HERO Passion Pro Manual
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Thank you for selecting a
continued riding pleasure in the years ahead.
We at
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-IV norms) regulation for emission, safety &
noise levels. We are also using non asbestos brake shoes/pads and engine gaskets which are
environment friendly in nature.
This 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
Passion Pro. Please take time to read it carefully. As with any fine machine,
Hero MotoCorp
proper care and maintenance are essential for trouble-free operation and optimum
performance.
Your Authorised
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.
PREFACE
Hero MotoCorp
are committed to demonstrate excellence in our environment
dealer will be glad to provide further information or
Passion Pro. We wish you many miles of

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Summary of Contents for HERO Passion Pro

  • Page 1 ON. This booklet is your guide to the basic operation and maintenance of your new Passion Pro. Please take time to read it carefully. As with any fine machine, Hero MotoCorp proper care and maintenance are essential for trouble-free operation and optimum performance.
  • 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 ‘Passion Pro’ COMPLIES WITH THE LATEST EMISSION NORMS. MotoCorp Ltd...
  • Page 3: Table Of Contents

    CATALYTIC CONVERTER STARTING THE ENGINE AIR SUCTION VALVE (ASV) RIDING EVAPORATIVE EMISSION CONTROL SYSTEM BRAKING POLISHING OF VEHICLE PARKING BASIC TROUBLESHOOTING TOOL KIT/FIRST AID KIT ROAD SIGNS CLEANING AND WASHING OF VEHICLE WARRANTY MAINTENANCE HERO GENUINE PARTS SAFETY PRECAUTION ZONAL/REGIONAL/AREA OFFICES...
  • Page 4: Vehicle Identification

    Year of Month of Assembly Plant Serial Number Description Manufacturing Manufacturing Model: Passion Pro Engine Variants Cast wheel/Electric start/Disc Cast wheel/Electric start/Drum VIN and Engine No. may be required: 1. During registration of the vehicle. 2. For dealing with legal & insurance departments.
  • Page 5: Vehicle Views

    VEHICLE VIEWS TOP VIEW (1) Horn switch (12) LCD panel (2) Turn signal switch (13) i3s indicator (3) Clutch lever (14) Master cylinder (optional) (4) Passing switch (15) i3s switch (5) Rear view mirror (16) Reset button (6) Dimmer switch (17) Front brake lever (7) Side stand indicator (18) Throttle grip...
  • Page 6 LEFT SIDE VIEW (1) Fuel valve (7) Left side cover (12) Tail/Stop lamp (2) Carburetor (8) Saree guard with women (13) Rear grip pillion step (3) Gearshift pedal (14) Seat lock (9) Rear turn signal lamp (4) Rider foot rest (15) Side stand switch (10) Reflex reflector (5) Main stand...
  • Page 7 RIGHT SIDE VIEW 3 4 5 6 (1) Pillion foot rest (6) Oil level dipstick (11) Headlamp (2) Battery compartment (inside) (7) Starter motor (12) Front visor (3) Kick starter pedal (8) Caliper (optional) (13) Air suction valve (4) Rider foot rest (9) Front disc (optional) (inside) (5) Rear brake pedal...
  • Page 8: Vehicle Specification

    VEHICLE SPECIFICATION ITEM SPECIFICATIONS Dimensions Overall length 1962 mm Overall width 717 mm Overall height 1087 mm Wheelbase 1236 mm Saddle height 781 mm Ground clearance 165 mm Weight 117 kg (Self/Cast/Disc) Kerb weight 116 kg (Self/Cast/Drum) Capacities Engine oil 1.25 liters at disassembly and 1.1 liters at draining Fuel tank 11 litres (Minimum)
  • Page 9 VEHICLE SPECIFICATION ITEM SPECIFICATIONS Front 2.75x18-4PR/42P Tyre size Rear 3.00x18-6PR/52P Front (Disc type) Disc. Dia. 240 mm (Optional) Front (Drum type) Brakes Dia. 130 mm (Internal expanding shoe type) Rear (Drum type) Dia. 130 mm (Internal expanding shoe type) Front wheel Cast wheel drum and disc Rear wheel Cast wheel drum...
  • Page 10: Accessories & Modification

    ACCESSORIES & MODIFICATIONS operation. Such changes could seriously impair your vehicle's handling, stability and Modifying your vehicle or using non- Hero braking, making it unsafe to ride. Removing or accessories can make your vehicle MotoCorp modifying your lamps, mufflers, emission unsafe.
  • Page 11: Vehicle Safety

    Hero MotoCorp vehicle. vehicle's size and weight.
  • Page 12: Ÿ Protective Apparel

    WARNING If you are involved in a crash Personal safety is your first priority. If you or Not wearing a helmet increases the chance of Ÿ 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 Ÿ...
  • Page 13: Safe Riding Tips

    Tightly wrap loose/hanging clothes & avoid Ÿ entangling with moving parts. Get your vehicle serviced regularly by the Ÿ Authorised workshop. Hero MotoCorp Before riding make sure in which mode you Ÿ are riding whether with i3s switch “ON’ or “OFF”.
  • Page 14: Tips For Healthy Environment

    Ÿ 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 Ÿ recommended by and make sure you change it every 6000 km. (with top Hero MotoCorp up every 3000 kilometres) to keep the engine fit and environment healthy.
  • Page 15: Parts Function

    PARTS FUNCTION Ignition switch “ON” ( ) position “OFF”( ) position/ Lock open (1) Ignition switch (2) Ignition key (3) Steering lock position “LOCK” position Key position Function Key removal The engine can be started, Turn signal lamps, Horn, Tail/Stop lamp and Passing Switch can “ON”...
  • Page 16: Ÿ Instruments And Indicators

    Instruments and Indicators The indicators are in the speedometer panel above the headlamp. The functions are as below. S.No. Description Function Light glows when vehicle is in neutral (1) Neutral indicator ( ) 2 Speedometer Indicates driving speed. ( ) 3 Turn signal indicator Flashes when turn signal switch is operated.
  • Page 17 The service reminder indicator (7) is to indicate user to bring the vehicle to an Authorised workshop for Hero MotoCorp service. The indicator shall start blinking when the vehicle covers kilometers as specified in the maintenance schedule. The indicator will...
  • Page 18: Features

    FEATURES Steering lock Steering lock with ignition switch, turn the ignition key (1) to "OFF" ( ) position & turn the handle bar towards left or right & push the key downwards & turn towards "LOCK” position. After locking take out the key. (1) Passing switch (2) Dimmer switch (3) Clutch switch...
  • Page 19: I3S (Idle Stop Start System)

    IMPORTANT: To switch “OFF” the turn 2. i3s switch signal after completing the turn, gently push There is an i3s switch provided to enable inside. the rider for turning i3s mode “ON” or “OFF” 5. Horn switch ( ) based on the traffic conditions. Press the horn switch (5) to operate the horn.
  • Page 20 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 vehicles and no special functions will be...
  • Page 21: Side Stand Indicator/Switch

    SIDE STAND INDICATOR/SWITCH A side stand switch (2) is provided in the side stand, when the vehicle is parked on side stand For the safety of the customer a side stand (Ignition switch “ON”), the switch enables the indicator (1) is provided. side stand indicator lamp to glow on the speedometer panel.
  • Page 22: Fuel Valve

    “OFF” ( ) position At “OFF” position (1) , fuel cannot flow from the tank to the carburetor. Turn the valve “OFF” whenever the vehicle is not in use. (4) Filler Neck (5) Fuel For locking, position the cap back on the Ÿ...
  • Page 23: Seat Lock

    “RES” ( ) position SEAT LOCK Location : On the rear left side of the seat, At "RES" position (3), fuel will flow from the reserve fuel supply to the carburetor. below the rear cowl. Use the reserve fuel only when the main Operation : Insert the ignition key (1) and supply is exhausted.
  • Page 24: Usb Charger (Optional)

    Do not leave the USB device and USB cable Ÿ in the tool kit compartment when the vehicle will not be responsible for Hero MotoCorp is parked. damages caused due to use of non standard Charge your device only when the engine is USB cable.
  • Page 25: Pre-Ride Inspection

    PRE-RIDE INSPECTION Clutch-Check for smooth operation. Ÿ Adjust free play (page 38). You should conduct pre-ride inspection Drive chain-Check condition and before riding the vehicle to enhance riding Ÿ slackness (page 40). Adjust and lubricate if comfort and safety. necessary. Clean your vehicle regularly.
  • Page 26: Starting The Engine

    STARTING THE ENGINE 5. Push the choke lever downward to “ON” position as indicated (Use choke during cold conditions). 3. Select neutral 1. Turn the ignition position & check N 6. Open the throttle switch “ON” ( ). indicator glows on slightly &...
  • Page 27: Riding

    Flooded engine lever and shift to gear by depressing the gearshift pedal. If the engine fails to start after repeated attempts, it may be flooded with excess fuel. The sequence is repeated progressively to Ÿ To clear a flooded engine, turn the ignition shift 3 and 4 (top gear).
  • Page 28: Parking

    TOOL KIT/FIRST AID KIT WARNING The tool kit (1) is located below the seat in the Independent use of only the front or rear Ÿ rear. Some emergency repairs, minor brake increases stopping distance. adjustments and parts replacement can be Extreme braking may cause wheel locking Ÿ...
  • Page 29: Cleaning And Washing Of Vehicle

    Wet the vehicle with light water spray. Avoid Ÿ the maintenance schedule. directing water to muffler outlets and Consult your Authorised Hero MotoCorp electrical parts. Dealer for recommendation applicable to Clean the headlamp lens and other plastic Ÿ your individual needs and use.
  • Page 30: Safety Precaution

    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, use Genuine Parts for repair and Hero MotoCorp replacement.
  • Page 31: Maintenance Schedule

    Maintenance work should be performed in accordance with standards and specifications of by properly trained and equipped Hero MotoCorp technicians. 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 32 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 ONCE IN EVERY...
  • Page 33 WHICHEVER DURING FREE SERVICE PERIOD COMES FIRST AFTER FREE SERVICE ONCE IN EVERY SERVICE ITEMS Next Next Next Next DAYS 1st 60 KM Note-1 500- 3000- 6000- 9000- 12000- 3000 6000 9000 12000 15000 3500 6500 9500 12500 Disc Wear/Pad wear Note-5 Brake Fluid Brake System (Brake...
  • Page 34: Spark Plug Inspection

    If you are reusing a plug, it should only take 1/8-1/4 turn after the plug seats. ENGINE OIL Use hero genuine engine oil or recommended grade oil. (1) Noise suppressor cap (2) Spark plug...
  • Page 35 Remove the oil level dipstick, wipe it clean Savita Oil Technologies Limited. • • and insert without screwing it in. Bharat Petroleum Corporation Limited. • Remove the oil level dipstick and check the • OIL CAPACITY: 1.25 liters oil level. Engine oil level inspection/Top up If required, add the specified oil up to the •...
  • Page 36: Oil Filter Screen & Centrifugal Filter

    muffler (3), remove the right side rider Stop the engine, let the engine oil settle • footrest (4) and remove the right crankcase down and recheck the oil level. cover (5). Make sure that oil level is at the “UPPER” •...
  • Page 37: Air Cleaner

    Reinstall the oil filter screen with the sharp required when riding in unusually wet or dusty • edged side facing inwards. area. Remove the left side cover (1) by removing Remove centrifugal filter cover (9) & clean • • the centrifugal filter (10) with non side cover screw (2).
  • Page 38 Remove the air cleaner element (5) • Clean the air cleaner housing using a shop • from air cleaner housing (6). towel. Install the new air cleaner element • Install the air cleaner element cover. • Install the left side cover. •...
  • Page 39: Carburetor

    The carburetor is factory pre-set in order to adjustment is to be done only by Authorised achieve optimum performance and meet workshop. Hero MotoCorp emission standards. If air screw is tampered it affects the overall However in case of specific requirement of performance characteristics of the vehicle.
  • Page 40 NOTE The checking or adjusting of valve clearance should be performed while the engine is cold. The clearance will change as the engine temperature rises. Remove the timing hole cap (4) and tappet Ÿ covers. Rotate the cam sprocket (7) clockwise using the special tool (8) until the ‘T’...
  • Page 41: Clutch Lever Free Play

    (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 •...
  • Page 42: Throttle Operation

    If proper adjustment cannot be obtained or the turn the adjuster (4). clutch does not work correctly, visit your Authorised workshop. Hero MotoCorp THROTTLE OPERATION Cable inspection Check for smooth rotation of the throttle grip from the fully open to the fully closed position.
  • Page 43: Drive Chain Slackness

    DRIVE CHAIN SLACKNESS remain constant as the wheel rotates. 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.
  • Page 44 Inspect the sprocket teeth for wear or • 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 •...
  • Page 45: Drive Chain Slider Inspection

    The NOTE level decreases gradually due to piston Visit Authorised workshop Hero MotoCorp movement to compensate pad wear. If the for inspection, cleaning, lubrication and level decreases abruptly, check for leakage in adjustment of drive chain at every 2000 km...
  • Page 46 • of the groove. Always replace both the pads as a set. • Visit your Authorised Hero MotoCorp workshop for this service. WARNING (2) Brake pads (3) Caliper (4) Brake disc Always apply front and rear brakes simultaneously to avoid skidding of vehicle.
  • Page 47 NOTE is seated on the brake joint pin (4) after If proper adjustment cannot be obtained by making final free play adjustment. this method, visit your Authorised Hero workshop. (A) Decrease free play (CW) MotoCorp (c) Rear brake inspection Adjustment Park the vehicle on its main stand.
  • Page 48 NOTE If proper adjustment cannot be obtained by this method, visit your Authorised Hero workshop. MotoCorp (d) Brake wear indicators (Drum type) 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...
  • Page 49: Suspension

    Rear brake wear indication 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. Rear shock absorber adjustment Rear shock absorber adjustment can be made according to the load/road conditions.
  • Page 50: Wheel

    WHEEL Position the front wheel between the fork • legs by aligning the slot on the speedometer (a) Front wheel (Disc type) gear box with the lug on the fork leg and the Removal disc between the brake pads to avoid Support the vehicle securely on the main •...
  • Page 51 from the speedometer gearbox. Disconnect the brake cable (3) from brake • arm (4) and brake panel (5) by removing the front brake adjusting nut (6). (10) Lug (11) Slot Adjust the front brake free play (page 43). • After installing wheel, apply the brake •...
  • Page 52: Main/Side Stand Lubrication

    Brake stopper arm nut torque: 1.8-2.5 kgf-m Adjust the rear brake free play (page 44) • and drive chain slackness (page 40). After installing the wheel, apply the brake • several times and check for free wheel rotation when released. CAUTION Always replace used split pins with new ones.
  • Page 53: Tyres

    TYRES The recommended “cold” tyre pressure are: The tyres that are fitted on your vehicle are designed to match the performance capabilities of your vehicle and provide the best combination of handling, braking, durability and comfort. WARNING The imported tyre(s) if fitted without ISI mark; are in compliance of BIS standard and Central Motor Vehicle Rules 1989, as declared by the Tyre manufacturer.
  • Page 54: Nuts, Bolts & Fasteners

    Check the tread wear indicator (1) for tyre wear. Unidirectional tyres Excessive tread wear. • Also, if you hit a pothole or hard object, pull • to the side of the road as soon as you safely can and carefully inspect the tyres for (1) Wear Indicator (2) Arrow mark damage.
  • Page 55: Battery

    *MF Battery, ETZ-4:12V 3 Ah Always visit your Authorised It is not necessary to check the battery Hero MotoCorp workshop if you see any symptom of battery electrolyte level or add distilled water as the discharge as earliest as possible to get the battery is a Maintenance Free (sealed) type.
  • Page 56: Fuse Replacement

    (1) Ignition key (2) Side cover (7) (-)ve terminal (8) (+)ve terminal Battery installation Remove the battery clamp bolt (3) and the • battery clamp (4). Reinstall in the reverse order of removal. Be • Pull the battery (5) out slightly and remove sure to connect the positive (+)ve terminal •...
  • Page 57: Stop Lamp Switch

    STOP LAMP SWITCH The stop lamp switch (1) must be adjusted so that stop lamp will glow when rear brake is applied. Rear brake free play (page 44) should be adjusted before performing stop lamp switch adjustment. The procedure for adjusting stop lamp switch is as follows: Turn the ignition switch to the “ON”...
  • Page 58: Catalytic Converter

    A defective catalytic converter contributes to Headlamp adjustment is done by the • air pollution and can impair your engine’s headlamp adjusting bolt (1) located below headlamp. performance. Follow these guidelines to protect your Park the vehicle on level ground. •...
  • Page 59: Evaporative Emission Control System

    into the atmosphere from the fuel tank, if the fuel system is unsealed or open. The 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.
  • Page 60: Basic Troubleshooting

    “ON” position Check fuel in fuel tank Refill No fuel Rectify Check fuel lines Leakage/air lock Consult Authorised Workshop Hero MotoCorp B. Electric starter not working Replace fuse (ref. Page 53) Check fuse Fused Consult Authorised Workshop Inspect battery Hero MotoCorp...
  • Page 61 Readjust free play of rear brake lever/pedal Improper adjustment Check tyre inflation pressure Correct tyre pressure Under inflated Consult Authorised Workshop Hero MotoCorp 4. ELECTRICAL SYSTEM Feeble horn sound or no light Replace fuse Check fuse Fused Consult Authorised Workshop...
  • Page 62: 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 63 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 64: Warranty

    Hero MotoCorp Ltd. WARRANTY Scope of warranty Passion Pro (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 65 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 Hero MotoCorp's authorized workshop. (2) If any other engine oil which is non compatible with product is used other than SAE 10W30 S Grade (JASO M ).
  • Page 66 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 67 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 68 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 69 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 70: 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 71 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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