Table of Contents
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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
strengthen the green supply chain.
Your vehicle is conforming to latest (Bharat stage- 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
Hero MotoCorp
machine, 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.
Hero MotoCorp
are committed to demonstrate excellence in our environment
all applicable legislation including environment legislation
Passion Xpro
. Please take time to read it carefully. As with any fine
dealer will be glad to provide further information or
PREFACE
Passion Xpro
IV
. We wish you many miles of
and
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Table of Contents
Related Manuals for HERO Passion Xpro
Summary of Contents for HERO Passion Xpro
- Page 1 PREFACE Passion Xpro 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 ‘Passion Xpro’ COMPLIES WITH THE LATEST EMISSION NORMS. MotoCorp Ltd...
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Page 3: Table Of Contents
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 DETAILS MAINTENANCE HERO GENUINE PARTS SAFETY PRECAUTIONS ZONAL/REGIONAL/AREA OFFICES MAINTENANCE SCHEDULE... -
Page 4: Vehicle Identification
JA06ET ##### Engine Year of Month of Assembly Plant Serial Number Description Manufacturing Manufacturing Model: Passion Xpro Engine Variants Cast wheel/Electric start/Disc JAW12 JA06ET Cast wheel/Electric start/Drum JAW11 JA06ET VIN and Engine No. may be required: 1. During registration of the vehicle. -
Page 5: Vehicle Views
VEHICLE VIEWS TOP VIEW 1112 (1) Horn switch (13) Right turn signal indicator (2) Turn signal switch (14) Mode/Reset button (3) Clutch lever (15) Master cylinder (Optional) (4) Pass lamp switch (16) i3s switch (5) Dimmer switch (17) Front brake lever (6) Rear view mirror (18) Throttle grip (7) Neutral indicator... - Page 6 LEFT SIDE VIEW 2 3 4 (1) Air suction valve (inside) (8) Side stand (14) Tail/Stop lamp (2) Fuel valve (9) Saree guard with women (15) Rear grip (3) Carburetor pillion step (16) Seat (4) Gearshift pedal (10) Seat lock/Helmet hanger (17) Left side cover (5) Rider footrest (11) Rear reflex reflector...
- Page 7 RIGHT SIDE VIEW 6 7 8 (1) Pillion foot rest (5) Rider footrest (11) Front suspension (2) Rear master cylinder (For (6) Starter motor (12) Headlamp #IBS) (inside) (7) Rear brake pedal (13) Front visor (3) Brake fluid reservoir (For (8) Oil level dipstick (14) Battery compartment (inside) #IBS) (inside)
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Page 8: Vehicle Specification
VEHICLE SPECIFICATION ITEM SPECIFICATIONS Dimensions Overall length 1967 mm Overall width 768 mm Overall height 1080 mm Wheelbase 1249 mm Saddle height 798 mm 165 mm Ground clearance Weight 119 kg (Self/Cast/Disc) Kerb weight 118 kg (Self/Cast/Drum) Capacities Engine oil 1.25 liters at disassembly and 1.1 liters at draining Fuel tank 8.2 litres... - Page 9 VEHICLE SPECIFICATION ITEM SPECIFICATIONS Front 80/100x18-47P (Tubeless Tyre) Tyre size Rear 90/90x18-51P (Tubeless Tyre) 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...
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Page 10: Accessories & Modifications
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: 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 • 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 13: Safe Riding Tips
Tightly wrap loose/hanging clothes & avoid • entangling with moving parts. Get your vehicle serviced regularly by the • Authorised workshop. Hero MotoCorp Before riding make sure in which mode you • are riding whether with i3s switch “ON’ or “OFF”. -
Page 14: 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 km. (with Hero MotoCorp top 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 indicator, Horn, Tail/Stop lamp and Passing switch can be “ON”... -
Page 16: Instruments And Indicators
Instruments and Indicators The indicators are in the speedometer panel above the headlamp. The functions are as below. Sl.No. Description Function Turn signal indicator (L) Flashes when left turn signal switch is operated. Indicator glows for few seconds and turns “OFF” ( ) 2 i3s indicator indicating that i3s system is functional. - Page 17 (a) Fuel gauge The fuel gauge (1) is of a Liquid Crystal Display (LCD) type. The approximate amount of fuel quantity available in the fuel tank is indicated by the number of segments (2) in the display. If only one segment (3) is displayed and blinks, this indicates that the fuel quantity is low and is in reserve.
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Page 18: Features
After locking take out the key. Authorised workshop for HANDLEBAR SWITCHES CONTROL Hero MotoCorp service. The indicator shall start blinking when Left handlebar controls the vehicle covers kilometers as specified in 1. Passing switch the maintenance schedule. -
Page 19: I3S (Idle Stop Start System)
During electric or clutch start, the engine will • cut-off if engine reaches 900 r/min if the relay is engaged for more than 5 seconds. (4) Turn signal lamp switch (5) Horn switch 4. Turn signal lamp switch ( Shift the turn signal lamp switch sideways for right/left indications and leave it to come back (1) Electric starter switch (2) i3s switch... - Page 20 30 secs. After the rst stop start every subsequent stop will be in 5 secs. In this condition, the engine can be restarted either with kick or electric start only. Driving with i3s Switch in “ON” position: While driving, if the engine is kept idling (while waiting in a traf c signal), the engine will cut off in 5 secs.
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Page 21: Side Stand Indicator/Switch
If the vehicle is driven without battery or with • the dead battery, the i3s system will not work. The i3s indicator on the speedometer console will start to glow continuously. The vehicle will be in normal operating conditions as other vehicles and no special functions will be performed. -
Page 22: Fuel Valve
Do not overfill the tank. There should be no “OFF” ( ) position • fuel (5) in the filler neck (4). 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... -
Page 23: Seat Lock/Helmet Hanger
“RES” ( ) position SEAT LOCK/HELMET HANGER 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 key (1) and turn it supply is exhausted. -
Page 24: Pre-Ride Inspection
PRE-RIDE INSPECTION Clutch-Check for smooth operation. • Adjust free play (page 37). You should conduct pre-ride inspection Drive chain-Check condition and before riding the vehicle to enhance riding • slackness (page 39). Adjust and lubricate if comfort and safety. necessary. Clean your vehicle regularly. -
Page 25: 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 position 1. Turn the ignition & check N indicator 6. Open the throttle switch “ON” ( ). glows on instrument slightly &... -
Page 26: Riding
Flooded engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine, turn the ignition switch “OFF” ( ) and turn the choke lever to “OFF”. Close the throttle fully and crank the engine several times with the kick starter. -
Page 27: Parking
TOOL KIT/FIRST AID KIT WARNING The tool kit (1) is located below the seat in the When riding in wet or rainy conditions, or on • rear. Some emergency repairs, minor loose surfaces, apply front brake carefully adjustments and parts replacement can be after applying rear brake to avoid wheel slip. -
Page 28: Cleaning And Washing Of Vehicle
Wet the vehicle with light water spray. void • 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 • your individual needs and use. -
Page 29: Safety Precautions
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 30: 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 31 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 32 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 (For disc and IBS) Brake Fluid Note-5...
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Page 33: 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 BRAND: Hero 4T plus Visually inspect the spark plug electrodes for •... - Page 34 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/ If required, add the specified oil up to the •...
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Page 35: 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 36: Air Cleaner
(page 27). Early replacement may be Reinstall the oil filter screen with the sharp • edged side facing inwards. required when riding in unusually wet or dusty area. Remove centrifugal filter cover (9) & clean • the centrifugal filter (10) with non Remove the seat (page 20). - Page 37 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. •...
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Page 38: 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 39 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 • covers. Rotate the cam sprocket (7) clockwise using the special tool (8) until the ‘T’...
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Page 40: 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 41: 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 42: Drive Chain Slackness
DRIVE CHAIN SLACKNESS If the chain is slack in one section and tight in another, some links are kinked and binding. The service life of the drive chain depends Binding can be eliminated by frequent upon proper lubrication and adjustment. lubrication. - Page 43 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 •...
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Page 44: Drive Chain Slider Inspection
& rear brakes activate jointly. NOTE (a) Front brake inspection (Disc type) Visit Authorised workshop Hero MotoCorp Master Cylinder/Reservoir. for inspection, cleaning, lubrication and Location: Right handle bar. adjustment of drive chain at every 2000 km. Brake fluid recommended: DoT 3 or DoT 4... - Page 45 Always replace both the pads as a set. reservoir parallel to the ground. The level Visit your Authorised Hero MoroCorp decreases gradually due to piston movement to workshop for the brake pad replacement. compensate pad wear. If the level decreases.
- Page 46 When one applies the Integrated/Rear brake pedal, front & rear brakes activate jointly. (1) Wear indicator groove WARNING (2) Integrated/Rear brake pedal Always apply front and rear brakes (3) Free play 20-30 mm simultaneously to avoid skidding of vehicle. The distance, the front brake lever (1) and integrated brake pedal (2) moves before each Brakes (Integrated braking system) brake starts to engage is called free play (3).
- Page 47 (f) Rear brake inspection Push the integrated brake arm (4) by hand • in the direction as shown. Adjustment Turn the first adjuster nut (5) till you cannot • Park the vehicle on its main stand. • turn it by hand. Check the free play of front brake lever.
- Page 48 Apply the brake several times and check for • free wheel rotation when released. NOTE If proper adjustment cannot be obtained by this method, visit your Authorised Hero workshop. MotoCorp (g) Brake wear indicators (Drum type) When the brake is applied, an arrow (1), fixed...
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Page 49: Suspension
SUSPENSION Front and rear suspension inspection Check the front forks by locking the front • brake and pumping the front fork up and down vigorously. The suspension action should be smooth and there should be no oil leakage. Front Rear (1) Pin spanner (2) Rear shock absorber (A) Stiffer... - Page 50 (1) Speedometer cable (2) Tab (3) Axle nut (1) Side collar (2) Speedometer drive gear (4) Axle (5) Side collar After installing the wheel apply the brake • several times and then check if the wheel CAUTION rotates freely. Recheck the wheel if the Do not operate front brake lever when the brake drags or if the wheel does not rotate wheel is removed.
- Page 51 Tighten the axle nut. • Axle nut torque: 5.0-6.0 Kgf-m Adjust the front brake free play (page 43). • After installing wheel, apply the brake • several times and check for free wheel rotation when released. (c) Rear wheel Removal Support the vehicle securely on the main •...
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Page 52: Main/Side Stand Lubrication
(1) Main stand (2) Side stand (8) Axle nut (9) Axle (10) Collar Installation TUBELESS TYRES Reverse the removal procedure • The tyres fitted on your vehicle are of Axle nut torque: 5.4 kgf-m TUBELESS type. Brake stopper arm nut torque: To safely operate your vehicle, your tyres must 1.8-2.5 kgf-m be of the proper type and size, in good... - Page 53 readings will be higher than if the tyres were WARNING "cold". This is normal, so do not let air out of Using tyres that are excessively worn or • the tyres to match the recommended cold air improperly inflated can cause a crash in pressures given below.
- Page 54 Repairing a puncture or removing a wheel requires special tools and technical expertise. If a tyre is punctured or damaged, it is advised to visit nearest tyre manufacture, Hero authorised dealer/workshop or the MotoCorp tyre repair shop who has expertise in Carefully inspect the tyres for any damage, •...
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Page 55: Nuts, Bolts & Fasteners
Always use the size and type of tyres • recommended in this owner's manual. NOTE For repair and replacement of tyre it is advised to visit your Authorised Hero MotoCorp workshop. -
Page 56: Battery
Maintenance Free (sealed) type. Battery charging If your battery seems weak and electrolyte is Always visit your Authorised Hero MotoCorp leaking (causing hard starting or other workshop if you see any symptom of battery electrical troubles), contact your Authorised discharge as earliest as possible to get the workshop. -
Page 57: Fuse Replacement
the positive (+)ve terminal lead (8). Pullout the battery from the battery box. • (1) Screws (2) Side cover Remove the fuse box A and fuse box B from • (7) (-)ve terminal (8) (+)ve terminal the battery clamp (4). Battery installation Remove the battery clamp bolt (3) and the •... -
Page 58: Stop Lamp Switch
STOP LAMP SWITCH The stop lamp switch 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 59: Headlamp Focus Adjustment
Adjust the headl beam vertically • loosening bolt & move the headlamp unit forward & backward for correct focus adjustment. WARNING An improperly adjust headlamp may blind oncoming rider/driver or it may fail to light the road for a safe distance. CATALYTIC CONVERTER This vehicle is equipped with a catalytic (3) Adjusting nut... -
Page 60: Air Suction Valve (Asv)
Follow these guidelines to protect your into the atmosphere from the fuel tank, if the vehicle’s catalytic converter. fuel system is unsealed or open. The evaporative emission control system is used to Always use unleaded petrol. Even a small • prevent petrol vapours from escaping into the amount of leaded petrol can contaminate atmosphere from fuel tank. -
Page 61: 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 54) Check fuse Fused Consult Authorised Workshop Inspect battery Hero MotoCorp... - Page 62 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...
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Page 63: 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 64 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 65 Hero MotoCorp Ltd. WARRANTY Scope of warranty Passion Xpro (hereinafter called ‘ ') warrants its Hero MotoCorp Ltd. Hero MotoCorp vehicles, 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 66 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 67 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 68 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 69 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 70 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 •...
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Page 71: 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 72 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.