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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). 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. 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
!
Improper service or repairs can create an
unsafe condition that can cause your
customer or others to be seriously hurt or
killed. Follow the procedures and
precautions in this manual and other
service materials carefully.
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.

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Summary of Contents for HERO ECO DELUXE

  • Page 1 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.
  • Page 2 MEMO...
  • Page 3: Table Of Contents

    CONTENTS SECTION HOW TO USE THIS MANUAL This shop manual describes the service procedures for ECO DELUXE. GENERAL INFORMATION Follow the Maintenance Schedule (Section-3) recommendations to ensure that the vehicle is in peak operating condition. FRAME/BODY PANELS/EXHAUST SYSTEM Performing the first scheduled maintenance is very important. It...
  • Page 4 MEMO...
  • Page 5 SYMBOLS SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOLS DEFINITION Replace the part(s) with new one (s) before assembly. Apply oil. Use engine oil unless otherwise specified. Apply grease.
  • Page 6 SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOLS DEFINITION Feeler gauge Micrometer Cylinder bore gauge Dial gauge Degreasing Vernier caliper...
  • Page 7: General Service Precautions

    IN A PATTERN After assembling, check every part for proper Use only genuine Hero MotoCorp parts and installation, movement and operation. recommended lubricants. Always ensure mutual safety when working with Use specified special and common tools only.
  • Page 8: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION FRONT FRONT FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side steering head. of the crankcase. FRONT CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is stamped on the...
  • Page 9: Specifications

    GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS Overall length 1965 mm Overall width 720 mm Overall height 1045 mm Wheelbase 1235 mm Saddle height 805 mm Dimensions Ground clearance 165 mm Kerb weight 107 kg (kick start)/110 kg (electric start) Minimum turning radius 2.10 meters Maximum payload 130 kg...
  • Page 10 GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS Carburetor type Side draft variable venturi type with TCIS Identification number PBCC7 Venturi diameter 18 mm Float level 11.7 mm turns out Air screw initial opening 1⅝ Carburetor ±100 rpm Idle speed 1400 Main jet # 105 Slow jet # 35...
  • Page 11: Maintenance

    ENGINE OIL At Draining 0.85 litre Engine Oil Capacity At Disassembly 1.05 litres Brand: Hero 4T Plus Grade: SAE 10W30 SJ Grade (JASO MA) Manufactured by: Recommended Engine Oil 1. Tide Water Oil Co. (India) Limited. 2. Savita Oil Technologies Limited.
  • Page 12: Fuel System

    GENERAL INFORMATION Unit: mm FUEL SYSTEM ITEM SPECIFICATIONS Carburetor type Side draft variable venturi type with TCIS Identification number PBCC7 18 mm Venturi diameter 11.7 mm Float level Air screw initial opening 1-⅝ turns out Idle speed 1400±100 rpm Main jet # 105 Slow jet # 35...
  • Page 13: Clutch/Gearshift Linkage

    GENERAL INFORMATION Piston O.D 49.975-49.995 49.88 Piston pin hole I.D 13.002-13.008 13.055 Piston pin O.D 12.994-13.000 12.980 Piston-piston pin clearance 0.002-0.014 0.075 Connecting rod small end I.D 13.016-13.034 13.10 Cylinder-piston clearance 0.010-0.040 0.15 Piston Connecting rod-piston pin clearance 0.010-0.034 0.15 0.015-0.050 0.12 Piston ring-groove clearance...
  • Page 14: Front Wheel/Brake/ Suspension/Steering

    GENERAL INFORMATION Unit: mm FRONT WHEEL/SUSPENSION/STEERING ITEM STANDARD SERVICE LIMIT Minimum tyre tread depth Rider only 1.75 kgf/cm (25 psi) Cold tyre pressure Rider & Pillion 1.75 kgf/cm (25 psi) Front axle run-out 0.20 Radial Front wheel rim run-out Axial Fork spring free Length Fork tube run-out 0.20...
  • Page 15: Lamps/Meters/Switches

    GENERAL INFORMATION Primary coil resistance 0.72-0.88 Ω Ignition Coil With plug cap 17.33-20.07 KΩ @ 20°C Secondary coil resistance Without plug cap 12.33-15.07 KΩ @ 20°C Stator coil resistance 0.2-1.2 Ω @ 20°C Alternator Pulse generator resistance 50-200 Ω @ 20°C Pulse generator 1.5V (minimum) @ 300 rpm Peak Voltage...
  • Page 16: Torque Values

    GENERAL INFORMATION TORQUE VALUES TORQUE THREAD ITEM VALUES REMARKS SIZE & TYPE kgf-m BODY PANELS/EXHAUST SYSTEM Exhaust muffler joint nuts 6 mm 8~12 0.8~1.2 Exhaust muffler mounting bolt 8 mm 18~25 2.8~3.5 Upper mounting nut 10 mm 29~39 3.0~4.0 Under mounting cap nut 10 mm 29~39 3.0~4.0...
  • Page 17 GENERAL INFORMATION TORQUE VALUES TORQUE THREAD ITEM VALUES REMARKS SIZE & TYPE kgf-m FRONT WHEEL/BRAKE/SUSPENSION/STEERING Handle upper holder bolt 6 mm 10~14 1.0~1.4 Socket bolt Front axle nut 12 mm 49~59 5.0~6.0 PT nut 8 mm 15~25 1.5~2.5 Fork socket bolt Fork cap 26 mm 15~30...
  • Page 18: Lubrication & Seal Points

    Flange bolt for tightening of rachet guide plate threaded portion TB# 2415 or DL-200 or equiv. Crankshaft tapered area Degreasing ACG flywheel tapered area NOTE Engine oil for applying will be Hero 4T Plus, GRADE:SAE 10W 30 SJ Grade (JASO MA) engine oil without molybdenum. 1-12...
  • Page 19 GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS Air cleaner connection tube case connecting area #540 cemedine or equiv. Air cleaner duct case connecting area Spreading Left handle grip inside of grip Silicon grease Throttle cable inside of boot (TSG 3251) Filling Clutch cable inside of boot or equivalent Rear brake pivot sliding portion...
  • Page 20: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Flywheel puller To remove the flywheel from crankshaft. 070HHKTC004 Socket wrench To remove lock nut from clutch assembly and rotor filter. 070HH198002 Universal holder To hold the flywheel while removing flywheel nut. 070HH198003 Clutch centre holder To hold the centre clutch while removing the lock nut.
  • Page 21 GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Front fork oil seal driver attachment dia, 31mm To drive in new oil seal. 070HHKFN004 Crankcase bearing remover collect, 15mm To remove bearing from crankcase. 070HHKFN005 Crankcase bearing remover shaft To remove bearing from crankcase. 070HHKFN006 Crankcase bearing remover weight To remove bearing from crankcase.
  • Page 22 GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Flywheel puller To remove the flywheel from crankshaft. 070HHKTN001 Collet, 17mm To remove bearing from crankcase. 070HHKTN002 Crankshaft bearing (LHS) puller To remove the bearing from crankshaft. 070HHKTN003 To remove top and bottom cone races from the Bottom cone race driver 070HHKTN005 steering head pipe.
  • Page 23 To restrict water entry during washing. 070HHKZA004 131 Muffler plug (Small) To restrict water entry during washing. 070HHK06004 132 Hero integrate diagnostic instrument For immobilizer diagnosis & key registration. HMCL0214AABA01 133 HIDI wire harness For sync between instrument & bike wire harness.
  • Page 24 GENERAL INFORMATION FRONT VIEW-HEAD LAMP AREA RIGHT TURN SIGNAL CORD FRONT BRAKE CABLE LEFT TURN SIGNAL CORD SPEEDOMETER CORD HARNESS WIRE INSERT CLIP INTO HOLE OF STAY HARNESS WIRE FRONT STOP SWITCH CORD SPEEDOMETER CABLE START SWITCH CORD CLUTCH CABLE COMB &...
  • Page 25 GENERAL INFORMATION TOP VIEW-HANDLEBAR AREA COMBINATION & LOCK SWITCH THOTTLE CABLE TURN SIGNAL SWITCH CORD FRONT BRAKE CABLE CLUTCH CABLE BAND B1, WIRE START SWITCH CORD CLUTCH SWITCH CORD (SELF TYPE ONLY) FRONT STOP SWITCH CORD BAND B1, WIRE HARNESS WIRE 1-19...
  • Page 26 GENERAL INFORMATION FRONT RIGHT VIEW CLUTCH CABLE START SWITCH CORD (SELF TYPE ONLY) HARNESS WIRE THROTTLE CABLE HORN CORD CLUTCH CABLE IGNITION COIL IGNITION COIL CORD SPEEDOMETER CABLE FRONT BRAKE CABLE 1-20...
  • Page 27 GENERAL INFORMATION LH SIDE VIEW IGNITION COIL CORD (+)VE: BLACK/YELLOW THROTTLE SWITCH CORD IGNITION COIL CORD (-)VE: GREEN HORN CORD MAIN HARNESS REAR STOP SWITCH CORD CDI UNIT VACUUM TUBE ACG CORD WATER GUARD RUBBER ENGINE BREATHER TUBE OVER FLOW TUBE SHALL BE DIRECTION TOWARD THE LOWER CROSS PIPE SIDE 1-21...
  • Page 28 GENERAL INFORMATION RH SIDE VIEW HORN CORD WIRE HARNESS CLUTCH CABLE THROTTLE CABLE FUEL UNIT COUPLER AIR VENT TUBE SHALL GO THROUGH WATER GARD HOLE WATER GUARD RUBBER CLIP RUBBER SHALL GO THROUGH WATER GUARD HOLE OVER FLOW TUBE CLIP RUBBER SHALL GO THROUGH WATER GUARD HOLE STAY AIR/ C LOWER SHALL GO THROUGH WATER GARD HOLE...
  • Page 29 GENERAL INFORMATION RH SIDE BATTERY & ELECTRICAL COMPONENTS WIRE HARNESS BATTERY (+)CORD CDI UNIT FUSE BOX BATTERY (-)CORD TURN SIGNAL RELAY WIRE HARNESS CLUTCH CABLE REAR STOP SWITCH CORD REAR STOP SWITCH 1-23...
  • Page 30 GENERAL INFORMATION TAIL LAMP VIEW RIGHT TURN SIGNAL CORD TAIL LIGHT CORD LEFT TURN SIGNAL CORD 1-24...
  • Page 31 GENERAL INFORMATION RR UNIT FRAME EARTH POINT TO BE BUTTED 1-25...
  • Page 32 GENERAL INFORMATION SET GROMMET FIRMLY ACG CORD TUBE SHALL BE BUTTED TO STATOR SIDE PULSER 1-26...
  • Page 33 GENERAL INFORMATION REAR WHEEL SIDE SWING ARM BRAKE, PEDAL COMPONENT STOP SWITCH SPRING BRAKE ARM STOPPER BRAKE PANEL ASSEMBLY 1-27...
  • Page 34 Carbon monoxide does not react in the same way, but it is toxic. Hero MotoCorp Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

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