HERO DAWN-150 Manual
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A FEW WORDS ABOUT SAFETY
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Hero MotoCorp, must determine the risks to their personal safety and the safe
operation of the vehicle.
If you need to replace a part, use genuine Hero MotoCorp parts with the correct
part number or an equivalent part. We strongly recommend that you do not use
replacement part of inferior quality.
FOR YOUR CUSTOMER'S SAFETY
Proper service and maintenance are essential to the customer's safety and the
reliability of the vehicle. Any error or oversight while servicing a vehicle can result in
faulty operation, damage to the vehicle, or injury to others.
FOR YOUR SAFETY
Because this manual is intended for the professional service technician, we do not
provide warnings about many basic shop safety practices (e.g., Hot parts-wear
gloves). Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can arise in
performing service and repair procedures. Only you can decide whether or not you
should perform a given task.
IMPORTANT SAFETY PRECAUTION
Make sure you have a clear understanding of all basic shop safety practices and
that you are wearing appropriate clothing and using safety equipment. When
performing any service task, be especially careful of the following:
• Read all of the instructions before you begin and make sure you have the tools, the replacement or repair parts and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire of explosion, be careful
when working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
WARNING
!
Improper service or repairs can create an
unsafe condition that can cause your
customer or others to be seriously hurt or
killed. Follow the procedures and
precautions in this manual and other
service materials carefully.
WARNING
!
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in
this manual carefully.

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Summary of Contents for HERO DAWN-150

  • Page 1 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Hero MotoCorp, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 2 MEMO...
  • Page 3: Table Of Contents

    HOW TO USE THIS MANUAL CONTENTS SECTION This service manual describes the service procedures for DAWN-150 Follow the Maintenance Schedule (Section 3) recommendations to GENERAL INFORMATION ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It BODY PANELS/EXHAUST SYSTEM compensates for the initial wear that occurs during the break-in period.
  • Page 4 MEMO...
  • Page 5 SYMBOLS SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOLS DEFINITION Replace the part(s) with new one (s) before assembly. Apply oil.Use engine oil unless otherwise specified. Apply grease Apply silicone grease.
  • Page 6 SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOLS DEFINITION Feeler gauge Micrometer Cylinder bore gauge Dial gauge Degreasing Vernier caliper...
  • Page 7: General Service Precaution

    Tighten these to the specified torque using a criss-cross pattern. IN A PATTERN After assembling, check every part for proper installation, Use only genuine Hero MotoCorp parts and movement and operation. recommended lubricants. Use specified special and common tools only.
  • Page 8: Feature

    GENERAL INFORMATION FEATURE ENGINE Powerful and Economical 4-Stroke engine - Fuel efficient and powerful 4-stroke OHC engine with latest design. Aluminium cylinder with steel liner- For better heat dissipation and greater reliability. Constant Vacuum Carburetor - For delivering optimum performance. CCVI - Carb controlled variable ignition- For controlled ignition timings at variable speeds.
  • Page 9: General Saftey

    GENERAL INFORMATION GENERAL SAFETY ELECTRICAL WIRES WARNING CARBON MONOXIDE Route all electrical wire/harness and cables. Keep If the engine must be running to do some work, make sure them away from sharp edges and area where they the area is well ventilated. Never run the engine in an might be pinched between moving parts.
  • Page 10: Battery Hydrogen Gas & Electrolyte

    SERVICE RULES 1. Use genuine Hero MotoCorp recommended parts, lubricants and sealants. Parts that do not meet Hero MotoCorp’s design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, Cotter pins, Lock plates etc. when reassembling.
  • Page 11: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION FRONT FRONT FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side steering head. of the crankcase. FRONT CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is stamped on the...
  • Page 12: Specifications

    GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS Overall length 2061mm Overall width 763 mm Overall height 1100 mm Wheelbase 1290 mm Dimensions Minimum turning radius 1.90 mtrs Dry weight 130 kg Kerb weight 140 kg Ground clearance 160 mm Frame type Tubular, Diamond type Front suspension Telescopic Hydraulic fork...
  • Page 13 GENERAL INFORMATION ITEM SPECIFICATIONS Carburetor type CV Type with Throttle Sensor AVK 4 FB Identification number Venturi dia 26 mm Carburetor Main jet #118 Slow jet Air screw initial opening 1-¾ turns Float level 18.2 mm Idle speed 1400±100 rpm Clutch system Multi-plate wet type 4-speed constant mesh...
  • Page 14: Maintenance

    At disassembly 1.2 litres Engine oil capacity At oil change 1.0 litre BRAND: Hero 4T plus GRADE: SAE 10W 30 SJ Grade (JASO MA). Manufactured by : Recommended engine oil 1. Tide Water Oil Co. (India) Ltd. 2. Savita Oil Technologies Limited.
  • Page 15: Lubrication System

    ENGINE OIL At Draining 1.0 litre Engine Oil Capacity At Disassembly 1.2 litres Brand: Hero 4T Plus Grade: SAE 10W30 SJ Grade (JASO MA) Manufactured by: Recommended Engine Oil 1. Tide Water Oil Co. (India) Limited. 2. Savita Oil Technologies Limited.
  • Page 16: Cylinder Head/Valves

    GENERAL INFORMATION SERVICE LIMIT CYLINDER HEAD/VALVES ITEM STANDARD SERVICE LIMIT 12.0±2.0 kgf/cm Cylinder (171±28 psi) compression Intake 0.08 mm Valve clearance (in cold condition) 0.12 mm Exhaust Intake 32.994-33.234 mm 32.95 mm Camshaft cam lobe height Exhaust 32.880-33.120 mm 32.84 mm Cylinder head warpage 0.10 mm 10.06 mm...
  • Page 17: Clutch/Gearshift Linkage

    GENERAL INFORMATION SERVICE LIMIT CLUTCH/GEARSHIFT LINKAGE/PRIMARY GEAR DRIVE ITEM STANDARD SERVICE LIMIT Lever free play 10-20 mm Spring free length 40.50 mm 39.6 mm Disc-A (n=2) green mark 2.92-3.08 mm 2.62 mm Friction disc thickness Disc-B (n=3) 2.92-3.08 mm 2.62 mm Clutch Plate warpage 0.20 mm...
  • Page 18: Crankshaft

    GENERAL INFORMATION SERVICE LIMIT CRANKSHAFT/TRANSMISSION ITEM STANDARD SERVICE LIMIT 10.000-10.018 mm 10.05 mm Shift fork Claw thickness 4.93-5.00 mm 4.53 mm Shaft O.D 9.986-9.995 mm 9.93 mm Left 23.959-23.980 mm 23.94 mm Right 20.959-20.980 mm 20.94 mm Shift drum Left 24.000-24.033 mm 24.05 mm Journal I.D Right...
  • Page 19: Front Wheel/Brake/Suspension/Steering

    GENERAL INFORMATION SERVICE LIMIT FRONT WHEEL/BRAKE/SUSPENSION/STEERING ITEM STANDARD SERVICE LIMIT 1.5 mm Minimum tyre tread depth Rider Only 1.75 Kgf/cm (25 psi) Cold tyre pressure Rider & Pillion 1.75 Kgf/cm (25 psi) Front axle runout 0.20 mm Radial 2.0 mm Front wheel rim runout Axial 2.0 mm...
  • Page 20: Ignition System

    GENERAL INFORMATION SERVICE LIMIT IGNITION SYSTEM ITEM SPECIFICATIONS Standard NGK-CPR 8 EA 9, Champion-RG 6YC Spark plug 0.8-0.9 Ignition coil primary side 100V minimum Peak voltage Ignition pulse generator 1.5V minimum @ 300 rpm “F“ mark 8 ±1 (1800 rpm) Ignition timing Full advance 27 ±1 (6000 rpm)
  • Page 21: Engine Torque Values

    GENERAL INFORMATION ENGINE TORQUE VALUE TORQUE ITEM THREAD VALUES REMARKS SIZE & TYPE kgf-m MAINTENANCE Spark Plug M 10x1.0 14~18 1.4~1.8 Tappet adjusting nut M 6x0.75 12~16 1.2~1.6 Apply engine oil Timing hole cap M 14x1.5 8~12 0.8~1.2 Apply grease Crankshaft hole cap M 32x1.5 10~20...
  • Page 22: Frame Torque Values

    GENERAL INFORMATION FRAME TORQUE VALUE TORQUE ITEM THREAD VALUES REMARKS SIZE & TYPE kgf-m ENGINE REMOVAL/INSTALLATION Front engine mounting M 8x1.25 24 29 2.4 3.0 BF and NF Rear engine mounting M 10x1.25 49 59 5.0 6.0 BF and NF STEERING Stem nut M 24 1.0...
  • Page 23 GENERAL INFORMATION FRAME TORQUE ITEM THREAD VALUES REMARKS SIZE & TYPE kgf-m OTHERS Side stand M 10x1.25 39~49 4.0~5.0 U nut (See note 3) Fuel unit M 6 1.0 7 11 0.7 1.1 Head lamp case nut M 8x1.25 10~20 1.0~2.0 Cover air cleaner M 5x0.8...
  • Page 24: General Torque Values

    GENERAL INFORMATION GENERAL TORQUE VALUES FASTENER TYPE TORQUE (kgf-m) TORQUE (N-m) 5 mm bolt and nut 4.4~6.0 0.45~0.6 6 mm bolt and nut 8.0~12 0.8~1.2 8 mm bolt and nut 18~25 1.8~2.5 10 mm bolt and nut 29~39 3.0~4.0 12 mm bolt and nut 49~59 5.0~6.0 5 mm screw...
  • Page 25: Lubrication & Seal Points

    GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Cylinder, inner surface of cylinder sleeve Engine oil M8 special nut (cylinder stud) threaded portion, seating surface Piston pin hole, ring groove, sliding area Piston ring whole surface M14 flange nut (flywheel) threaded portion, seating surface M14 flange nut (balancer driven gear) threaded portion, seating surface Balancer driven gear assembly sliding surface Cam chain whole surface...
  • Page 26 GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS Steering cone race rolling contact surface Shell Alvania EP2 or Excelite Steering ball race rolling contact surface EP2 (KY 000 Yushi Co. Ltd.) Steering dust seal lip surface or Equiv. Grip left handle matching surface # 540 (Cemedine) or Equiv.
  • Page 27: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Flywheel puller To remove the flywheel from crankshaft. 070HHKTC004 Socket wrench To remove lock nut from clutch assembly and rotor filter. 070HH198002 Universal holder To hold the flywheel while removing flywheel nut. 070HH198003 Clutch centre holder To hold the centre clutch while removing the lock nut.
  • Page 28 GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Front fork oil seal driver attachment dia, 31mm To drive in new oil seal. 070HHKFN004 Crankcase bearing remover collect, 15mm To remove bearing from crankcase. 070HHKFN005 Crankcase bearing remover shaft To remove bearing from crankcase. 070HHKFN006 Crankcase bearing remover weight To remove bearing from crankcase.
  • Page 29 GENERAL INFORMATION SPECIAL TOOLS DESCRIPTION APPLICATION PART NUMBER Flywheel puller To remove the flywheel from crankshaft. 070HHKTN001 Collet, 17mm To remove bearing from crankcase. 070HHKTN002 Crankshaft bearing (LHS) puller To remove the bearing from crankshaft. 070HHKTN003 To remove top and bottom cone races from the Bottom cone race driver 070HHKTN005 steering head pipe.
  • Page 30 To restrict water entry during washing. 070HHKZA004 131 Muffler plug (Small) To restrict water entry during washing. 070HHK06004 132 Hero integrate diagnostic instrument For immobilizer diagnosis & key registration. HMCL0214AABA01 133 HIDI wire harness For sync between instrument & bike wire harness.
  • Page 31: Cable Harness Routing

    GENERAL INFORMATION CABLE & HARNESS ROUTING CLUTCH CABLE HES CLIP METER WIRE LIGHTING WIRE METER WIRE COMBINATION SWITCH HEADLAMP WIRE HES CLIP METER WIRE SPEEDO METER CABLE WINKER SWITCH WIRE HARNESS CLIP WIRE HARNESS WIRE HARNESS THROTTLE CABLE FR. BRAKE CABLE (DRUM TYPE) WIRE BRAKE HOSE HARNESS...
  • Page 32 GENERAL INFORMATION CLUTCH CABLE CHOKE CABLE WINKER SWITCH WIRE LIGHTING SWITCH WIRE METER ASSEMBLY ARIAL VIEW STARTER MOTOR CABLE BATTERY EARTH CABLE CARBURETTOR DRAIN TUBE MIDDLE LEFT VIEW 1-26...
  • Page 33 GENERAL INFORMATION HIGH TENSION WIRE ENG EARTH WIRE THROTTLE CABLE CHOKE CABLE WIRE HARNESS CLUTCH CABLE RIGHT MIDDLE VIEW CHOKE CABLE WIRE HARNESS THROTTLE CABLE FR. BRAKE CABLE (DRUM BRAKE TYPE) SPEEDO METER CABLE LEFT FRONT VIEW (DRUM TYPE) 1-27...
  • Page 34 GENERAL INFORMATION STARTER MAGNETIC SWITCH REAR STOP SWITCH WIRE WIRE HARNESS STARTER MAGNETIC BATTERY CABLE BATTERY EARTH CABLE STARTER MOTOR CABLE BATTERY BREATHER TUBE BATTERY SIDE VIEW STARTER MAGNETIC REAR STOP SWITCH WIRE TO FUEL UNIT WIRE HARNESS SWITCH CDI UNIT PASSING RELAY FUSE BOX WINKER RELAY...
  • Page 35 GENERAL INFORMATION BODY EARTH TAIL LAMP EARTH TERMINAL WIRE HARNESS REAR WINKER RH/LH WIRE REGULATOR RECTIFIER VIEW 1-29...
  • Page 36: Emission Control System

    Carbon monoxide does not react in the same way, but is toxic. Hero MotoCorp Ltd. utilizes appropriate carburetor setting as well as other systems, to reduce carbon monoxide and hydrocarbons.
  • Page 37 MEMO...

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