HERO Karizma ZMR Manual
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HERO Karizma ZMR Manual

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PREFACE
Karizma ZMR
Thank you for selecting a
. We wish you many miles of
Hero MotoCorp
continued riding pleasure in the years ahead.
We at
are committed to demonstrate excellence in our environment
Hero MotoCorp,
performance on a continual basis, as an intrinsic element of our corporate philosophy. To
achieve this we commit ourselves to continue product innovations to improve environment
compatibility, comply with
all applicable legislation including environment legislation
and
strengthen the green supply chain.
Your
vehicle
is conforming to latest (Bharat stage- norms) regulation for emission, safety &
IV
noise levels. We are also using non asbestos brake shoes/pads and engine gaskets which are
environment friendly in nature.
This vehicle is fitted with a lighting feature known as "Automatic Headlamp ON". The feature
is mandated for all 2 Wheelers by Ministry of Road Transport & Highways (Government of
India) vide notification GSR 188 (E) dated 22nd February 2016. This feature helps in
conspicuity for improving rider safety. The headlamp of this vehicle will always be lit ON when
the engine gets ON.
This booklet is your guide to the basic operation and maintenance of your new
Karizma ZMR
. Please take time to read it carefully. As with any fine
Hero MotoCorp
machine, proper care and maintenance are essential for trouble-free operation and optimum
performance.
Your Authorised
dealer will be glad to provide further information or
Hero MotoCorp
assistance and is equipped to handle your future service needs.
Let us make this world a safer, healthier and more environment friendly place.

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Summary of Contents for HERO Karizma ZMR

  • Page 1 PREFACE Karizma ZMR Thank you for selecting a . We wish you many miles of Hero MotoCorp continued riding pleasure in the years ahead. We at are committed to demonstrate excellence in our environment Hero MotoCorp, performance on a continual basis, as an intrinsic element of our corporate philosophy. To...
  • Page 2 ACCESSORIES SHOWN MAY NOT BE THE PART OF STANDARD FITMENT. IT IS OUR ENDEAVOUR TO CONSTANTLY IMPROVE OUR PRODUCTS. THIS COULD LEAD TO CHANGE IN PRODUCT SPECIFICATIONS WITHOUT NOTICE. Hero ‘KARIZMA ZMR’ COMPLIES WITH THE LATEST EMISSION NORMS. MotoCorp Ltd...

  • Page 3: Table Of Contents

    TOOL KIT/FIRST AID KIT POLISHING OF VEHICLE CLEANING AND WASHING OF VEHICLE BASIC TROUBLESHOOTING MAINTENANCE ROAD SIGNS Importance of maintenance WARRANTY DETAILS • Maintenance safety INSTALLATION • Safety precaution HERO GENUINE PARTS • Maintenance schedule ZONAL/REGIONAL/AREA OFFICES • Spark plug inspection •...

  • Page 4: Vehicle Identification

    Month of Assembly Plant Serial Number Description Manufacturing Manufacturing Model: Karizma ZMR Engine Variants Electric start/Front disc/Rear disc/Cast wheel VIN and Engine No. may be required: 1. During registration of the vehicle. 2. For dealing with legal & insurance departments.
  • Page 5 VEHICLE VIEWS FRONT VIEW 1. Front fender 6. Front left turn signal lamp 2. Right position lamp guide 7. Left position lamp guide 3. Front right turn signal lamp 8. Headlamp (Hi-beam) 4. Front visor 9. Oil cooler 5. Headlamp (Lo-beam) *Accessories and features shown may not be part of standard fitment.
  • Page 6 VEHICLE VIEWS REAR VIEW 1. Left rear turn signal lamp 3. Right rear turn signal lamp 2. Tail/stop lamp 4. Licence plate lamp *Accessories and features shown may not be part of standard fitment.
  • Page 7 VEHICLE VIEWS FRONT VIEW 1. Horn switch 8. Ignition switch with steering lock 2. Turn signal lamp switch 9. Front brake lever 3. Clutch lever 10. Dynamic handlebar damper 4. Passing switch 11. Throttle grip 5. Dimmer switch 12. Electric starter switch 6.

  • Page 8: Vehicle Views

    VEHICLE VIEWS LEFT SIDE VIEW 2 3 4 1. Starter motor 6. Side stand 10. Rear grip 2. Gearshift pedal 7. Pillion foot rest 11. Document & tool kit 3. Side stand switch 8. Seat/helmet hanger compartment 4. Main stand 9.
  • Page 9 VEHICLE VIEWS RIGHT SIDE VIEW 1. Rear disc 7. Throttle body 13. Battery compartment 2. Pillion foot rest 8. Caliper assembly 14. Rear brake fluid reservoir 3. Rear master cylinder 9. Front disc 15. Fuse box 10. Front master cylinder 4.

  • Page 10: Vehicle Specification

    VEHICLE SPECIFICATION ITEM SPECIFICATIONS Dimensions Overall length 2100 mm Overall width 805 mm Overall height 1190 mm Wheelbase 1360 mm Saddle height 810 mm Ground clearance 145 mm Weight Kerb weight 157 kg Capacities Engine oil 1.35 litres at disassembly and 1.10 litres at draining Fuel tank 15.3 litres (Minimum) Hydraulic brake fluid...
  • Page 11 VEHICLE SPECIFICATION ITEM SPECIFICATIONS Trail length 94 mm Front 80/100x18-47P (Tubeless tyre) Tyre size Rear 120/80x18-62P (Tubeless tyre) Front (Disc type) Dia. 276 mm Brakes Rear (Disc type) Dia. 240 mm Front wheel Cast wheel Rear wheel Cast wheel Transmission Primary reduction 3.0909 (68/22) 3.0769 (40/13)

  • Page 12: Accessories & Modification

    ACCESSORIES & MODIFICATIONS impair your vehicle's handling, stability and Modifying your vehicle or using non- braking, making it unsafe to ride. Removing or Hero accessories can make your vehicle modifying your lamps, mufflers, emission MotoCorp unsafe. Before you consider making any...

  • Page 13: Vehicle Safety

    Hero MotoCorp handles, and to become accustomed to the vehicle. vehicle's size and weight.

  • Page 14: Protective Apparel

    If you are involved in a crash WARNING Personal safety is your first priority. If you or Not wearing a helmet increases the chance of • anyone else has been injured, take time to serious injury or death in a crash. assess the severity of the injuries and whether Be sure you and your pillion always wear a •...
  • Page 15 To make yourself more visible, wear bright • reflective clothing that fits well. Take care of loose/hanging clothes while • solo/pillion riding. Get your vehicle serviced regularly by the • Authorised workshop. Hero MotoCorp...

  • Page 16: Tips For Healthy Environment

    Hero MotoCorp 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 and make sure you change it every 6000 kms. (with Hero MotoCorp top up every 3000 kilometres) to keep the engine fit and environment healthy.

  • Page 17: Parts Function

    PARTS FUNCTION Ignition switch “ON” ( ) Position “OFF”( ) Position/ Lock Open (1) Ignition key (2) Ignition switch “LOCK” Position (3) Steering lock Key Position Key Removal Function The engine can be started. • The combination meter console LCD panel •...
  • Page 18 When the ignition switch is turned "ON" the combination meter console (1) LCD will display the following digital segments so that you can be sure the LCD display is functioning properly. 1. Combination meter console 6. Tripmeter 2. Digital clock (depending on last selection) 3.

  • Page 19: Instruments & Indicators

    Instruments and Indicators The indicators are in the combination meter console. Their functions are described in the tables on the followings pages. Description Sl. No. Function Lamp “ ” glows when the engine is running . Position lamp, Position Lamp Indicator Tail lamp and Licence plate lamp are functional.
  • Page 20 Programmed FI system is “OK”. If it “flashes”, or (15) malfunction indicator remains “ON” there is an abnormality in the Programmed FI lamp (MIL) system, it is recommended to reduce the speed and drive it to Authorised workshop for check up. Hero MotoCorp...
  • Page 21 (a) Digital clock To set the hour, press Reset Button (3) until • the desired hour is displayed. Digital Clock (1) shows hours and minutes. The time is advanced by 1 hour each time To adjust the time, proceed as follows : •...
  • Page 22 To set the minute press Reset Button (3) • TOTAL until the desired minute. The minute display will return to " " when " " is reached without affecting the hour display. The time advances by 1 minute, each • time the button is pressed.
  • Page 23 Sign-Off message: After the ignition is Press "Reset" button (4) to select value of • • turned "OFF" the Sign-Off Message will be 1 character. (The value will increase every displayed. .25 seconds if the button is pressed continuously) There are "6" characters and Side stand “ON”...
  • Page 24 After selecting the 6 character, finally press • the "SEL" button to "SAVE" the "User Name" in the memory and "END" the user name registration . RESET NOTE 4 5 6 If the button is not operated for more • than 30 seconds, the selected mode will x1000r/min x1000r/min...
  • Page 25 (d) Fuel gauge If only one segment (3) is displayed and blinks, this indicates that the fuel quantity is The fuel gauge (1) is of a Liquid Crystal low and the fuel tank should be refilled as soon Display (LCD) type. as possible.

  • Page 26: Handlebar Switches Control

    FEATURES Steering lock Steering lock is with in the Ignition switch, turn the key (1) to ‘OFF’ position & turn the handle bar towards left or right & push the key downwards & turn towards “LOCK” position. After locking take out the key. (1) Passing switch (2) Dimmer switch (1) Ignition key...

  • Page 27: Fuel Tank

    4. Horn switch Fuel tank Press the horn switch (4) to operate the horn. Fuel tank capacity is 15.3 litres (minimum). 5. Clutch switch To unlock fuel tank cap (1) lift the key hole • cover (2), insert ignition key (3) turn it There is a clutch switch (5) provided for the clockwise and remove the cap.

  • Page 28: Seat Lock/Seat Removal

    To lock-position the cap back on the Operation : Insert the ignition key (1) in • opening with the arrow mark " " on the seat lock (3) and turn it clockwise. Pull the cap facing towards the front of the vehicle knob (4) downwards, behind the lock to then press gently.

  • Page 29: Pre-Ride Inspection

    Lift the rider seat (8) to release the lugs (7) from the grommets (9) and pullout towards rear to release the tab (10) from the slot (11). Seat installation To install, engage the tab (10) of the rider seat with the slot (11) of the fuel tank and slide the seat towards front, then align the lugs (7) on to the grommets (9) located on the frame.

  • Page 30: Starting The Engine

    To protect the catalytic converter in your Fuel level-Ensure sufficient fuel is available • • vehicle's exhaust system, avoid extended in the fuel tank for your journey (page 24). idling and the use of leaded petrol. Check for leaks. Your vehicle's exhaust contains poisonous •...
  • Page 31 If the engine starts with unstable idle, • open the throttle slightly. If the engine does not start wait for 10 • seconds, then follow steps 1-3 again. Ignition cut-off Your vehicle is designed to automatically stop the engine and fuel pump, if the vehicle is over-turned (Bank angle sensor cuts-off the ignition).

  • Page 32: Riding

    RIDING Review vehicle Safe Riding Tips (page 12) before you ride. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when riding, idling or parking your vehicle. After engine has been warmed up, the •...

  • Page 33: Parking

    TOOL KIT/FIRST AID KIT should be smooth under these condition. Rapid acceleration, braking or turning may The tool kit (1) is located below the seat in the cause loss of control. For your safety, rear. Some emergency repairs, minor exercise extreme caution when braking, adjustments and parts replacement can be accelerating or turning.

  • Page 34: Cleaning And Washing Of Vehicle

    Rub the soiled area gently rinsing it maintenance schedule. frequently with fresh water. Consult your Authorised After cleaning spray water thoroughly. Hero MotoCorp • workshop for recommendation applicable to Dry the vehicle by wiping with dry soft cloth. • your individual needs and use.

  • Page 35: Maintenance Safety

    Remember that your Authorised Hero workshop knows your vehicle best MotoCorp and is fully equipped to maintain and repair it. To ensure best quality and reliability, it is recommended to use Hero MotoCorp genuine parts for repair and replacement.

  • Page 36: Maintenance Schedule

    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 by properly trained and equipped technicians. Hero MotoCorp Your Authorised workshop meets all of these requirements. Hero MotoCorp Ensure that each paid service is availed within 90 days or 3000 km from the date of previous service, whichever is earlier.
  • Page 37 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. WHICHEVER DURING FREE SERVICE PERIOD COMES FIRST AFTER FREE SERVICE SERVICE...
  • Page 38 WHICHEVER DURING FREE SERVICE PERIOD COMES FIRST AFTER FREE SERVICE ONCE IN EVERY SERVICE ITEMS Next Next Next Next DAYS 1st 60 500- 3000- 6000- 9000- 12000- KM Note-1 3000 6000 9000 12000 15000 3500 6500 9500 12500 Brake Pad wear Note-5 Brake Fluid Stop Lamp Switch...

  • Page 39: Spark Plug Inspection

    Spark plug needs to be cleaned periodically as per the maintenance schedule (page 33). It is advised that you visit your Authorised workshop for this type of Hero MotoCorp service. Spark plug removal (3) Noise suppressor cap (4) Spark plug Remove the heat deflector (1) by removing •...

  • Page 40: Engine Oil

    Engine oil level marks on the oil level dipstick. Do top up if oil level reaches towards the Use hero genuine engine oil or recommended • grade oil. lower level mark or on every 3000 km.

  • Page 41: Centrifugal Oil Filter

    Centrifugal oil filter needs to be cleaned periodically as per the maintenance schedule (page 33). It is advised that you visit your Authorised workshop for this type of Hero MotoCorp service. (4) Drain cap After the oil has completely drained, reinstall •...

  • Page 42: Oil Cooler

    Oil cooler Remove the left side cover screw (3). • (1) Oil cooler (1) Nuts (2) Bolts (3) Left side cover screw Remove the left side cover screws (4). CAUTION • No hard objects to be used for cleaning the •...
  • Page 43 (5) & (6) Screw (9) Air cleaner element Remove the air cleaner element cover • screws (8) and the cover (7). (10) Wire mesh side Install a new air cleaner element in the reverse (7) Cover (8) Screw order of removal. Remove the air cleaner element (9).

  • Page 44: Valve Clearance Adjustment

    Gradually release the clutch lever and open and adjusted if necessary by your Authorised the throttle. The vehicle should start workshop as per the Hero MotoCorp smoothly and accelerate. maintenance schedule (page 33). Clutch lever free play adjustment NOTE Refer to the safety precautions (page 32).

  • Page 45: Drive Chain Slackness Adjustment

    Drive chain slackness adjustment The service life of the drive chain dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets. The drive chain (1) should be checked and lubricated as part of the Pre-ride inspection (page 26).
  • Page 46 Kinked or binding links • Drive chain slack should be adjusted at your Excessive wear • Authorised workshop as per Improper adjustment Hero MotoCorp • the specification. Damaged or missing O-rings • Sprockets Turn the chain to view chain lock plate (4). •...
  • Page 47 NOTE (2) Sleeve nut (3) Drive chain lock nut (4) Drive chain adjusting nut (5) Index mark Never install a new drive chain on a worn sprocket (6) Rear edge of adjusting slot or a worn chain on new sprocket. Always replace drive chain and both sprocket as set.

  • Page 48: Drive Chain Slider Inspection

    O-ring may deteriorate, fail and lose their sealing properties. Visit Authorised workshop for • Hero MotoCorp inspection, cleaning, lubrication and adjustment of drive chain at every 1000 km. Lubrication Apply SAE 90 Grade oil on the inner side of •...

  • Page 49: Brakes

    (6) by using a water jet. level decreases abruptly, check for the leakages in the brake system and consult your Front Caliper Authorised workshop. Hero MotoCorp (4) Caliper (5) Brake pads (6) Disc Master Cylinder (1) Master cylinder...
  • Page 50 Do not grooves, replace both as a set. Visit your mix DoT3 or DoT4 brake fluids. Authorised workshop for this Hero MotoCorp Brake pad wear service. Brake pad wear depends upon the severity of usage, type of riding & road conditions.

  • Page 51: Suspension

    It is recommended you visit to your Remove the front axle nut (1) remove the Authorised workshop for rear • Hero MotoCorp axle and wheel. shock absorber adjustment. Adjustment can be made according to the load/road conditions. In direction A : stiffer.
  • Page 52 If this occurs, servicing of the brake system will be necessary. Visit your Authorised workshop Hero MotoCorp for this service. Avoid grease, oil or dirt on the disc or pads • surfaces. Any contamination can cause poor brake performance or rapid pad wear after re-assembly.
  • Page 53 (b) Rear wheel removal Align the caliper assembly bracket with the • swingarm slot. Refer to the safety precautions (page 32). Insert the axle along with a washer from the Support the vehicle securely on the main • • left side through the swingarm with chain stand and raise the rear wheel off the adjuster assembly, wheel hub, side collar, ground.

  • Page 54: Main/Side Stand Lubrication

    Visit • Check the spring (1) for damage or loss of your Authorised workshop • Hero MotoCorp for this service. tension and the side stand assembly for free Avoid grease, oil or dirt on the disc or pads movement. •...

  • Page 55: Tubeless Tyre

    Tubeless tyres have some self-sealing ability if Tubeless tyre they are punctured. However, because leakage The tyres fitted on your vehicle are of is often very slow, you should look closely for TUBELESS type. punctures whenever a tyre is not fully inflated. To safely operate your vehicle, your tyres must Always check air pressure when your tyres are be of the proper type and size, in good...
  • Page 56 CAUTION Over inflation/Under inflation will affect the performance. Inspection Whenever you check the tyre pressure, you should also examine tyre treads & side walls for wear, damage & foreign objects: Look for : Bumps or bulges in the side of the tyre or •...
  • Page 57 For repair and replacement of tyre it is advised Tyre replacement to visit your Authorised Hero MotoCorp The tyres that were installed on your vehicle workshop. were designed to match the performance capabilities of your vehicle and provide the best combination of handling, braking, durability and comfort.

  • Page 58: Nuts, Bolts & Fasteners

    If your battery seems weak and/or electrolyte is leaking (causing hard starting or other electrical troubles), contact your Authorised workshop. Hero MotoCorp NOTE This symbol on the battery means that this product must not be treated as household waste.
  • Page 59 Battery charging Always visit your Authorised Hero MotoCorp workshop if you see any symptom of battery discharge as earliest as possible to get the battery charged. The battery has a tendency to...

  • Page 60: Fuse Replacement

    Fuse replacement Remove the right side cover under screws • (5). Refer to the safety precautions (page 32). Remove the right side cover screws (6). Fuse Box (A) Location : Below the seat • Fuse Type : Blade fuse (6) Right side cover screws Start Mag.

  • Page 61: Stop Lamp Switch

    However in case of adjustment required, fusing of the bulbs and permanent damage please visit your Authorised to certain electrical components. Hero MotoCorp workshop as per the maintenance schedule Turn the ignition switch "OFF" before • (page 33).

  • Page 62: Catalytic Converter

    Catalytic Converter acts on HC, CO and NOx. atmosphere from fuel tank. The canister (1) A replacement unit must be a genuine Hero collects the fuel vapour from the fuel tank and part. MotoCorp...
  • Page 63 (1) Canister POLISHING OF VEHICLE After washing your vehicle, wax all painted surface (except matte painted surfaces) using a commercially available polish/quality liquid or paste wax to finish the job. Use only a non abrasive polish or wax made specifically for automobiles.

  • Page 64: Basic Troubleshooting

    Refill the fuel tank (page 24) Check fuel gauge Only one segment displayed Consult Authorised Workshop Check fuel lines Refill Hero MotoCorp Leakage Check for operating sound of fuel pump Secure connections Broken fuel pump wire/connector Consult Authorised Workshop Hero MotoCorp B.
  • Page 65 BASIC TROUBLESHOOTING 2. ENGINE STARTS BUT STALLS Consult Authorised Workshop Check fuel lines Hero MotoCorp Leakage Replace Check Air Filter Dirty/Clogged Consult Authorised Workshop Hero MotoCorp 3. POOR PICK UP Tighten the Spark Plug (page 36) Spark Plug Loose in Cylinder Head...

  • Page 66: Road Signs

    ROAD SIGNS Mandatory signs: These road signs inform drivers/riders of the traffic rules that apply on a certain stretch of road, thereby instructing them on how to drive/ride. Mandatory signs are distinguished by the bright red circle with black and blue markings. It is imperative that all riders follow these signs as they help avoid accidents.
  • Page 67 ROAD SIGNS Cautionary signs: These signs inform the driver/rider of the road conditions ahead. Cautionary signs therefore serve as a warning. They are usually in a red triangle with black pictures on a white background. Illustrations, diagrams and symbols are used to forewarn about dangers ahead.
  • Page 68 Hero MotoCorp Ltd. WARRANTY Scope of warranty Karizma ZMR (hereinafter called ‘ ') warrants its vehicles, Hero MotoCorp Ltd. Hero MotoCorp assembled/manufactured in its Plants and sold through its channel partners, to be free from any defect-both in material and workmanship, under normal use and conditions, subject to the following terms &...
  • Page 69 Hero MotoCorp Ltd. LIMITATIONS OF WARRANTY The warranty shall not apply— If all free services/paid services/oil top-ups are not availed as per the recommended schedule at authorized Hero MotoCorp's workshop. (2) If any other engine oil which is non compatible with product is used other than SAE 10W30 S Grade (JASO M ).
  • Page 70 Hero MotoCorp Ltd. BATTERY WARRANTY PERIOD 1. 18 months from date of sale of vehicle or 20000 km. or 2. 21 months from the date of charging (whichever is earlier). 3. 3 months idle period is allowed from the date of charging to date of sale on vehicle.
  • Page 71 Hero MotoCorp Ltd. EMISSION WARRANTY Scope of warranty Warrants all its vehicles, assembled/manufactured at its various Plants and sold through its Authorised dealers, to Hero MotoCorp Ltd. comply with emission standards as specified in S.No. of table in item(i) of sub rule (2) of Rule 115 of Central Motor Vehicles Rules, 1989, which stipulates that "Idle CO (Carbon monoxide) emission limit for all two wheeled petrol driven vehicles shall not exceed 3.

  • Page 72: Installation

    Hero MotoCorp Ltd. INSTALLATION Explanation on important "Must know" points to customer during delivery of vehicle by Dealer sales executive. Function and operation of all digital display of multifunction meter console. • Explanation on collapsible visor mounted rear view mirrors.
  • Page 73 WHAT ARE THE BENEFITS OF Hero MotoCorp 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 •...
  • Page 74 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 • Higher emission level • Spark Plug Poor engine performance •...

  • Page 75: Zonal/Regional/Area Offices

    Hero MotoCorp Ltd., 3rd Floor, Tower-A, DLF Centre Court, Sector-42, Golf Course Road, DLF Phase 5, Gurgaon -122002, Haryana, India. Tel: 0124-4754800, E-mail: delhi@heromotocorp.com Hero MotoCorp Ltd., 602, 6th Floor, Office Tower-1, Plot No BW58, Logix City Center, Sector-32, Noida – 201301. Tel: 0120-4631000, E-mail: noida@heromotocorp.com Hero MotoCorp Ltd., S.C.O-367-368, First Floor, Sector-34A, Chandigarh-160022, India.
  • Page 76 ZONAL/REGIONAL/AREA OFFICES NORTH ZONE Hero MotoCorp Ltd., Summit Building (10th Floor) Plot No TCG 3/3 Vibhuti Khand, Gomti Nagar Lucknow – 226010, India. Tel: 0522-4006594, E-mail: lucknow@heromotocorp.com Hero MotoCorp Ltd., C-19/134-B ,Third Floor I .P Grand, Lallapura, Sigra , Varanasi, Uttar Pradesh - 221010, India.

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