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HERO DAWN-125 Manual

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No : IBAB
PREFACE
Thank you for selecting a Hero MotoCorp DAWN-125. 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 and strengthen the green supply chain. We are also using non
asbestos brake shoes 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 DAWN-125. 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.
Authorised Distributor or the authorised dealer(s) of the Distributor ("Dealer") will be
glad to provide further information or assistance and 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 DAWN-125

  • Page 1 No : IBAB PREFACE Thank you for selecting a Hero MotoCorp DAWN-125. 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 and strengthen the green supply chain.
  • Page 2 Hero MotoCorp Ltd. reserves the right to make changes in its contents at any time without notice and/or incurring any obligation, whatsoever.

  • Page 3: Table Of Contents

    CONTENTS Pg. No. Pg. No. MOTORCYCLE IDENTIFICATION OIL SCREEN FILTER/ CENTRIFUGAL FILTER SPARK PLUG PRODUCT SPECIFICATION AIR CLEANER SAFE RIDING TIPS THROTTLE OPERATION ACCESSORIES & MODIFICATIONS VALVE CLEARANCE TIPS FOR HEALTHY ENVIRONMENT CARBURETOR DESCRIPTION CLUTCH PARTS FUNCTION DRIVE CHAIN INSTRUMENTS & INDICATORS FRONT BRAKE IGNITION SWITCH REAR BRAKE...

  • Page 5: Motorcycle Identification

    Assembly Month of Serial Engine Year of Assembly Month of Serial Code Description Mfg. Plant Mfg. Number Description Mfg. Plant Mfg. Number Model Code: DAWN-125 Frame Model Engine (Kick /Drum/Spoke/Without visor) (Self /Drum/Spoke/Without visor) (Self /Drum/Cast/Without visor) (Self /Drum/Cast/With visor)

  • Page 6: Product Specification

    PRODUCT SPECIFICATION ITEM SPECIFICATIONS DIMENSIONS Overall Length 1995 mm 735 mm Overall Width Overall Height 1095 mm 1265 mm Wheelbase 785 mm Saddle Height 150 mm Ground Clearance WEIGHT Kerb Weight 121 kg CAPACITIES 0.95 litre at disassembly Engine Oil 0.75 litre at draining 13 litres (minimum) Fuel Tank...
  • Page 7 ITEM SPECIFICATIONS CHASSIS AND SUSPENSION Front Suspension Telescopic Hydraulic Shock Absorbers Rectangular Swing Arm with 5 step adjustable Rear Suspension Hydraulic Shock Absorber Caster 26° Trail length 89 mm Tyre size, front 2.75x 18-42P/4 PR Tyre size, rear 2.75x 18-48P/6 PR Front Brake Drum Type Dia 130 mm...

  • Page 8: Safe Riding Tips

    SAFE RIDING TIPS Do's: Don’t: 1. Always conduct simple pre-ride 1. Never use cell phone while riding the inspection (page 20). motorcycle. 2. Always wear a helmet with chinstrap 2. Avoid sudden acceleration, braking and securely fastened and insist on a helmet turning of your motorcycle.

  • Page 9: Accessories & 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 10: Tips For Healthy Environment

    Genuine Engine Oil: Use Hero 4T Plus SAE 10W 30 SJ grade (JASO MA) engine oil recommended by Hero MotoCorp and make sure you change it every 6000 km.

  • Page 11: Description

    DESCRIPTION 8 9 10 PARTS LOCATION (1) Headlamp dimmer switch (10) Fuel gauge (2) Horn switch (11) High beam indicator (3) Turn signal switch (12) Turn signal indicator (4) Headlamp switch (13) Front brake lever (5) Clutch lever (14) Throttle grip (6) Rear view mirror (15) Electric starter switch (7) Odometer...

  • Page 12: Left Side View

    LEFT SIDE VIEW (1) Fuel valve (6) Side cover left (11) Tail/ Stop lamp (2) Carburetor (7) Side stand (12) Rear carrier (3) Gear shift pedal (8) Large pillion step (13) Seat (4) Rider foot rest (9) Rear number plate (14) Front turn signal lamp (5) Main stand (10) Reflex reflector...

  • Page 13: Right Side View

    RIGHT SIDE VIEW (1) Large pillion step (6) Oil filler cap (10) Utility box (2) Kick starter pedal (7) Starter motor (11) Battery compartment (inside) (3) Rider foot rest (8) Front suspension (12) Rear turn signal lamp (4) Oil level window (9) Headlamp (13) Rear shock absorber (5) Rear brake pedal...

  • Page 14: Parts Function

    PARTS FUNCTIONS INSTRUMENTS AND INDICATORS The indicators are in the speedometer panel above the headlamp. The function are as below. Sl. No. Description Function Speedometer Indicates riding speed Shows accumulated distance traveled Odometer Turn signal indicators Flashes when turn signal switch is operated Light glows when vehicle is in neutral Neutral indicator Light glows when headlamp is in Hi Beam...

  • Page 15: Ignition Switch

    IGNITION SWITCH “ON” Position “OFF” Position/Lock Open 1. Ignition switch 2. Ignition key 3. Steering lock position “LOCK” Position The engine can be started. Turn signal lamps, Horn, Tail/Stop “ON” ( ) lamp and Fuel gauge will be functional Engine cannot be started and no “OFF”...

  • Page 16: Left Handlebar Controls

    LEFT HANDLEBAR CONTROLS 3. Turn signal lamp switch 1. Headlamp switch Shift the turn signal switch sideways for The switch has three position. right/left indications and leave it to come marked by white dot. back to its normal position on its own. Position Action IMPORTANT: To switch “OFF”...

  • Page 17: Right Handlebar Controls

    RIGHT HANDLEBAR CONTROLS STEERING LOCK Steering lock is with ignition switch. Put Starter Switch the key (2) to "OFF" ( ) position & turn the Ensure starter switch (1) is operated when handle bar towards left or right & push the the vehicle is in neutral.
  • Page 18 At “RES”, fuel will flow from the reserve fuel supply to the carburetor. Use the reserve fuel only when the main supply is gone. Refill the tank as soon as possible after switching to “RES”. The usable reserve fuel supply is 1 litre (usable). (1) “OFF”...

  • Page 19: Fuel Tank

    FUEL TANK 2. Do not overfill the tank. There should be no fuel (4) in filler neck (5). Fuel tank capacity is 13 litres (minimum) including reserve supply of 1 litre (usable). 3. To lock-position the cap back on the 1.

  • Page 20: Engine Oil

    ENGINE OIL TOP UP ENGINE OIL PROCESS Use only Hero Genuine Engine Oil. 1. Start the engine & let it idle for 3-5 BRAND : Hero 4T plus minutes. GRADE : SAE 10W 30 SJ Grade (JASO MA). Manufactured by : 1.

  • Page 21: Engine Oil Replacement Process

    ENGINE OIL REPLACEMENT PROCESS Replace engine oil once in every 6000 km/ 6 months whichever is earlier. Drain engine oil with the engine warm and park the motorcycle on its main stand. 1. To drain the oil, remove the oil filler cap and drain plug (1).

  • Page 22: Tyres

    TYRES The tyres that are fitted on your motorcycle are designed to match the performance capabilities of your motorcycle and provide the best combination of handling, braking, durability and comfort. To safely operate your motorcycle, the tyres must be of recommended type and size, in good condition with adequate tread and correctly inflated.
  • Page 23 Inspection Whenever you check the tyre pressures, 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 the tread. Replace the tyre if you find any bumps or bulges.

  • Page 24: Pre-Ride Inspection

    PRE - RIDE INSPECTION You should conduct pre- ride inspection 5. Clutch- check for smooth operation. before riding the motorcycle to enhance Adjust free play (page 36). riding comfort and safety. 6. Drive chain- check condition and Clean your motorcycle regularly. It slackness (page 37 to 39).

  • Page 25: Starting The Engine

    STARTING THE ENGINE Pull the choke lever Turn the ignition upwards to “ON” switch “ON” ( ) position as indicated (Use choke during cold conditions). 5. Open the throttle Turn the fuel slightly & press valve “ON”. the starter switch. (Alternatively, kick pedal can be used for starting).

  • Page 26: Riding

    3. Slowly release the clutch lever and at Flooded Engine If the engine fails to start after repeated the same time, gradually increase engine attempts, it may be flooded with excess speed by opening the throttle. fuel. To clear a flooded engine, turn the coordination of the throttle and clutch ignition switch “OFF”...

  • Page 27: Braking/Parking

    All your actions should be smooth under these conditions. sudden Do not shift gears without operating clutch acceleration, braking or turning may and without closing the throttle otherwise cause loss of control. For your safety, this would lead to damage of gears. exercise extreme caution when BRAKING braking, accelerating to turning.

  • Page 28: Anti-Theft Tips / Utility Box

    UTILITY BOX ANTI- THEFT TIPS To store some important utility items a 1. Always lock the steering and never leave utility box has been provided. the key in the ignition switch . 2. Park your motorcycle in a locked garage whenever possible.

  • Page 29: Tool Kit

    (4) Inner utility box cover (5) Upper hook TOOL KIT The tool kit (1) is stored in the utility box. Some emergency repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. Kit consists of following tools. Tool bag Driver No.2 plus minus Wrench sparking plug...

  • Page 30: Safety Precautions

    * Burns from hot parts. To ensure best quality and reliability, use Let the engine and exhaust system only new Hero MotoCorp Genuine Parts cool before touching. for repair and replacement. * Injury from moving parts.

  • Page 31: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE Dear Customer, We would strongly recommend the following schedule, to keep your motorcycle in perfect running condition and healthy environment. Motorcycle subjected to severe use or ridden in dusty area will require more frequent servicing. 10th 11th Next 90 Next Next Next...
  • Page 32 10th 11th 1st 60 Next 90 Next 90 Next 90 Next 90 Next 90 Next 90 Next 90 Next 90 Next 90 Next 90 18000- 27000- 12000- 15000- 21000- 24000- 30000- 500-750 3000-3500 6000-6500 9000-9500 12500 15500 18500 27500 21500 24500 30500 Stop Lamp Switch...

  • Page 33: Oil Screen Filter/ 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), 6.

  • Page 34: Spark Plug

    SPARK PLUG 3. Visually inspect the spark plug electrodes for wear. The centre electrode (1) Spark plug (2) Noise suppressor cap should have square edges and the side Recommended plug : NGK- CPR 6 EA9 electrode should not be eroded. Discard For most riding conditions this spark plug the spark plug if there is apparent wear or heat range number is satisfactory.

  • Page 35: Air Cleaner

    AIR CLEANER The air cleaner element is of dry paper pleated type it should be serviced at regular intervals (page 27). When riding in dusty areas, more frequent service may be necessary. Remove the side cover (1) by removing side cover screw (2). Pull out from the front and release the lugs (3) by releasing the side cover from the slots in the rear (4) Air cleaner cover screws...
  • Page 36 (8) Air cleaner element (9) Element holder The air cleaner element should be cleaned by blowing moisture free 6. Replace it earlier if it becomes very dirty, pressurized air. damaged on surface or on the sealing area. Start cleaning by directing the air nozzle Install the air cleaner element, on holder (10) inside the element and cleaning it by insert the air cleaner assembly into the...

  • Page 37: Throttle Operation

    THROTTLE OPERATION Cable inspection Check for smooth rotation of the throttle grip from the fully open to the fully closed position. Check at full left and full right steering positions. Inspect the condition of the throttle cable from the throttle grip down to the carburetor.
  • Page 38 NOTE The adjustment must be made when the piston is at Top Dead Center and The checking or adjusting of valve both the inlet and exhaust valves are clearance should be performed while the closed. engine is cold. The clearance will change This condition can be determined by as the engine temperature rises.

  • Page 39: Carburetor

    Standard clearance 1. Warm up the engine and park the motorcycle on the main stand. In. 0.05 mm Ex. 0.05 mm 2. Adust idle speed with the throttle stop Adjust by loosening the lock nut (6) and screw (1). turning the adjusting screw (5) until there is a slight drag on the feeler gauge.

  • Page 40: Clutch

    CLUTCH not stall, and the motorcycle does not creep. Gradually release the clutch lever Clutch adjustment may be required if the and open the throttle. The motorcycle motorcycle stalls when shifting into gear should start smoothly and accelerate. or tends to creep or if the clutch slips, causing acceleration to lag behind engine speed.

  • Page 41: Drive Chain

    DRIVE CHAIN The service life of the drive chain is 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 20).
  • Page 42 5. If the drive chain or sprockets are drive chain slack is obtained. Turn the excessively worn or damaged, they adjusting nut clockwise to decrease the slack or anticlockwise to increase the should be replaced. Never use a new chain with worn out sprockets since this slack of the chain.

  • Page 43: Front Brake

    NOTE : Visit Authorised Distributor/Dealer for inspection, cleaning, lubrication and adjustment of drive chain at every 2000 FRONT BRAKE Adjustment 1. Measure the distance, the front brake lever (1) moves before the brake starts to take hold. Free play (2) should be 10- 20 (2) Sleeve nut (3) Drive chain lock nut (4) Drive chain adjusting nut mm at the tip of the brake lever.

  • Page 44: Rear Brake

    Cast wheel version Spoke wheel version (3) Adjusting nut (A) Decrease free play (4) Brake arm pin (B) Increase free play 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 Distributor/ Dealer.
  • Page 45 Cast wheel version (1) Rear brake pedal (2) Free play 20-30 mm (3) Adjusting nut (4) Brake arm pin If adjustment is necessary, turn the rear (A) Decrease free play (Clockwise) brake adjusting nut (3). (B) Increase free play (Anticlockwise) Make sure that the cut- out on the 4.
  • Page 46 Front brake wear indication BRAKE WEAR INDICATORS Cast wheel version When the brake is applied, an arrow (1), fixed to the brake arm (2), moves toward a reference mark (3) on the brake panel (4). If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced.

  • Page 47: Battery

    Rear brake wear indication It is not necessary to check the battery electrolyte level or add distilled water as the battery is an Maintenance-Free (Sealed) type. If your battery seems weak and electrolyte is leaking (causing hard starting or other electrical troubles), contact your Authorised Distributor /Dealer.
  • Page 48 4. Ensure the battery leads are properly connected to the battery terminals The battery gives off explosive hydrogen during installation. gas during normal operation. Battery removal A spark or flame can cause the battery to explode with enough force to 1.M ake sure the ignition switch is "O FF"...

  • Page 49: Stop Lamp Switch

    STOP LAMP SWITCH FUSE REPLACEMENT The stop lamp switch (1) must be adjusted Fuse Box (1) : Location : Mounted on the so that stop lamp will glow when rear battery clamp (2). brake is applied. Rear brake free play The specified fuse is 15 A (3) with a spare (page 40) should be adjusted before fuse 15 A (4).

  • Page 50: Headlamp Adjustment

    SUSPENSION HEADLAMP ADJUSTMENT Headlamp is factory pre-set. However in Inspection case of adjustment required, please follow Check the front forks by locking the the steps as given below: front brake and pumping the front fork Headlamp adjustment is done by up and down vigorously.

  • Page 51: Front Wheel Removal

    FRONT WHEEL REMOVAL Rear shock absorber adjustment Spoke wheel version Rear shock absorber adjustment can be made according to the load/ road conditions. 1. Raise the front wheel off the ground. 2. Remove the speedometer cable (1) by • In direction A Stiffer pressing the tab (2) &...
  • Page 52 Installation notes FRONT WHEEL REMOVAL Cast wheel version Reverse the removal procedure. 1. Raise the front wheel off the ground. Install the front wheel by ensuring 2. Remove the speedometer cable (1) by theat lug (8) on the left fork is located pressing the tab (2) &...

  • Page 53: Rear Wheel Removal

    Installation notes REAR WHEEL REMOVAL Spoke wheel version Reverse the removal procedure. 1. Raise the rear wheel off the ground. Install the front wheel by ensuring 2. Remove the rear brake adjusting nut theat lug (8) on the left fork is located (1) and disconnect the brake rod (2) in the slot (9) in the brake panel.
  • Page 54 REAR WHEEL REMOVAL Cast wheel version 1. Raise the rear wheel off the ground. 2. 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 55: Washing The Motorcycle

    WASHING THE MOTORCYCLE Follow the below mentioned steps for washing the motorcycle. 1. Wet the motorcycle with light water spray. Avoid directing water to muffler outlets and electrical parts. 2. Clean the headlamp lens and other plastic parts using a cloth or sponge dampened with a solution of mild detergent and water.

  • Page 56: Catalytic Converter

    CATALYTIC CONVERTER This motorcycle is equipped with a catalytic converter in the silencer (muffler) to meet the emission norms. This catalytic converter contains noble metals that serve as catalyst, promoting chemical reactions to convert CO and HC in the exhaust to CO and H O (water vapour).

  • Page 57: Basic Trouble Shooting

    BASIC TROUBLE SHOOTING 1. Starting trouble - Engine does not start A. Fuel system “OFF” Turn to “ON” position Check fuel valve position No fuel Refill Check fuel in fuel tank Leakage/ Air lock Rectify Check fuel lines Consult Authorised Distributor/Dealer B.
  • Page 58 C. No spark at spark plug “OFF” ( ) Position Turn ignition switch “ON” ( ) Check ignition switch Check spark plug for No spark Replace plug/adjust fouling/ improper gap (0.8-0.9 mm) electrode gap Loose contact Secure properly Check for poorly connected or loose spark plug wire Consult Authorised Distributor/Dealer 2.
  • Page 59 3. Poor pick-up Loose Spark plug loose in Tighten the spark plug cylinder head Clogged Clean and refit (page 31-32) Check air cleaner Improper adjustment Readjust the free play Check brake binding or brake lever/pedal Underinflated Check tyre inflation Correct tyre pressure pressure Consult Authorised Distributor/Dealer...
  • Page 60 4. Electrical system Feeble horn sound or no light Fuse Replace fuse Check fuse Weak Inspect battery Consult Authorised Distributor/Dealer Fuse/ wrong wattage Replace bulbs Check bulbs Loose Secure connections Check connections Consult Authorised Distributor/Dealer...
  • Page 61 Hero MotoCorp Ltd. No :IBAB I certify having taken delivery of one Hero MotoCorp DAWN-125 Motorcycle bearing the following particulars:- I have been explained by the Authorised Distributor/Dealer about correct and safe driving habits, service schedules and maintenance tips.
  • Page 62 Hero MotoCorp Ltd. The vehicle has been delivered in factory fresh condition to my satisfaction & I have understood all terms and conditions and shall abide by them. Authorised Distributor / Dealer Name Authorised Distributor / Dealer Address Tool bag, Driver No. 2 Plus, Minus, Wrench sparking plug, Spanner 14x17, No. 3...
  • Page 63 Hero MotoCorp Ltd. No :IBAB I certify having taken delivery of one Hero MotoCorp DAWN-125 Motorcycle bearing the following particulars:- I have been explained by the Authorised Distributor/Dealer about correct and safe driving habits, service schedules and maintenance tips. Authorised Distributor/Dealer Copy...
  • Page 64 Hero MotoCorp Ltd. The vehicle has been delivered in factory fresh condition to my satisfaction & I have understood all terms and conditions and shall abide by them. Authorised Distributor / Dealer Name Authorised Distributor / Dealer Address Tool bag, Driver No. 2 Plus, Minus, Wrench sparking plug, Spanner 14x17, No. 3...

  • Page 65: Genuine Parts

    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 66 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 67 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 Poor braking effeciency Brake Pads / Shoes Rider safety - an issue Discs / Drum wear out, resulting in subsequent repair cost...

  • Page 68: Jobs Applicable To Periodic Services

    Hero MotoCorp Ltd. JOBS APPLICABLE TO PERIODIC SERVICES 1. Wash the vehicle, blow dry with air at every service. 2. Fuel line inspection at every service. 3. Inspect throttle free play and operation at every service, adjust if necessary .
  • Page 69 Engine Oil Authorised Top-up/ Distributor/Dealer Replace (Sig. & Stamp) 500 - 750 3000 - 3500 6000 - 6500 9000 - 9500 12000 - 12500 15000 - 15500 18000 - 18500 VIII 21000 - 21500 24000 - 24500 NOTE : It is mandatory to avail all services as per the recommended schedule. Please ensure that each service is availed within 90 days from the date of previous service or as per the recommended schedule, whichever is earlier.
  • Page 70 Engine Oil Authorised Top-up/ Distributor/Dealer Replace (Sig. & Stamp) 27000 - 27500 30000 - 30500 33000 - 33500 XIII 36000 - 36500 39000 - 39500 42000 - 42500...
  • Page 71 Authorised Distributor/Dealer (Sig. & Stamp)
  • Page 72 Hero MotoCorp Ltd. OWNERSHIP RECORD AND DATA AUTHORISED DISTRIBUTOR/DEALER NAME AUTHORISED DISTRIBUTOR/DEALER NAME AUTHORISED DISTRIBUTOR/DEALER STAMP AND SIGNATURE...

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