HERO Passion PRO TR Manual
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HERO Passion PRO TR Manual

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PREFACE
Thank you for selecting a Hero MotoCorp Passion PRO TR. 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 TR. 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 TR. 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

    BRAKE WEAR INDICATOR (REAR BRAKE) STEERING LOCK / SEAT LOCK FUSE REPLACEMENT SIDE STAND INDICATOR/ SIDE STAND SWITCH 15 STOP LAMP SWITCH FUEL VALVE SIDE STAND HEADLAMP ADJUSTMENT ENGINE OIL/ENGINE OIL TOP UP PROCESS / PARKING ANTI THEFT TIPS UTILITY BOX HERO GENUINE PARTS...
  • Page 4 YYYYY Manufacturer Vehicle Year of Assembly Month of Serial XXXXEN YYYYY Code Description Mfg. Plant Mfg. Number Engine Year of Assembly Month of Serial Model Code : Description Mfg. Plant Mfg. Number Model Engine Passion PRO TR (Cast wheel/Electric start/Disc)
  • Page 5 PRODUCT SPECIFICATION ITEM SPECIFICATIONS DIMENSIONS 1980 mm 840 mm 1085 mm 1235 mm Saddle Height 795 mm 165 mm WEIGHT 119 kg CAPACITIES 1.05 litres at disassembly 0.85 litre at draining 12.8 litres 1.0 litre (usable) 162-165 ml ENGINE Maximum Power 5.74 kW (7.8 Ps) @ 7500 r/min Maximum Torque 0.82 kgf-m (8.04 N-m) @ 4500 r/min...
  • 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 - 6 PR / 50L 3.00 x 18 - 6 PR / 52P Disc Type Dia 240 mm 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 (8) Saree guard with women (14) Side stand switch (2) Carburetor pillion step (15) Air suction valve (3) Gear shift pedal (9) Rear turn signal lamp (16) Front number plate (4) Rider foot rest (10) Reflex reflector (17) Headlamp grill (5) Main stand...
  • Page 12 (1) Pillion foot rest (7) Bash plate (13) Headlamp (2) Battery compartment (inside) (8) Oil level dipstick (14) Front visor (3) Kick starter pedal (9) Utility box (15) Hand guard (4) Rider foot rest (10) Caliper assembly (16) Fuel tank knee pad (5) Starter motor (11) Front disc (17) Rear number plate...
  • 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 “LOCK” Position The engine can be started, Turn “ON” signal lamps, Horn, Tail/Stop lamp and Passing Switch can be operated. Fuel Gauge, Odometer and Tripmeter reading will be functional. “OFF” Engine cannot be started and no electrical system 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: Steering Lock / Seat Lock

    6. Clutch Switch Never hold starter switch continuously for There is a clutch switch provided for the more than 10 seconds as continuously safety of the rider. The motorcycle cannot cranking of engine will drain the battery. be started by electric starter switch until STEERING LOCK the clutch lever is operated when the vehicle is engaged in gear.

  • 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 “OFF” 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 “RES” 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: Engine Oil/Engine Oil Top Up Process

    1. Start the engine & let it idle for 3-5 minutes. ENGINE OIL Use hero genuine engine oil or recommended grade oil. BRAND: Hero 4T plus GRADE: SAE 10W 30 SL Grade (JASO MA2).
  • Page 22 3. Reinsert the oil level dipstick without 6. Stop the engine and let the engine oil screwing it in and check the oil level. settle down. 7. Recheck the oil level. 4. If required, add the specified oil up to 8.
  • Page 23 TYRES 3.00 2.25 33 psi 2.25 33 psi Over inflation / Under inflation will affect the performance...
  • 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). 3. Front brake (Disc type) - check for 13.
  • 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 e n g i n e f o r f e w 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 Some emergency repairs, minor box. For some emergency first aid can be adjustments and parts replacement can be performed by medicine contained in the performed with the tools contained in the kit.

  • 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 Replace once in every two years or 30000 kms. whichever is earlier. 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.

  • Page 34: Oil Filter Screen & Centrifugal Filter

    OIL FILTER SCREEN & 5. Remove centrifugal filter cover (8) & CENTRIFUGAL FILTER clean the centrifugal filter (9) with non 1. Drain the engine oil thoroughly. flammable or high flash point solvent 2. Remove the kick starter pedal (1), (kerosene). disconnect the clutch cable (2), remove the bash plate (3) remove the muffler (4), 6.
  • Page 35 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 Tighten a new spark plug ½ turn with a base. box wrench to compress the washer. If...
  • 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 Drive chain slack (3) should be adjusted or the clutch does not work correctly, visit your Authorised Hero MotoCorp to allow approximately 25 mm (1 inch) 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) "MIN" mark NOTE Visit Authorised Hero MotoCorp Brake fluid recommended: DOT 3 or DOT 4 workshop for inspection, cleaning, Fluid level - Ensure that the brake fluid lubrication and adjustment of drive chain at level does not fall below “MIN”...

  • Page 46: Brake Pad Wear (Front Brake)

    • 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 47 Make sure that the cut-out on the adjusting nut is seated on the brake joint pin (4) after the final adjustment has been made. If proper adjustment cannot be obtained by this method, visit your Authorised Hero MotoCorp workshop. (2) Free play 20-30 mm...

  • Page 48: Brake Wear Indicator (Rear Brake)

    Maintenance-Free (sealed) type. If battery seems weak and/or electrolyte is leaking (causing hard starting or other electrical troubles), contact your Authorised Hero MotoCorp workshop. *MF stands for Maintenance Free...
  • Page 49 NOTE : Battery charging This symbol on the battery means Always visit your Authorised Hero that this product must not be MotoCorp workshop if you see any treated as household waste. symptom of battery discharge as earliest as This symbol on the battery means possible to get the battery charged.

  • Page 50: Fuse Replacement

    5. Disconnect the negative (-) terminal (2) from the battery first, then disconnect the positive (+) terminal (3). 6. Remove the battery (1) from the battery box. Battery installation 1. Reinstall in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (-) terminal.

  • Page 51: 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 52: 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 53 Rear Shock Absorber Adjustment Rear shock absorber adjustment can be Check the front forks by locking the made according to the load/road conditions. • In direction A Stiffer front brake and pumping the front fork • In direction B Softer up and down vigorously.
  • Page 54 1. Raise the front wheel off the ground. 2. Remove the speedometer cable (1) by pressing the tab (2) & then pull out the cable. 3. Remove the axle nut (3). 4. Remove the axle then remove the wheel. Remove the axle nut (8) and pull out the rear axle (9).
  • Page 55 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 56 AIR SUCTION VALVE (1) Air Suction Valve Further to meet emission standards this motorcycle is provided with the air suction valve. Air Suction Valve (1) supplies fresh air from the air filter to the exhaust manifold to convert carbon monoxide to carbon dioxide.
  • Page 57 BASIC TROUBLESHOOTING Fuel System Check fuel valve position Consult Authorised Hero MotoCorp Workshop Electric Starter Not Working Fuse Check Fuse Replace Fuse (page 47) Weak Inspect Battery Consult Authorised Hero MotoCorp Workshop Loose Check connections, Ignition Secure connctions switch / starter switch...
  • Page 58 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 59 Check Air Cleaner Consult Authorised Hero MotoCorp Workshop Consult Authorised Hero MotoCorp Workshop Consult Authorised Hero MotoCorp Workshop...
  • Page 62 & conditions. Terms & conditions Passion PRO TR vehicle is warranted for a period of 5 years or 70000 Km, 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.
  • Page 63 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 64 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 65 (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 66 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 67 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 68 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 69 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 70 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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