A FEW WORDS ABOUT SAFETY

SERVICE INFORMATION

The service and repair information contained in this manual is intended for use by qualified, professional technicians.

Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also

damage the vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures

require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

procedure or a tool that is not recommended by Hero MotoCorp, must determine the risks to their personal safety and the safe

operation of the vehicle.

If you need to replace a part, use genuine Hero MotoCorp parts with the correct part number or an equivalent part. We strongly

recommend that you do not use replacement part of inferior quality.

FOR YOUR CUSTOMER’S SAFETY

Proper service and maintenance are essential to the customer’s safety and the

reliability of the vehicle. Any error or oversight while servicing a vehicle can result in

faulty operation, damage to the vehicle or injury to others.

FOR YOUR SAFETY

Because this manual is intended for the professional service technician, we do not

provide warnings about many basic shop safety practices (e.g., Hot parts-wear

gloves). If you have not received shop safety training or do not feel confident about

your knowledge of safe servicing practice, we recommended that you do not

attempt to perform the procedures described in this manual. Some of the most

important general service safety precautions are given below. However, we cannot

warn you of every conceivable hazard that can arise in performing service and

repair procedures. Only you can decide whether or not you should perform a given

task.

IMPORTANT SAFETY PRECAUTION

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin and make sure you have the tools, the replacement or repair parts and the skills

required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around

pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,

make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.

This will help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire of explosion, be careful when

working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

!

WARNING

Failure to properly follow instructions and

precautions can cause you to be seriously

hurt or killed.

Follow the procedures and precautions in

this manual carefully.

!

WARNING

MEMO

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5

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DASH

DASH

CONTENTS SECTION

ENGINE & DRIVE TRAIN

CHASSIS

ELECTRICAL

!

CAUTION

!

WARNING

!

DANGER

• Instructions-how to service this vehicle correctly and safely.

GENERAL INFORMATION

1

BODY PANELS/EXHAUST SYSTEM

2

MAINTENANCE

3

LUBRICATION SYSTEM

4

FUEL SYSTEM

5

ENGINE REMOVAL/INSTALLATION

6

CYLINDER HEAD/VALVES

7

CYLINDER/PISTON

8

9

FINAL REDUCTION

10

ALTERNATOR

11

CRANKCASE/CRANKSHAFT

12

REAR WHEEL/BRAKE/SUSPENSION

14

TUBELESS TYRES

15

BATTERY/CHARGING SYSTEM

16

13

FRONT WHEEL/SUSPENSION

/STEERING

IGNITION/IMMOBILIZER SYSTEM

17

ELECTRIC STARTER

18

LAMPS/METERS/SWITCHES

19

TROUBLESHOOTING

21

WIRING DIAGRAM

20

SYMBOLS

SYMBOLS

Apply a Locking agent

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Use special tool.

Use fork oil.

Check for continuity.

Replace the part(s) with new one (s) before assembly.

Apply oil. Use engine oil unless otherwise specified.

Apply Grease

Apply Silicone Grease.

Apply Moly Paste.

Apply Sealant

Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning

associated with them respectively.

DESCRIPTION

Torque control required. Data beside it indicates specified torque.

NEW

OIL

BF

V

A

TOOL

G

S

M

LOCK

SEAL

FORK

5

0

45

50

0

10

20

30

40

50

60

70

80

90

SYMBOLS

Feeler Gauge

Micrometer

Cylinder Bore Gauge

Dial Gauge

Degreasing

Vernier Caliper

DESCRIPTION

MEMO

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1.GENERAL INFORMATION

OIL

GENERAL SERVICE PRECAUTIONS

Always replace gaskets, O-rings, circlips

and cotter pins with new ones.

When tightening nuts and bolts, start first with the

larger or centre ones. Tighten these to the specified

torque using a criss-cross pattern.

Use only genuine Hero MotoCorp parts and

recommended lubricants.

Use specified special and common tools only.

When engine and final drive components are

disassembled and inspected, coat the mating

surface with a lubricant to prevent corrosion.

After assembling, check every part for proper

installation, movement and operation.

Always ensure mutual safety when working with

a partner.

IN A x PATTERN

O-RING

COTTER PIN

After assembling components, use proper

assembly lubricants.

SOLVENT

CIRCLIP

GASKET

General Service Precautions

1-1

General Safety

1-2

Features

1-3

Model Identification

1-13

Specifications

1-14

Service Limit

1-16

Engine Torque Values

1-22

Frame Torque Values

1-23

General Torque Values

1-24

Lubrication & Seal Points

1-25

Special Tools

1-28

Emission control system

1-32

Cable/Wiring Harness/Tubes

1-34

/Hoses Routing

M

1

! WARNING

The exhaust contains poisonous carbon monoxide

gas that can cause loss of consciousness and may

lead to death.

GENERAL SAFETY

CARBON MONOXIDE

If the engine must be running to do some work, make sure

the area is well ventilated. Never run the engine in an

enclosed area.

Run the engine in an open area or with an exhaust

evacuation system in an enclosed area.

GASOLINE

Work in a well ventilated area. Keep cigarettes, flames or

sparks away from the area or where gasoline is stored.

! WARNING

Gasoline is extremely flammable and is explosive

under certain conditions.

KEEP OUT OF REACH OF CHILDREN.

! WARNING

HOT COMPONENTS

Engine and exhaust system parts become very hot and

remain hot for some time after the engine is run.

Wear insulated gloves or wait for the engine and exhaust

system to cool down before handling these parts.

! WARNING

BATTERY

The battery gives of explosive gases: keep sparks, flame

and cigarettes away. Provide adequate ventilation for

charging.

! WARNING

Inhaled fibers have been found to cause respiratory

disease and cancer.

! WARNING

USED ENGINE/TRANSMISSION OIL

! WARNING

Route all electrical wire/harness and cables. Keep them

away from sharp edges and area where they might be

pinched between moving parts.

ELECTRICAL WIRES

! WARNING

BATTERY HYDROGEN GAS & ELECTROLYTE

• Battery gives off explosive gases ; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.

• Battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and

face shield.

- If electrolyte gets on your skin, flush with water.

- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician.

• If swallowed, drink large quantity of water or milk of magnesia or vegetable oil and call a physician.

KEEP OUT OF REACH OF CHILDREN.

SERVICE RULES

1. Use genuine Hero MotoCorp recommended parts and lubricants or their equivalents.

Parts that do not meet Hero MotoCorp’s design specifications may damage the scooter.

2. Use the special tools designed for this product.

3. Install new gaskets, O-rings, Cotter pins, Lock plates etc. when reassembling.

4. When tightening a series bolts or nuts, begin with the larger diameter of inner bolts first, and tighten to specified torque

diagonally, in incremental steps unless a particular sequence is specified.

5. Clean parts in cleaning solvent on disassembly. Lubricate any sliding surfaces before reassembly.

6. After assembly, check all parts for proper installation and operation.

7. Route all electrical wires, Cable/Wiring Harness/Tubes/Hoses as shown from page 1-29 through 1-57.

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GENERAL INFORMATION

FEATURES

COMBINATION LOCK

Multi-functional combination lock with ignition ON-OFF,

seat catch opening, fuel tank lid cover opening and

steering lock option for more convenience.

CENTER COMPARTMENT

- Large under seat compartment to accommodate a

helmet, documents and tools.

- Maximum weight capacity is 10 kg.

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GENERAL INFORMATION

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HELMET HOLDER

Two helmet holders are located under the seat. To secure

the helmet to the holder, remove the seat, attach the

helmet strap or ring to the helmet holder and close the

seat.

LUGGAGE HOOKS

Two luggage hooks are provided in scooter to carry a light

luggage like shopping bags or carry bags. one hook is

provided below the handlebar weighing up to 3 kg and the

other hook is located below the front end of the seat

weighing up to 1.5 kg.

1-4

GENERAL INFORMATION

EXTERNAL FUEL FILLING

- An external fuel filling port provided near the rear grip for

convenient filling.

- To open the filler cap, insert the key & while pushing in

turn it clockwise to ”Fuel Open” position . The lid will be

open.

- Remove the fuel filler cap by turning it anti-clockwise.

AIR FILTER

Maintenance free viscous paper pleated type air filter is

used in this scooter for enhanced filtration of air for longer

engine life.

ENGINE

Fuel efficient and powerful 4-stroke OHC engine with

latest design.

DRY AUTOMATIC CENTRIFUGAL CLUTCH

The system is equipped with dry automatic centrifugal

clutch and there is no need for clutch operation when

starting or stopping.

ROLLER ROCKER ARM

The rocker arm roller rolls over the cam lobe instead of

sliding and hence reduces the friction and wear.

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GENERAL INFORMATION

1

CENTRIFUGAL DECOMPRESSION SYSTEM

Automatic centrifugal decompression system reduces kick

starting effort and kick back during starting. Reduces the

load on the battery during electric start.

PISTON PIN

- Off-Set piston pin reduces stress on reciprocating parts.

- In addition it also reduces piston slap at the dead centres

leading to enhanced engine life and low noise level.

AUTOMATIC CAM CHAIN TENSIONER

The cam chain tensioner takes up slack in the cam chain

automatically.

FRAME

High rigidity under bone frame, most suitable for step-thru

vehicles ensuring rider comfort.

1-6

GENERAL INFORMATION

PARKING BRAKE

Rear parking brake is a safety feature which prevents

scooter from rollover when parked on side stand.

INTEGRATED BRAKING SYSTEM

Integrated braking delivers enhanced braking & stability by

simultaneously actuating front and rear brake. This leads

to shorter braking distance for safety.

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GENERAL INFORMATION

TUBELESS TYRES

Designed for an enhanced performance, tubeless tyre

prevent sudden deflation in case of puncture.

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EXHAUST MUFFLER

Stylish muffler with 2-way catalytic converter to reduce

harmful content from the exhaust gases and two piece heat

protector for pillion safety.

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GENERAL INFORMATION

BALL CAGE STEERING HEAD BEARING

Bigger diameter and rugged design with an ability to

handle greater load.

Can work under slight pre-load to avoid risk of unwanted

free play leading to precise steering and better handling on

rough terrain.

TURN SIGNAL LAMPS

Turn signal lamps have elongated clear lens with multi

focal reflector and amber bulb to enhance visibility &

safety.

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GENERAL INFORMATION

MAINTENANCE FREE BATTERY

MF Battery ensures sufficient cold cranking ampere (CCA)

for easy starting even in cold conditions. Does not require

topping up of distilled water and specific gravity inspection

once filled & sealed.

FULLY TRANSISTORISED IGNITION

SYSTEM (FTIS)

Fully transistorised ignition system provided a longer spark

duration which improves combustion and reduces exhaust

emission.

SERVICE REMINDER

A ”service reminder” is provided in meter console, to

indicate the user to bring the vehicle to an authorised Hero

MotoCorp workshop for service.

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