from
discharge rapidly if optional electrical the battery clamp (4).
accessories are fitted on the vehicle. • Remove the battery clamp bolt (3) and the
Battery storage battery clamp (4).
• If in case your vehicle is not used for more • Pull the battery (5) out slightly and remove
than a month remove the battery, fully the battery terminal case cover (6).
charge and store in a cool and dry place.
58
 6 5 • Check all fasteners are secured properly.
FUSE REPLACEMENT
Fuse Box (A): Location: Mounted on the
battery clamp (1). The specified fuses are
4
20A and 15A (2) with spare fuses 20A and
15 A (3).
Fuse Box (B): Location: Mounted on the
battery clamp (1). The specified fuse are 15A
(4) with spare fuse 15A (5).
B A 3 ! WARNING
(3) Battery clamp bolt (4) Battery clamp • Never use a fuse with a different rating from
(5) Battery (6) Battery terminal case cover that specified. It may lead to serious damage
(A) Fuse box A (B) Fuse box B to the electrical system or a fire due to short
• Disconnect the negative (-)ve terminal lead circuit.
(7) from the battery first, then disconnect • Battery gives off explosive gases. Keep
the positive (+)ve terminal lead (8). sparks, flames & cigarettes away.
• Pullout the battery from the battery box. 4 5 2 3
7 8

1 B A
(7) (-)ve terminal (8) (+)ve terminal (1) Battery clamp (2) Blade fuse: 20A &15A
Battery installation (3) Spare fuse: 20A & 15A
• Reinstall in the reverse order of removal. Be (4)
(A)
Blade fuse: 15A (5) Spare fuse: 15A
Fuse box A (B) Fuse box B
sure to connect the positive (+)ve terminal
first, then the negative (-)ve terminal.
59
 ! CAUTION 1
• Do not attempt to start or ride the vehicle
without a charged battery, it can cause
fusing of the bulbs and permanent damage
to certain electrical components.
• Turn the ignition switch "OFF" before
checking or replacing the fuse to prevent
accidental short-circuiting.
2
(1) Screw (2) Right pillion step cover
• Turn the adjusting nut (3) to position stop
lamp switch (4) at a point where the stop
lamp will glow just before the brake pedal is
depressed to the limit of its free play. Turn
the adjusting nut in direction (A) to advance
switch timing or in direction (B) to retard
switch timing.
4
STOP LAMP SWITCH
The stop lamp switch must be adjusted so that
stop lamp will glow when rear brake is applied.
Rear brake free play (page 50) should be 3
adjusted before performing stop lamp switch B
adjustment. The procedure for adjusting stop A
lamp switch is as follows:
• Turn the ignition switch to the “ON” ( )
position.
• Remove the right pillion step cover screw
(1) and right pillion step cover (2) . (3) Adjusting nut (4) Stop lamp switch
(A) Advance (B) Retard

60
HEADLAMP FOCUS ADJUSTMENT
Headlamp is factory preset. However in case
of adjustment required, please follow the steps
as given below:
• Headlamp adjustment is done by the
headlamp adjusting bolt (1) located below
headlamp.
• Park the vehicle on level ground.
• Turn the ignition switch to “ON” position
( ) and start the engine.
(1) Headlamp adjusting bolt
• Adjust the headlamp beam vertically
by loosening the bolt & move the headlamp
unit forward & backward for correct focus
adjustment.
! WARNING
An improperly adjust headlamp may blind • converter
oncoming rider/driver or it may fail to light the Keep the engine tuned up.
road for a safe distance.
61
CATALYTIC CONVERTER
This vehicle is equipped with a catalytic
converter in the muffler to meet the emission
norms. This catalytic converter contains noble
metals that serve as catalyst, promoting
chemical reactions to convert CO and HC in
the exhaust to CO2 and H2O (water vapour).
A defective catalytic converter contributes to
air pollution and can impair your engine’s
performance.
1
(1) Catalytic converter
Follow these guidelines to protect your
vehicle’s catalytic converter.
• Always use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
ineffective.
AIR SUCTION VALVE (ASV)
(SECONDARY AIR INJECTION SYSTEM)
Further to meet emission standards this
vehicle is provided with an air suction valve.
Air suction valve (1) supplies fresh air from
the air filter to the exhaust manifold to convert
carbon monoxide to carbon dioxide. This
reduces the CO% in the vehicle’s exhaust.

1
1
(1) Canister
POLISHING OF VEHICLE
After washing your vehicle, wax all painted
(1) Air suction valve (ASV) surfaces (except matte painted surfaces) using
a commercially available polish/quality liquid
EVAPORATIVE EMISSION CONTROL or paste wax to finish the job. Use only a non
SYSTEM abrasive polish or wax made specifically for
This vehicle is equipped with an evaporative automobiles. Apply the polish or wax
emission control system to meet emission according to the instructions on the container.
standards. During warm weather, the petrol NOTE
vapours which contain HC evaporates easily Polishing or waxing is not applicable for
into the atmosphere from the fuel tank, if the
fuel system is unsealed or open. The models having matte paint.
evaporative emission control system is used to
prevent petrol vapours from escaping into the
atmosphere from fuel tank. The canister (1)
collects the fuel vapour from the fuel tank and
then the fuel vapour is drawn into the engine
for re-burning to avoid pollution caused by
the fuel vapour diffused into the air.

62
 BASIC TROUBLESHOOTING
1. STARTING TROUBLE - ENGINE DOES NOT START
A. Fuel System
Check fuel valve position “OFF” Turn to “ON” ( ) position
“ON” position
Check fuel in fuel tank No fuel Refill
Ok
Check fuel lines Leakage/air lock Rectify
Ok
Consult Authorised Distributor/Dealer
B. Electric Starter Not Working
Check fuse Fused Replace fuse (ref. Page 59)
Ok
Inspect battery Weak Consult Authorised Distributor/Dealer
Ok
Check connections, ignition switch/starter switch Loose Secure connections
Ok
Consult Authorised Distributor/Dealer
C. No Spark At Spark Plug
Check ignition switch “OFF” Turn ignition switch “ON” ( )
Ok
Check spark plug for fouling/ Replace spark plug/adjust
Improper electrode gap No spark Spark plug gap (0.6-0.7 mm)
Ok
Check for poorly connected Secure properly
Or loose spark plug wire Loose contact
Ok
Consult Authorised Distributor/Dealer
2. ENGINE STARTS BUT STALLS
Check choke lever position “ON” Turn to “OFF” position
“OFF” position
Check air cleaner element Dirty Replace
Ok
Consult Authorised Distributor/Dealer
63
 BASIC TROUBLESHOOTING
3. POOR PICK UP
Spark plug loose in cylinder head Loose Tighten the spark plug
Ok
Check air cleaner element Clogged Replace
Ok
Check brake binding Improper Readjust free play of rear brake lever/pedal
Ok Adjustment
Check tyre inflation pressure Under inflated Correct tyre pressure
Ok
Consult Authorised Distributor/Dealer
4. ELECTRICAL SYSTEM
Feeble horn sound or no light
Check fuse Fused Replace fuse
Ok
Inspect battery Weak Consult Authorised Distributor/Dealer
Ok
Check bulbs Fuse/wrong wattage Replace bulbs
Ok
Check connections Loose Secure connections
Ok
Consult Authorised Distributor/Dealer
5. i3s SYSTEM
Check i3s switch “ON”/“OFF” position Turn i3s switch “ON”
Ok
Inspect fuse Fused Replace fuse
Ok Consult Authorised
Replace Bulbs
Inspect battery Distributor/Dealer
Ok Weak/i3s indicator blinking
Check neutral indication Loose contact Secure connections/replace switch
Ok
Consult Authorised Distributor/Dealer
64
 CU
ST
OM
ER
HMCL Niloy Bangladesh Ltd.

’S
CO
PY
DELIVERY CERTIFICATE
No.: IB14D

I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

Passion XPRO Vehicle bearing the following particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.

Customer’s Copy
 HMCL Niloy Bangladesh Ltd.
Alongwith the vehicle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool kit
Tool Bag, +, - No. 2 driver, Grip, Box wrench P 16 X 14, Pin spanner
 DIS
TR
IBU AU
TO THO
R/ RI
DE SE
HMCL Niloy Bangladesh Ltd. AL D
ER
COP
Y

DELIVERY CERTIFICATE
No.: IB14D

I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

Passion XPRO Vehicle bearing the following particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.

Authorised Distributor/Dealer copy

 HMCL Niloy Bangladesh Ltd.
Alongwith the vehicle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool kit
Tool Bag, +, - No. 2 driver, Grip, Box wrench P 16 X 14, Pin spanner
WHAT ARE THE BENEFITS OF GENUINE SPARE PARTS ?
• Assures long life
• Ensures economy for a long time
• Safety of vehicle and rider
• Peace of mind
• Value for money
• Assured quality
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
• Material used is inferior
• Damages other parts of clutch like, clutch center and
Clutch plate outer clutch
• Affects fuel efficiency
• Poor acceleration

Cam chain kit • Poor performance

• Reduced life
• Improper sealing
Gasket cylinder head • Engine knocking
• Leads to leakage and smoky exhaust
• Higher emission level
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
• Improper air filtration resulting in premature engine failure
Element air cleaner • Affects fuel efficiency
• Poor engine performance

• Frequent stalling of engine

Spark plug • Higher emission level
• Poor engine performance
• Affects fuel efficiency
• Poor braking efficiency
Brake pads/Shoes • Rider safety-an issue
• Discs/Drum wear out, resulting in subsequent repair cost

Chain sprocket kit • Noisy operation

• Failure of chain can cause fatal accident
 HMCL Niloy Bangladesh Ltd.
JOBS APPLICABLE TO PERIODIC SERVICES
• Wash the vehicle, blow dry with air.
• Inspect fuel line at every service.
• Inspect throttle free play and operation at every service, adjust if necessary.
• Clean carburetor at first service then every 6000 km, adjust if necessary.
• Replace air cleaner element at every 15000 km.
• Inspect, clean spark plug at every service, adjust if necessary (replace at every 12000 km).
• Inspect the valve clearance at every service, adjust if necessary.
• Replace engine oil or top up as per the maintenance schedule.
• Clean engine oil strainer screen at first service then at every 6000 km.
• Clean engine oil centrifugal filter at first service then at every 6000 km.
• Inspect electric starter operation at every service.
• Inspect and lubricate the starter reduction gear shaft at every 6000 km.
• Inspect oil circulation at every service.
• Inspect, clean, lubricate and adjust the drive chain at every 2000 km.
• Inspect drive chain slider.
• Inspect battery voltage at every service and charge if required.
• Inspect brake shoe wear at every service, adjust if necessary.
• Clean and lubricate brake cam at second service, then at every 6000 km.
• Inspect brake pads, disc wear and brake fluid level at every service. Top-up if necessary. Replace brake fluid
once in every two years or 30000 km. whichever is earlier.
• Inspect all lamps, horn and switches at every service, adjust if necessary.
• Inspect headlamp focus at every service, adjust if necessary.
• Inspect clutch free play at every service, adjust if necessary.
• Lubricate the side stand and main stand at every service.
• Inspect and clean the side stand switch at every service.
• Inspect whether i3s system is working properly at every service.
• Inspect all the fasteners and tighten to the specified torque (if required).
• Inspect wheels, wheel bearings and tyre pressure at every service.
• Inspect steering for smooth operation, adjust in every alternate service and lubricate at every 12000 km.
• Inspect front suspension at every service, replace oil once in every 2 year or 30000 km whichever is earlier.
• Inspect rear suspension mounting bushes play, replace if necessary.
• Inspect secondary air injection system at every 6000 km.
• Check idle CO emission along with idle rpm/idle CO adjustment (if required).
• Inspect the canister hoses for deterioration, damage or loose connections and canister for cracks or other damages.
• Polish entire vehicle.
 SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km. Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
I 500 - 750
II 3000 - 3500
III 6000 - 6500
IV 9000 - 9500
V 12000 - 12500
VI 15000 - 15500
VII 18000 - 18500
VIII 21000 - 21500
IX 24000 - 24500
X 27000 - 27500
XI 30000 - 30500
XII 33000 - 33500
XIII 36000 - 36500
XIV 39000 - 39500
XV 42000 - 42500
XVI 45000 - 45500
XVII 48000 - 48500
NOTE
It is mandatory to avail all free and paid services as per the recommended schedule to be eligible for
the warranty benefits. Please ensure that each paid service is availed within 90 days from the date of
previous service or as per the recommended schedule, whichever is earlier.
 SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km. Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
XVIII 51000 - 51500
XIX 54000 - 54500
XX 57000 - 57500
XXI 60000 - 60500
XXII 63000 - 63500
XXIII 66000 - 66500
XXIV 69000 - 69500
XXV 72000 - 72500
REMARKS (IF ANY)
 SERVICE ADVICE SHEET
Normal wear and tear components replacement advice
Kms Authorised Completion Dt.
Date Advice Distributor/Dealer
Job Card No. (Sig. & Stamp) Job Card No.
 HMCL Niloy Bangladesh Ltd.
OWNERSHIP RECORD AND DATA

VIN

AUTHORISED DISTRIBUTOR/DEALER NAME

ADDRESS

AUTHORISED DISTRIBUTOR/DEALER
STAMP AND SIGNATURE