HERO Passion Pro Manual
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HERO Passion Pro Manual

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PREFACE
Thank you for selecting a Hero MotoCorp Passion Pro. We wish you many miles of
continued riding pleasure in the years ahead.
We, at Hero MotoCorp, 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 legislation including
environment legislation and strengthen the green supply chain.
Your motorcycle is conforming to latest (Bharat Stage-III 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 booklet is your guide to the basic operation and maintenance of your new Hero
MotoCorp Passion Pro. 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.
Your Authorised Hero MotoCorp dealer will be glad to provide further information or
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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  • Page 1 PREFACE Thank you for selecting a Hero MotoCorp Passion Pro. We wish you many miles of continued riding pleasure in the years ahead. We, at Hero MotoCorp, are committed to demonstrate excellence in our environment performance on a continual basis, as an intrinsic element of our corporate philosophy. To...
  • Page 2 AVAILABLE AT THE TIME OF ITS PRINTING APPROVAL, AND THE ACCURACY OR CORRECTNESS OF THE SAME IS NOT UNDERTAKEN OR GUARANTEED. Hero MotoCorp Limited. 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 Hero MotoCorp Limited.

  • Page 3: Table Of Contents

    FUEL GAUGE / ODOMETER / TRIP METER THROTTLE CONTROLLED IGNITION SYSTEM SERVICE REMINDER INDICATOR RIGHT HANDLEBAR CONTROLS BRAKE WEAR INDICATORS FUSE REPLACEMENT SIDE STAND INDICATOR/ SIDE STAND SWITCH 15 STOP LAMP SWITCH FUEL VALVE SIDE STAND HEADLAMP ADJUSTMENT / PARKING ANTI THEFT TIPS HERO GENUINE PARTS...
  • Page 4 Year of Assembly Month of Serial Model Code.: Description Mfg. Plant Mfg. Number Model Engine Passion Pro (Spoke wheel/Kick start/Drum) Passion Pro (Cast wheel/Kick start/Drum) Passion Pro (Spoke wheel/Electric start/Drum) Passion Pro (Cast wheel/Electric start/Drum) Passion Pro (Cast wheel/Electric start/Disc)
  • Page 5 PRODUCT SPECIFICATION ITEM SPECIFICATIONS DIMENSIONS 1980 mm 725 mm 1075 mm 1235 mm Saddle Height 795 mm 165 mm WEIGHT 116 kg (Kick start) / 119 kg (Electric start) CAPACITIES 1.05 litres at disassembly 0.85 litre at draining 12.8 litres 1.0 litre (usable) 162-165 ml ENGINE...
  • Page 6 ITEM SPECIFICATIONS CHASSIS AND SUSPENSION Front Suspension Telescopic Hydraulic Shock Absorbers Swing Arm with 5 step adjustable Hydraulic Shock Absorber Rear Suspension 85 mm Trail length 2.75 x 18 - 4 PR / 42P 3.00 x 18 - 6 PR / 52P Disc Type Dia 240 mm (Optional) Front Wheel...
  • Page 7 9. To make yourself more visible, wear bright reflective clothing that fits well. 10. Take care of loose / hanging clothes while solo / pillion riding. 11. Get your motorcycle serviced regularly by the Authorised Hero MotoCorp workshop.

  • Page 8: Accessories And Modifications

    ACCESSORIES & MODIFICATIONS Modifying your motorcycle or using non- • Do not pull a trailer or sidecar with Hero MotoCorp accessories can make your motorcycle. This motorcycle was not designed for these attachments, your motorcycle unsafe. Before you and their use can seriously impair your consider making any modifications or motorcycle's handling.
  • Page 9 Genuine Engine Oil: Use Hero 4T Plus SAE 10W 30 SL grade (JASO MA2) engine oil recommended by Hero MotoCorp and make sure you change it every 6000 kms.
  • Page 10 DESCRIPTION (1) Horn switch (12) Turn signal indicator (2) Turn signal switch (13) LCD panel (3) Clutch lever (14) Reset button (4) Headlamp switch (15) Master cylinder (5) Passing switch (16) Front brake lever (6) Rear view mirror (17) Throttle grip (7) Dimmer switch (18) Electric starter switch (8) Side stand indicator...
  • Page 11 LEFT SIDE VIEW (1) Fuel valve (7) Left side cover (12) Rear grip (2) Carburetor (8) Saree guard with women (13) Seat lock / Helmet hanger (3) Gear shift pedal pillion step (14) Side stand switch (4) Rider foot rest (9) Rear turn signal lamp (15) Air suction valve (5) Main stand...
  • Page 12 (1) Pillion foot rest (6) Rear brake pedal (11) Front suspension (2) Battery compartment (inside) (7) Oil level dipstick (12) Headlamp (3) Kick starter pedal (8) Utility box (13) Front visor (4) Rider foot rest (9) Caliper (14) Rear suspension (5) Starter motor (10) Front disc *Accessories and features shown may not be part of standard fitment.
  • Page 13 PARTS FUNCTION INSTRUMENTS AND INDICATORS headlamp SERVICE REMINDER Sl. No. Description Function Neutral indicator Light glows when vehicle is in neutral Speedometer Indicates driving speed Turn signal indicator Flashes when turn signal switch is operated Fuel gauge Indicates approximate fuel quantity in the form of digital segments.
  • Page 14 IGNITION SWITCH “ON” Position “OFF” Position / Lock Open (1) Ignition switch “LOCK” Position (2) Ignition key (3) Steering lock position “ON” The engine can be started, Turn signal lamps, Horn, Tail/Stop lamp and Passing Switch can be operated. Fuel Gauge, Odometer and Tripmeter reading will be functional.

  • Page 15: Fuel Gauge / Odometer / Trip Meter

    ‘‘ON’’ thereafter. TRIPMETER The Service Reminder Indicator can be The Tripmeter (5) shows distanced traveled reset at an Authorised Hero MotoCorp per trip. The Tripmeter can be reset to zero workshop. by pressing the RESET button (6).
  • Page 16 NOTE After getting the vehicle serviced, make sure that the Service Reminder Indicator has been reset. Tail/Stop lamp Speedometer L.E.D. LEFT HANDLEBAR CONTROLS Headlamp “ON” Dimmer switch Passing switch 4. Turn signal lamp switch Functions in DC when the passing switch Shift the turn signal knob sideways for knob is pressed in the following condition.

  • Page 17: Right Handlebar Controls

    6. Clutch Switch (For Electric Start Model) Never hold starter switch continuously for more than 5 seconds as continuously There is a clutch switch provided for the cranking of engine will drain the battery. safety of the rider. The motorcycle cannot be started by electric starter STEERING LOCK switch until the clutch lever is operated...

  • Page 18: Side Stand Indicator Side Stand Switch

    (1) Seat Lock (2) Knob (3) Helmet Hanger (1) Side stand indicator Operation : Insert the key and turn it SIDE STAND SWITCH clockwise. Pull the knob (2) downwards to release the seat. To install, engage the A side stand switch (2) is provided in the hook on the underside of the seat with the side stand, when the vehicle is parked on frame and push on the top rear side of the...

  • Page 19: Fuel Valve

    FUEL VALVE FUEL ON At “OFF” (1), fuel cannot flow from the tank to the carburetor. Turn the valve “OFF” whenever the motorcycle is not in use. (2) “ON” Position FUEL ON At “RES” (3), fuel will flow from the reserve fuel supply to the carburetor.
  • Page 20 NOTE motorcycle FUEL TANK (1) Key hole cover (2) Fuel tank cap Fuel tank capacity is 12.8 litres including a (3) Ignition key reserve supply of 1.0 litre (usable). 1. To remove the fuel tank cap (2), open the key hole cover (1) and insert the ignition key (3) turn it clockwise and remove the cap.
  • Page 21 U s e h e r o g e n u i n e e n g i n e o i l o r recommended grade oil. BRAND: Hero 4T plus GRADE: SAE 10W 30 SL Grade (JASO MA2).
  • Page 22 7. Quantity of oil to be filled is 0.85 litre 6. Stop the engine and let the engine oil (approx.) during oil change when right settle down. crankcase cover is not removed. 7. Recheck the oil level. 8. Reinstall the oil level dipstick and check 8.
  • Page 23 TYRES ride more harshly, are more prone to damage from surface hazards and wear unevenly. NOTE 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. To safely operate your motorcycle, the tyres must be of recommended type and size, in good condition with adequate tread, and correctly...
  • Page 25 PRE - RIDE INSPECTION s 20 & 21). 38 & 39). 39 to 42). 35). 9. Lamps and Horn - check that headlamp, tail/stop lamp, turn signal lamps and horn function properly. 17). 13. Air Suction Valve - make sure all tube connections are secured properly (page 57).
  • Page 26 STARTING THE ENGINE 2. Turn the fuel Open the throttle valve “ON”. slightly & press the starter switch. (Alternatively kick pedal can be used for starting). Select neutral 6. Push the choke lever downwards to “OFF” position as indicated, indicator after warming up the engine for few seconds.
  • Page 27 Recommended max. operating speed in each gear. 20 km/hr 45 km/hr 70 km/hr 100 km/hr RIDING...

  • Page 28: Parking

    Do not shift gears without operating clutch and without closing the throttle otherwise this would lead to damage of gears. BRAKING For normal braking, close the throttle and gradually apply both front and rear brakes simultaneously while shifting down gears to suit your road speed. PARKING "OFF", turn the ignition switch "OFF", park While parking vehicle on side stand...

  • Page 29: Anti Theft Tips

    UTILITY BOX ANTI-THEFT TIPS To store some important utility items a 1. Always lock the steering and never utility box has been provided. leave the key in the ignition switch . 2. Park your motorcycle in a locked garage whenever possible. 3.
  • Page 30 TOOL KIT FIRST AID KIT The tool kit (1) is stored in the utility box. The first aid kit (2) is stored in the utility S o m e e m e r g e n c y r e p a i r s , m i n o r box.

  • Page 31: Safety Precautions

    * Carbon monoxide poisoning from engine exhaust. Remember that your Authorised Hero Be sure there is adequate ventilation MotoCorp Dealer knows your motorcycle whenever you operate the engine. best and is fully equipped to maintain and repair it.
  • Page 32 MAINTENANCE MAINTENANCE SCHEDULE 1st 60 Next 100 Next 100 Next 100 Next 100 Next 100 3000-3500 6000-6500 9000-9500 12000- 15000- 3000 6000 9000 12000 15000 12500 15500 Air Cleaner* Electric Starter Electric Starter Chain I,C,L,A at every 2000 kms I,C,L,A at every 2000 kms Battery Voltage Brake Shoe / Pad Wear...
  • Page 33 Electric Start version only. Check idle CO emission along with idle r/min / idle CO adjustment (if required). Visit Authorised Hero MotoCorp workshop for inspection, cleaning, lubrication and adjustment of drive chain at every 2000 kms. NOTE:- Always wipe the water from the motorcycle after washing. Use clean soft cloth or pressurised air for completely drying the water.

  • Page 34: Oil Filter Screen & Centrifugal Filter

    OIL FILTER SCREEN & 5. Remove centrifugal filter cover (7) & CENTRIFUGAL FILTER clean the centrifugal filter (8) with non flammable or high flash point solvent 1. Drain the engine oil thoroughly. (kerosene). 2. Remove the kick starter pedal (1), disconnect the clutch cable (2), remove 6.
  • Page 35 (1) Noise suppressor cap (2) Spark plug Recommended spark plugs : NGK-CR7HSA, BOSCH-UR4AC, Champion-P-RZ9HC (Federal Mogul) number, consult Authorised Hero MotoCorp workshop on this if required. Clean any dirt around the spark plug base. Disconnect the noise suppressor cap (1)
  • Page 36 AIR CLEANER The air cleaner element is of Dry Paper Pleated type, it should be serviced at regular intervals (page 29). When riding in dusty areas, more frequent service may be necessary. Remove the seat assembly. Remove the side cover screws (2). 3.
  • Page 37 (8) Air cleaner element (9) Element Holder The Air Cleaner Element should be cleaned by blowing moisture free pressurized air. 5. Replace it earlier if it becomes very dirty, damaged on surface or on the sealing area. Install the air cleaner element on holder, insert the air cleaner assembly into the inlet air duct &...
  • Page 38 THROTTLE OPERATION Slide the grommet (2), loosen the lock nut (3) and turn the adjuster (4). (2) Grommet (3) Lock nut (4) Adjuster (1) Free play 2-6 mm...
  • Page 39 VALVE CLEARANCE 1. Remove the crankshaft hole cap (1) and timing hole cap (2) and tappet covers. 2. Rotate the flywheel anticlockwise until the ‘T’ mark (3) on the flywheel coincides with the index mark (4) on the left crankcase cover. In this position the piston will either be on the compression or exhaust stroke.
  • Page 40 (5) Adjusting screw (6) Lock nut (7) Feeler gauge park tip. 0.10 mm 0.10 mm R/MIN CAUTION Never adjust air screw (2). Air screw adjustment is to be done only by Authorised service dealers. If air screw is tampered it affects the overall performance characteristics of the vehicle.

  • Page 41: Throttle Controlled Ignition System

    (1) Throttle stop screw (A) Decrease r/min (2) Air screw (B) Increase r/min (3) Throttle position sensor switch Throttle Controlled Ignition System (TCIS) Throttle position sensor switch (3) alters the ignition timing as per the throttle operation and ensures optimum driving performance.
  • Page 42 (2). If proper adjustment cannot be obtained or Drive chain slack (3) should be adjusted the clutch does not work correctly, visit your to allow approximately 25 mm (1 inch) Authorised Hero MotoCorp Workshop. vertical movement by hand.
  • Page 43 If the chain has a slack in one section and tight in another, some links are kinked and binding. Binding can frequently be eliminated by lubrication. (4) Chain lock plate (5) Open end Drive chain slack 25 mm (approx.) Turn the chain to view chain lock plate (4) inside the hole.
  • Page 44 Adjustment Park the motorcycle on its main stand with the transmission in neutral and the ignition switch in "OFF" position. Loosen the rear axle nut (1) and sleeve nut (2). Loosen the drive chain lock nut (3). Turn both the adjusting nuts (4) in an equal number of turns until the correct drive chain slack is obtained.
  • Page 45 SAE # 90 oil. (1) Front brake lever (2) Free play 10-20 mm NOTE Visit Authorised Hero MotoCorp workshop for inspection, cleaning, lubrication and adjustment of drive chain at Spoke wheel version every 2000 kms.
  • Page 46 CUT-OUT NOT SEATED If proper adjustment cannot be obtained by this method, visit your Authorised Hero MotoCorp workshop. FRONT BRAKE (Disc Type) CUT-OUT SEATED (3) Adjusting nut (4) Brake joint pin (1) "MIN" mark Cast wheel version Brake fluid recommended: DoT 3 or DoT 4 Fluid level - Ensure that the brake fluid level does not fall below “MIN”...
  • Page 47 • Clean the dirt and mud accumulation between the brake pads (1), caliper (2) and the disc (3) by using a water jet. • Always contact your Authorised Hero MotoCorp workshop for refilling of master cylinder when necessary. Do not mix DoT 3 and DoT 4 brake fluids.
  • Page 48 (4) after the final adjustment has been made. Brake joint pin (2) Free play 20-30 mm If proper adjustment cannot be obtained by this method, visit your Authorised Hero MotoCorp workshop.

  • Page 49: Brake Wear Indicators

    Rear Brake Wear Indication Drum Type (Spoke wheel version) Front Brake Wear Indication Drum Type (Cast wheel version)
  • Page 50 Front Brake Wear Indication Kick Start Model-*MF Battery MF-3:12V 3 Ah Rear Brake Wear Indication Electric Start Model-*MF Battery MF-4:12V 3 Ah (1) Battery (2) (-) ve terminal (3) (+)ve terminal (4) Bolt (5) Battery clamp *MF stands for Maintenance Free...
  • Page 51 (causing hard to explode with enough force to seriously hurt you. starting or other electrical troubles), contact your Authorised Hero MotoCorp Wear protective clothing and a face shield, or have skilled mechanic do the workshop. battery maintenance.

  • Page 52: Fuse Replacement

    4. Ensure the battery leads are properly connected to the battery terminals during installation. Battery removal 1.M ake sure the ignition switch is “O FF”. 2. Remove the seat (pages 14 & 15). 3. Remove the right side cover screws and remove the side cover.

  • Page 53: Stop Lamp Switch

    3. While the vehicle is removed from side stand, the side stand indicator (2) should not glow. 4. If the side stand indicator (2) does not operate as described in steps 2 or 3, please visit your Authorised Hero MotoCorp workshop. Stop lamp switch...

  • Page 54: Headlamp Adjustment

    HEADLAMP ADJUSTMENT Headlamp is factory pre-set. However in case of adjustment required, please follow the steps as given below : Headlamp adjustment is done by the headlamp adjuster bolt (1) located below headlamp. Park the motorcycle on level ground. Adjust the headlamp beam vertically (2) Side stand indicator by loosening the bolt &...
  • Page 55 NOTE Always adjust both the rear shock absorbers to the same position. Use the rear shock absorber adjustment tool (Pin Spanner) (1) available in the tool kit. Check the rear shock absorber by pushing hard downwards on rear grip while the motorcycle is not parked on stand.
  • Page 56 Switch on the ignition, rotate the front wheel and see if speedometer needle is working. 5.4 kgf-m (pages 42 & 43). (1) Speedometer cable (2) Tab (3) Front brake cable (4) Brake arm (5) Brake panel Drum Type (Cast wheel version) (6) Front brake adjusting nut (7) Axle nut 1.
  • Page 57 Switch on the ignition, rotate the front wheel and see if speedometer needle is working. kgf-m 43). (1) Speedometer cable (2) Tab (3) Front Disc Type (Cast wheel version) brake cable (4) Brake arm (5) Brake panel 1. Raise the front wheel off the ground. (6) Front brake adjusting nut (7) Axle nut 2.
  • Page 58 (Spoke wheel version) Remove the rear brake adjusting nut (1) and disconnect the brake rod (2) from the brake arm (3) by pushing down the brake (9) Rear axle pedal. Disconnect the brake stopper arm (4) from the brake panel (5) by removing split pin (6) and lock nut (7).
  • Page 59 (Cast wheel version) Remove the rear brake adjusting nut (1) and disconnect the brake rod (2) from the 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).
  • Page 60 2. 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. 3. After cleaning spray water thoroughly. 4.
  • Page 61 BASIC TROUBLESHOOTING Fuel System Check fuel valve position Consult Authorised Hero MotoCorp Workshop Electric Starter Not Working (Electric Start Model Only) Fuse Check Fuse Replace Fuse (page 49) Weak Inspect Battery Consult Authorised Hero MotoCorp Workshop Loose Check connections, Ignition...
  • Page 62 No Spark At Spark Plug Replace Spark Plug / Adjust Spark Plug Gap (0.6 - 0.7 mm) Consult Authorised Hero MotoCorp Workshop Check Air Cleaner Consult Authorised Hero MotoCorp Workshop...
  • Page 63 Check Air Cleaner Consult Authorised Hero MotoCorp Workshop Consult Authorised Hero MotoCorp Workshop Consult Authorised Hero MotoCorp Workshop...
  • Page 66 , whichever is earlier, from the date of purchase. It is advised that the purchaser avails all free and paid services from the Hero MotoCorp’s authorized workshop as per the recommended schedule, to be eligible for warranty benefits. Each paid service should be availed within 90 days from the date of previous service or as per the recommended schedule, whichever is earlier.
  • Page 67 Hero MotoCorp Ltd. 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...
  • Page 68 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 69 (s) which is/are considered to be the cause of non-compliance with the emission standards. The emission warranty shall be applicable only to those vehicles, which are being regularly maintained at Hero MotoCorp Authorised Dealers/Service Points in accordance with the maintenance schedule provided in the owner's manual.
  • Page 70 WHAT ARE THE BENEFITS OF HERO MOTOCORP GENUINE SPARE PARTS ? 4Assures long life 4Ensures economy for a long time 4Safety of vehicle and rider 4Peace of mind 4Value for money 4Assured quality...
  • Page 71 CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS Clutch Plate Material used is inferior Damages other parts of clutch like, clutch center and outer clutch Affects fuel efficiency Poor acceleration Cam Chain Kit Poor performance Reduced life Gasket Cylinder Head Improper sealing Engine knocking Leads to leakage and smoky exhaust Higher emission level...
  • Page 72 CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS Element Air Cleaner Improper air filtration resulting in premature engine failure Affects fuel efficiency Poor engine performance Spark Plug Frequent stalling of engine Higher emission level Poor engine performance Affects fuel efficiency Brake Pads / Shoes Poor braking effeciency Rider safety - an issue Discs / Drum wear out, resulting in subsequent repair cost...
  • Page 73 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 74 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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