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
! WARNING
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 Improper service or repairs can create an
faulty operation, damage to the vehicle, or injury to others. unsafe condition that can cause your
customer or others to be seriously hurt or
FOR YOUR SAFETY killed. Follow the procedures and
Because this manual is intended for the professional service technician, we do not precautions in this manual and other
provide warnings about many basic shop safety practices (e.g., Hot parts- wear service materials carefully.
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 ! WARNING
performing service and repair procedures. Only you can decide whether or not you Failure to properly follow instructions and
should perform a given task. precautions can cause you to be seriously
IMPORTANT SAFETY PRECAUTION hurt or killed.
Make sure you have a clear understanding of all basic shop safety practices and Follow the procedures and precautions in
that you are wearing appropriate clothing and using safety equipment. When this manual carefully.
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.
MEMO
HOW TO USE THIS MANUAL
This shop manual describes the service procedures for HUNK. CONTENTS SECTION
Follow the Maintenance Schedule (Section 3) recommendations to
ensure that the vehicle is in peak operating condition. GENERAL INFORMATION 1
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break- in FRAME/ BODY PANELS/ EXHAUST SYSTEM 2
period.
Sections 1 and 3 apply to the whole motorcycle. Section 2 MAINTENANCE 3
illustrates procedures for removal/ installation of components that
may be required to perform service described in the following LUBRICATION SYSTEM 4
sections.
Section 4 through 19 describe parts of the motorcycle, grouped FUEL SYSTEM 5

ENGINE & DRIVE TRAIN

according to location.
TO LOCATE WHAT YOU ARE LOOKING FOR ENGINE REMOVAL/ INSTALLATION 6
1. The text of this manual is divided into sections.
2. As the title of these sections is listed on the previous page as CYLINDER HEAD/ VALVES 7
GROUP INDEX, select the section where you are looking
for. CYLINDER/ PISTON 8
3. Holding the manual as shown at the right will allow you to find the
first page of the section easily. CLUTCH/ GEARSHIFT LINKAGE 9
4. On the first page of each section, its contents are listed. Find the
item and page you need. ALTERNATOR/ STARTER CLUTCH 10
1
2
HUNK
3

6
5
4
CRANKSHAFT/ TRANSMISSION 11
7
8
9
HUNK 10

FRONT WHEEL/ SUSPENSION/ STEERING 12

CHASSIS

REAR WHEEL/ SUSPENSION 13

You will find important safety information in a variety of forms

including: TUBELESS TYRES 14
• Safety Labels- on the vehicle
• Safety Messages- preceded by a safety alert symbol and
HYDRAULIC BRAKE SYSTEM 15
one of three signal words, DANGER, WARNING or CAUTION.
These signal words mean: BATTERY/ CHARGING SYSTEM 16
You WILL be SERIOUSLY HURT if you don’t
! DANGER
ELECTRICAL

follow instructions. IGNITION SYSTEM 17

You CAN be SERIOUSLY HURT if you don’t
! WARNING
follow instructions. ELECTRIC STARTER 18
! CAUTION
You CAN be HURT if you don’t follow
instructions. LAMPS/ METERS/ SWITCHES 19
• Instructions- how to service this vehicle correctly and safely.
WIRING DIAGRAM 20
As you read this manual, will find information that is preceded by a
NOTE symbol. The purpose of this message is to help prevent damage
to your vehicle, other property or the environment. TROUBLESHOOTING 21
ALL INFORMATION, ILLUSTRATIONS, PHOTOGRAPHS, DIRECTIONS,
SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS
WORKSHOP MANUAL ARE BASED ON THE LATEST PRODUCT
INFORMATION 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.
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 DESCRIPTION

Replace the part(s) with new one (s) before assembly.

Apply oil. Use engine oil unless otherwise specified.

G Apply grease

Apply silicone grease.

Apply moly paste.

SEAL Apply sealant

Use fork oil.

LOCK Apply a locking agent

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Check for continuity.

Use special tool.

Torque control required. Data beside it indicates specified torque.

SYMBOLS
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning
associated with them respectively.

SYMBOLS DESCRIPTION

Feeler gauge

Micrometer
0

45
50

Cylinder bore gauge

20

30
10

40
0

50
90

60
70
80

Dial gauge

Vernier Caliper
MEMO
 1.GENERAL INFORMATION

General Service Precautions 1-1 Engine Torque Values 1-11

Model Identification 1-2 Frame Torque Values 1-12
Specification 1-3 Lubrication & Seal Points 1-14 1
Service Limit 1-5 Special Tools 1-16
Standard Torque Values 1-10 Emission Control System 1-35

GENERAL SERVICE PRECAUTION

Always replace gaskets, O-rings, circlips and cotter pins When engine and final drive components are
with new ones. disassembled and inspected, coat the mating surface with
GASKET a lubricant to prevent corrosion.
O- RING COTTER PIN

CIRCLIP SOLVENT

OIL

When tightening nuts and bolts, start first with the After assembling components, use proper assembly
larger or centre ones. Tighten these to the specified lubricants.
torque using a criss- cross pattern.

IN A X PATTERN OIL

Use only genuine Hero MotoCorp parts and After assembling, check every part for proper installation,
recommended lubricants. movement and operation.

Use specified special and common tools only. Always ensure mutual safety when working with a partner.

1-1
GENERAL INFORMATION

MODEL IDENTIFICATION

FRONT FRONT

FRAME SERIAL NUMBER ENGINE SERIAL NUMBER

The frame serial number is stamped on the right side of The engine serial number is stamped on the lower
the steering head. left side of the crankcase.

FRONT

CARBURETOR IDENTIFICATION NUMBER

The carburetor identification number is stamped on the
carburetor body right side.

1-2
 GENERAL INFORMATION

SPECIFICATION
GENERAL
ITEM SPECIFICATIONS
Overall length 2080 mm
Overall width 765 mm 1
Overall height 1095 mm
Dimensions Wheelbase 1325 mm
Saddle height 795 mm
Kerb weight 146 kg (Fr. Disc/ Rr. Drum)/ 147 kg (Fr. Disc/ Rr. Disc)
Ground clearance 145 mm
Frame type Tubular Diamond Type
Front suspension Telescopic hydraulic type
Front cushion stroke 130 mm
Rear suspension Rectangular Swingarm with Nitrox GRS (Gas Reservoir Suspension)
Rear cushion stroke 80 mm
Front tyre size 80/100 X 18 - 47 P (Tubeless)
Rear tyre size 100/90 X 18 - 56 P (Tubeless)
Front 2.00 kgf/cm2 (29 psi)
Rider only
Rear 2.00 kgf/cm2 (29 psi)
Cold tyre pressure
Frame Front 2.00 kgf/cm2 (29 psi)
Rider & Pillion
Rear 2.25 kgf/cm2 (33 psi)
Front brake Disc type Disc Dia. 240 mm
Rear brake Drum/ Disc Dia 130 mm/ Dia. 220 mm
Fuel tank capacity 12.4 litres (minimum)
Fuel tank reserve capacity 2.2 litres (usable reserve)
Caster angle 26°
Trail length 96.2 mm
Fork oil capacity 143 ml
Type Air cooled, 4 Stroke single cylinder, OHC
Cylinder arrangement Single cylinder 10°, inclined from vertical
Bore and stroke 57.3 x 57.8 mm
Displacement 149.2 cc
Compression ratio 9.1: 1
Valve train Silent chain drive, OHC, Poppet valve
1.2 Litres at disassembly
Engine oil capacity
1.0 Litres at oil change
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Engine
Oil filtration Wire mesh & centrifugal filter
Air filtration Dry, Paper Pleated Type
Cylinder compression pressure 12.0±2.0 kgf/cm2
Open 10° BTDC
Intake valve
Close 35° ABDC
Open 35° BBDC
Exhaust valve
Close 5° ATDC
Intake 0.08 mm (in cold condition)
Valve clearance
Exhaust 0.12 mm (in cold condition)
Idle speed 1400±100 rpm

1-3
GENERAL INFORMATION

ITEM SPECIFICATIONS
Clutch Multi - plate, wet type
Transmission 5 - speed constant mesh
Primary reduction 3.3500 (67/20)
1st 3.0769 (40/13)
2nd 1.7895 (34/19)
Drive train
Gear ratio 3rd 1.3043 (30/23)
4th 1.0909 (24/22)
5th 0.9375 (30/32)
Final reduction 3.0714 (43/14)
Gearshift pattern Toe shift 1- N- 2- 3- 4- 5
Ignition system Digital-DC CDI Ignition (AMI with CCVI***)
“F” mark 80 BTDC @ 1400 rpm
Ignition timing
Full Advance 270 BTDC @ 6000 rpm
Alternator 140W @ 5000 rpm
Electrical
Battery capacity 12V 4Ah, MF* Battery
System
Spark plug NGK - CPR 8EA9
Spark plug gap 0.8 - 0.9 mm
Fuses 10A, 15A, 20A
Headlamp (Hi/Lo) 12V - 35W/35W Halogen bulb, MFR**
Tail lamp/Stop lamp 12V - 0.5W/4.1W LED
Turn signal lamp 12V - 10W X 4MFR** (Amber bulb with clear lens)
Meter illumination LED
Lamps Neutral indicator 12V - 2.3W
Turn signal indicator LED
Position lamp 12V - 3W
Hi beam indicator LED
Licence plate lamp 12V - 5W
MF* stands for Maintenance Free
MFR** stands for Multi- focal reflector
CCVI*** stands for Carburetor Controlled Variable Ignition

1-4
 GENERAL INFORMATION

SERVICE LIMIT
Unit: mm
LUBRICATION
ITEM STANDARD SERVICE LIMIT
1
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.
3. Bharat Petroleum Corporation Limited.

Outer rotor- body clearance 0.15- 0.21 0.26

Oil pump Rotor tip clearance 0.15 0.20
Pump end clearance 0.03- 0.09 0.15

Unit: mm
CYLINDER HEAD/VALVES
ITEM STANDARD SERVICE LIMIT

12± 2 (kgf/cm2) -
Cylinder compression
171± 28 (psi) -
Intake 0.08 -
Valve clearance (in cold condition)
Exhaust 0.12 -
Intake 32.994- 33.234 32.95
Camshaft cam lobe height
Exhaust 32.880- 33.120 32.84
Cylinder head warpage - 0.10
I.D 10.000- 10.015 10.06
Rocker arm Shaft O.D 9.972- 9.987 9.95
Rocker arm to-shaft clearance 0.013- 0.043 0.11
Intake 4.975- 4.990 4.945
Stem O.D
Exhaust 4.955- 4.970 4.925
Intake 5.000- 5.012 5.03
Guide I.D
Valve Exhaust 5.000- 5.012 5.03
Intake 0.010- 0.037 0.08
Stem- to-guide clearance
Exhaust 0.030- 0.057 0.10
Intake/
Spring free length 37.78 36.78
Exhaust
Valve seat width 0.9- 1.1 1.5

1-5
GENERAL INFORMATION

Unit: mm
CYLINDER/PISTON/RINGS
ITEM STANDARD SERVICE LIMIT

I.D 57.300- 57.310 57.38

Ovality - 0.10
Cylinder
Taper - 0.10
Warpage - 0.10
Piston O.D 57.280 - 57.295 57.21
Piston pin hole I.D 14.002 - 14.008 14.04
Piston pin O.D 13.994 - 14.000 13.96
Piston- piston pin clearance 0.002 - 0.014 0.07
Connecting rod small end I.D 14.010 - 14.028 14.06
Cylinder- piston clearance 0.010 - 0.030 0.10
Piston
Connecting rod- piston pin clearance 0.010 - 0.034 0.10
Top 0.03 - 0.06 0.10
Piston ring- groove clearance
2nd 0.03 - 0.06 0.10
Top 0.10 - 0.25 0.60
Piston ring end gap 2nd 0.10 - 0.25 0.70
Oil (Side Rail) 0.20 - 0.70 1.10

Unit: mm
CLUTCH/GEAR SHIFT LINKAGE
ITEM STANDARD SERVICE LIMIT

Lever free play 10- 20 -

Spring free length 40.50 39.6

Disc-A (n=2) Green mark 2.92 - 3.08 2.62
Friction disc thickness
Disc-B (n=3) 2.92 -3.08 2.62
Clutch
Plate warpage - 0.20
Clutch outer guide I.D 16.991- 17.009 17.05
Clutch outer guide O.D 22.959 - 22.980 22.93

Clutch outer I.D 23.000 - 23.021 23.08

1-6
 GENERAL INFORMATION

Unit: mm
CRANKSHAFT/TRANSMISSION
ITEM STANDARD SERVICE LIMIT

I.D 10.000 - 10.018 10.05

1
Shift fork Claw thickness 4.93- 5.00 4.53
Shaft O.D 9.986 - 9.995 9.93
Left 23.959 - 23.980 23.94
O.D
Right 20.959 - 20.980 20.94
Shift drum
Left 24.000 - 24.033 24.05
Journal I.D
Right 21.000- 21.021 21.04
M4, M5 20.000 - 20.021 20.06
C3 23.025 - 23.046 23.09
Gear I.D
C2 23.020 - 23.041 23.08
C1 20.500 - 20.521 20.56
M4, M5 19.959 - 19.980 19.91
Bush O.D C1 20.459 - 20.480 20.41
C2, C3 22.984 - 23.005 22.93
M4,C1 17.000 - 17.018 17.04
Bush I.D
C2,C3 20.020 - 20.041 20.07
M5, C1, C3 0.020 - 0.062 0.10
Transmission
Gear to bush clearance C2 0.015 - 0.057 0.10
M4 0.020 - 0.062 0.11
At M4, C1 16.966 - 16.984 16.93
Mainshaft/countershaft O.D At C2 19.978 - 19.989 19.94
At C3 19.979 - 20.000 19.94
M2, M3 0.016 - 0.052 0.09
Gear to shaft clearance
C4 0.020 - 0.062 0.10
M4, C1 0.016 - 0.052 0.09
Bush-to-shaft clearance C2 0.020 - 0.057 0.10
C3 0.020- 0.062 0.10
Run out - 0.05
Crankshaft Big end side clearance 0.10 - 0.35 0.60
Big end radial clearance 0- 0.008 0.05
Gear I.D 29.000 - 29.021 29.06
Starter driven gear
Collar O.D 45.660 - 45.673 45.64

Pinion O.D 16.016 - 16.034 16.09

Kick starter
Spindle O.D 15.966 - 15.984 15.95

1-7
GENERAL INFORMATION

Unit: mm
FRONT WHEEL/ SUSPENSION/ STEERING
ITEM STANDARD SERVICE LIMIT
Minimum tyre tread depth - 1.5
2
Rider only 2.00 kgf/cm ( 29 psi ) -
Cold tyre pressure
Rider & Pillion 2.00 kgf/cm2 ( 29 psi ) -
Front axle run out - 0.20
Radial - 2.0
Front wheel rim runout
Axial - 2.0
Fork spring free length 468 454
Fork tube run out - 0.20
Fork oil capacity 143 ml -

Unit: mm
REAR WHEEL/ BRAKE/ SUSPENSION
ITEM STANDARD SERVICE LIMIT
Minimum tyre tread depth - 2.0
2
Rider only 2.00 kgf/cm (29 psi) -
Cold tyre pressure 2
Rider & Pillion 2.25 kgf/cm (33 psi) -
Rear axle run out - 0.20
Radial - 2.0
Rear wheel rim runout
Axial - 2.0
Rear brake pedal free play 20 - 30 -
Rear brake drum I.D 130 131
Rear brake lining thickness 4.0 2.0

Unit: mm
HYDRAULIC BRAKES
ITEM STANDARD SERVICE LIMIT
Specified brake fluid DOT 3 or DOT 4 -
Brake disc thickness 3.8- 4.2 3.5
Brake disc runout - 0.30
Front Master cylinder I.D 12.700 - 12.743 12.76
Master cylinder piston O.D 12.657- 12.684 12.64
Caliper cylinder I.D 25.400 - 25.450 25.46
Caliper piston O.D 25.335 - 25.368 25.31
Caliper piston O.D 31.965 - 31.998 31.95
Caliper cylinder I.D 32.03 - 32.08 32.10
Master cylinder piston O.D 12.657 - 12.684 12.64
Rear Master cylinder I.D 12.70 - 12.74 12.76
Brake disc runout - 0.30
Brake disc thickness 5.0 4.0
Specified brake fluid DOT 3 or DOT 4 -

1-8
 GENERAL INFORMATION

Unit: mm
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS

Capacity 12V - 4Ah, MF Battery

Battery Current leakage 0.1 mA maximum
1
Voltage @ 20°C/68°F 12.4V minimum
Capacity 140W @ 5000 rpm
Alternator
Charging coil resistance (20°C/68°F) 0.2 - 1.0O
Lamp coil regulated voltage (with battery) 14.5V max @ 6000 rpm
Night 2.5A@ 2500 rpm
Lamp coil regulated current (with battery)
Day 2.9A@ 2500 rpm

Unit: mm
IGNITION SYSTEM
ITEM SPECIFICATIONS
Standard NGK - CPR 8EA9
Spark Plug
Spark plug gap 0.8 - 0.9 mm
Ignition coil primary side 100V (min)
Peak Voltage
Pulse generator 1.5 V (min)
"F" mark, deg 8° BTDC @1400 rpm
Ignition Timing
Full Advance 27° BTDC @6000 rpm
Primary coil resistance @ 20°C/68°F 0.75 - 0.85 W
Ignition Coil Secondary coil resistance (without plug cap) @ 20°C/ 68°F 12.0 - 14.0 kW
Ignition pulse generator resistance @ 20°C/68°F 50 - 200 W

1-9
GENERAL INFORMATION

STANDARD TORQUE VALUES

FASTENER TYPE TORQUE (N-m) TORQUE (kgf-m)
5 mm bolt and nut 4.4 ~ 6.0 0.45 ~ 0.6
6 mm bolt and nut (include SH flange bolt) 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 3.4 ~ 5.0 0.35 ~ 0.5
6 mm screw 7.0 ~ 11 0.7 ~ 1.1
6 mm SH bolt 8.0 ~ 12 0.8 ~ 1.2
6 mm flange bolt (Include NSHF) and nut 10 ~ 14 1.0 ~ 1.4
8 mm flange bolt and nut 24 ~ 29 2.4 ~ 3.0
10 mm flange bolt and nut 3.0 ~ 44 3.5 ~ 4.5

NOTE
• Torque specifications listed below and on the next page are for important fasteners.
• Others should be tightened to standard torque values listed above.

1-10
 GENERAL INFORMATION

ENGINE
TORQUE PR
SR. THREAD
ITEM VALUES REMARKS
NO. SIZE & TYPE
N-m kgf- m N-m 1
MAINTENANCE
1 Spark plug M10 x 1.0 14 ~ 18 1.4 ~ 1.8 16
2 Tappet adjusting nut M6 x 0.75 12 ~ 16 1.2 ~ 1.6 14 Apply engine oil
3 Timing hole cap M14 x 1.5 4.0 ~ 6.0 0.4 ~ 0.6 5
4 Crankshaft hole cap M32 x 1.5 10 ~ 20 1.0 ~ 2.0 15 Apply grease
5 Oil drain bolt (Left crankcase) M12 x1.5 25 ~ 34 2.5 ~ 3.5 30
6 Oil filter rotor cap oval screw M5 x 0.8 3.0 ~ 5.0 0.3 ~ 0.5 4
7 Carburetor insulator flange bolt M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12
8 Insulator band, pan screw M5 x 0.8 0.8 ~1.2 0.8 ~ 0.12 1
LUBRICATION
1 Oil pump tapping screw M4 x 0.8 2.5 ~ 3.9 0.25 ~ 0.4 3
2 Oil filter rotor lock nut M14 x 1.0 59 ~ 69 6.0 ~ 7.0 64 Apply engine oil
CYLINDER HEAD/CYLINDER/ VALVE
1 Cylinder head bolt stud M8 x 1.25 7.0 ~ 15 0.7 ~ 1.5 11
2 Head cover, special bolt M6 x 1.0 8.0 ~ 12 0.8 ~ 1.2 10
3 Camshaft holder, special nut M8 x 1.25 30 ~ 34 3.1 ~ 3.5 32 Apply engine oil
4 Camshaft holder, flange bolt M5 x 0.8 4.4 ~ 6.0 0.45 ~ 0.6 5
5 Cam sprocket, flange knock bolt M5 x 0.8 7.0 ~ 11 0.7 ~ 1.1 9

6 Tensioner lifter adjusting hole M6 x 1.0 3.4 ~ 5.0 0.35 ~ 0.5 4

cap, pan screw
ALTERNATOR
1 ACG. Flywheel, flange nut M14 x 1.0 69 ~ 78 7.0 ~ 8.0 74 Apply engine oil
2 Pulser, socket bolt M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12 TB #1322N equiv
3 ACG. cord clamper, socket bolt M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12 TB #1322N equiv
CLUTCH/ GEARSHIFT/KICK STARTER
1 Clutch assy, special flange nut M14 x 1.0 69 ~78 7.0 ~ 8.0 74
Apply engine oil
2 Clutch assy. lifter plate flange bolt M6 x 1.0 10 ~14 1.0 ~ 1.4 12
3 Starting clutch outer, spl. socket bolt M6 x 1.0 14 ~18 1.4 ~ 1.8 16
4 Shift drum stopper plate, flange bolt M6 x 1.0 10 ~14 1.0 ~ 1.4 12 TB #1322N equiv
5 Shift drum stopper, spl. flange bolt M6 x 1.0 10 ~14 1.0 ~ 1.4 12
CRANK SHAFT/TRANSMISSION
Bearing hold plate, mainshaft bearing
1 flange bolt (Right crankcase) M6 x 1.0 10 ~14 1.0 ~ 1.4 12

2 Bearing push, SH flange bolt M6 x 1.0 8.0 ~ 12 0.8 ~ 1.2 10 TB #1322N equiv
3 Drive sprocket, special hex. bolt M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12
4 R/L crankcase, bolt cylinder stud M8 x 1.25 7.0 ~ 15 0.7 ~ 1.5 11

1-11
GENERAL INFORMATION

FRAME
TORQUE PR
SR. THREAD
ITEM VALUES REMARKS
NO. SIZE & TYPE
N-m kgf-m N-m

ENGINE REMOVAL/ INSTALLATION

1 Front engine hanger nut M8 x 1.25 24 ~ 29 2.4 ~ 3.0 26 BF and NF
2 Rear engine hanger nut M10 x 1.25 49 ~ 59 5.0 ~ 6.0 54 BF and NF
STEERING
1 Stem nut M24 x 1.0 59 ~ 88 6.0 ~ 9.0 74 See note 3
2 Top thread M26 x 1.0 2.9 ~ 3.9 0.3 ~ 0.4 3.4
3 Top bridge (front fork) M10 x 1.25 39 ~ 49 4.0 ~ 5.0 44
4 Bottom bridge (front fork) M8 x 1.25 29 ~ 34 3.0 ~ 3.5 32 BF
5 Handle bar upper holder bolt M6 x 1.0 10~ 14 1.0 ~ 1.4 12 BF
6 Handle lock M8 x 1.25 15 ~ 25 1.5 ~ 2.5 20
7 Left handle lever pivot M6 x 1.0 0.5 ~ 1.5 0.05 ~ 0.15 1.0
8 Left handle lever pivot nut M6 x 1.0 4.9 ~ 6.9 0.5 ~ 0.7 5.9
WHEEL
1 Front axle nut M12 x 1.25 54 ~ 70 5.5 ~ 7.0 62 PT nut
2 Rear axle nut M14 x 1.5 59 ~ 78 6.0 ~ 8.0 68 PT nut
3 Front brake disc bolt M8 x 1.25 39 ~ 44 4.0 ~ 4.5 42
4 Driven sprocket nut M10 x 1.25 59 ~ 69 6.0 ~ 7.0 64
5 Sleeve nut M22 x 1.0 49~ 69 5.0 ~ 7.0 59
BRAKES
1 Front caliper (front fork ) M8 x 1.25 2 7 ~ 33 2.8 ~ 3.4 30 BF (TB2361)
2 Front stop switch M4 x 0.7 0.8 ~ 1.5 0.08 ~ 0.15 1.2 1.2 Screw
3 Front master cylinder cap M4 x 0.7 0.8 ~ 1.5 0.08 ~ 0.15 1.2 Screw
4 Right handle lever pivot (bolt) M6 x 1.0 0.5 ~ 1.5 0.05 ~ 0.15 1.0
5 Right handle lever pivot (nut) M6 x 1.0 5.0 ~ 7.0 0.5 ~ 0.7 6.0
6 Master cylinder holder M6 x 1.0 8.0 ~ 10 0.8 ~ 1.0 9.0 BF
7 Oil bolt M10 x 1.25 29 ~ 39 3.0 ~ 4.0 34 BF
8 Front caliper bleeder M10 x 1.25 12 ~ 16 1.2 ~ 1.6 14
Rear brake stopper
9 M8 x 1.25 18 ~ 25 1.8 ~ 2.5 22 NH
(Swing arm side)
Rear brake stopper
10 (Caliper side) M8 x 1.25 18 ~ 25 1.8 ~ 2.5 22 NH

11 Rear caliper bleeder M8 x 1.25 3.9 ~ 6.9 0.4 ~ 0.7 5.4

12 Rear caliper pin bolt M8 x 1.25 14.7 ~ 19.6 1.5 ~ 2.0 18
13 Rear caliper torque nut M8 x 1.25 19.6 ~ 24.5 2.0 ~ 2.5 22 Apply ASECAS 10 AQ

1-12
 GENERAL INFORMATION

FRAME
TORQUE PR
SR. THREAD
ITEM VALUES REMARKS
NO. SIZE & TYPE
N-m kgf-m N-m
1
BRAKES

14 Rear caliper hanger pin M10 x 1.0 14.7 ~ 19.6 1.5 ~ 2.0 17 -
15 Rear master cylinder cap M4 x 0.7 1.0 ~ 2.0 0.1 ~ 0.2 1.5 Screw
16 Rear master cylinder rod joint M8 x 1.25 14.7 ~ 19.6 1.5 ~ 2.0 17 -
17 Rear master cylinder connector M4 x 0.7 1.0 ~ 2.0 0.1 ~ 0.2 1.5 Apply locktite 569
Rear master cylinder (Step holder
18 M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12 -
fitting use)
19 Rear caliper holder fitting use M8 x 1.25 27 ~ 33 2.8 ~ 3.4 30 BF (TB2361)
SUSPENSION
1 Rear cushion upper nut M10 x 1.25 19 ~ 29 2.0 ~ 3.0 24 Cap nut
2 Rear cushion lower bolt M10 x 1.25 19 ~ 29 2.0 ~ 3.0 24 BF
3 Front fork bolt M26 x 1.0 15 ~ 29 1.5 ~ 3.0 22 Fork bolt
4 Bolt socket 8 mm M8 x 1.25 15 ~ 25 1.5 ~ 2.5 20 -
SWINGARM
1 Swingarm pivot nut M14 x 1.5 45 ~ 65 4.5 ~ 6.5 54 PT nut apply oil

OTHERS
1 Side stand M10 x 1.25 39 ~ 49 4.0 ~5.0 44 U nut
2 Cover, muffler M6 x 1.0 7 ~ 11 0.7 ~1.1 9
3 Muffler protector M6 x 1.0 11.8 ~ 15.7 1.2 ~ 1.6 13.7 SH
4 Air cleaner cover M5 x 0.8 1.3~ 1.7 0.13 ~ 0.17 1.5 -
5 Seat lock assembly M6 x 1.0 10 ~ 14 1.0 ~ 1.4 12 Bolt break off

6 Mirror assembly right/left M10 x 1.25 29 ~ 39 3.0 ~ 4.0 34

(Left thread)

NOTE
• Factor for conversion of torque value SI unit (N-m) from customary unit (kgf-m) shall be 9.81 in this table.
• Center Values in Pr value shall be used for service procedure.
• Tighten marked nut while holding the mating bolt steady.
• Silver painting on break section of bolt head.

1-13
GENERAL INFORMATION

LUBRICATION& SEAL POINTS

ENGINE
LOCATION MATERIAL REMARKS
Cylinder, inner surface of cylinder sleeve
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
Rocker arm shaft whole surface
Rocker arm inner surface of boss, roller surface
Tapped adjusting nut threaded portion, seating surface
Oil pump assembly rotor
M14 lock nut (oil filter rotor) threaded portion, seating surface Engine oil Each bearing (1ml min.)
Oil through sliding surface
Clutch disk whole surface
Clutch lifter rod whole surface
M14 flange nut (clutch center) threaded portion, seating surface
Gear (primary, mission, starter) tooth flank
Shift fork shaft whole surface
Shift drum journal outer surface sliding area
Change spindle journal outer surface sliding area
Starter reduction gear shaft whole surface
Ball/ needle bearing rolling surface
O- ring whole surface
Starter clutch rolling surface
Cap (32 mm) threaded portion
Push plug, whole surface
Crankshaft comp, needle bearing of conn. rod big end
Crankshaft comp, inner surface of conn. rod small end
Piston pin outer surface
Valve Inlet/ exhaust outer surface of stem, end
Camshaft comp, whole cam surface
Clutch outer guide outer surface
Engine oil with MoS
Clutch outer comp. sliding surface
M4, M5 gear inner surface
M4, M5 gear inner bush whole surface
C1, C2, C3 gear inner surface
C1, C2, C3 gear inner bush whole surface
M3, C4, C5 gear shift fork groove surface
Bearing, roller 30x 58x 17 rolling surface
Bearing push plate (left crankcase) threaded portion
Bearing hold plate (right crankcase) threaded portion
Shift drum stopper plate threaded portion TB #1322, #1322N or
Shift drum stopper #1324 or 2415 or
Socket bolt (starter clutch outer) threaded portion loctite #200
Socketr bolt (pulser) threaded portion
Socket bolt (ACG cord clamper)

Left crankcase mating surface Three bond #1215

ACG Gromet sealing surface or #1207G

Crankshaft tapped area and ACG flywheel tapered area Degreasing

1-14
 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.)
1
Steering dust seal lip surface or Equiv.
Front fork inside Fork fluid (Bharat SS 8)
Front fork oil seal lip surface Liquid 'O' ring #400 or equiv.
Front brake caliper primary pin inside pin seat
Front brake caliper bush boot pin inside insulator Grease
Front brake lever pivot sliding portion
Front/rear brake master cylinder push rod sliding portion
Front brake caliper secondary pin threaded portion Apply adhesive
Front/rear brake master cylinder inside of master cylinder cup DOT 3 or DOT 4
Rear brake cam dust seal all around Idemitsu Autolub 30
or Mechanic 44 or equiv.
Tyre bead seat area Vegetable soap solution
Front wheel oil seal lip surface
Driven flange dust seal lip surface
Rear wheel hub o-ring all around
Clutch lever pivot bolt sliding portion
Grip comp. throttle contact area of throttle cable end
Rear brake pedal pivot sliding portion
Change pedal pivot sliding portion HES D2012- 2- 1- 2
Tie rod sliding portion
Side stand pivot sliding portion
Main stand pivot sliding portion
Seat lock sliding portion
Rear brake cam, cam and shaft
Rear brake panel anchor shaft
Swingarm bearing needle inside
Swingarm pivot dust seal lip surface
HES D2012- 3- 1- 2
Swingarm pivot nut threaded portion
Grip left handle matching surface
Air cleaner case connecting tube duct case connecting area 540 (Cemedine) or equiv.
Throttle cable inside of boot
Clutch cable inside of boot Silicone grease (TSG3251) or equiv.
Choke cable inside of seal
Throttle cable inside of casing
Clutch cable inside of casing TSG 3203 or molybdenum
Choke cable inside of casing alloy oil M- A0 or equiv.
Seat lock cable inside of casing

1-15
GENERAL INFORMATION

SPECIAL TOOLS

SL. DESCRIPTION APPLICATION PART NUMBER

NO.
1 Flywheel Puller To remove the flywheel from crankshaft. 070HH198001
2 Socket Wrench To remove lock nut from clutch assembly and rotor filter. 070HH198002
3 Universal Holder To hold the flywheel while removing flywheel nut. 070HH198003
4 Clutch Centre Holder To hold the center clutch while removing the lock nut. 070HH198004
To compress the valve spring and remove the
5 Valve Spring Compressor 070HH198005
cotters and valve.
6 Tappet Adjuster with Socket (9 mm) To adjust valve clearance. 070HH198006
7 Ball Race Driver To remove and install ball races from head pipe. 070HH198007
8 Bottom Cone Race Punch (Driver Stem Bearing) To insert bottom cone race in steering stem. 070HH198008
9 Universal Bearing Puller To remove crankshaft bearing. 070HH198009
10 Valve Guide Remover To remove valve guide from cylinder head. 070HH198010
11 Tappet Cover Wrench To open and tighten the tappet cover. 070HH198011
12 Socket 20 mm To be used with pneumatic gun-clutch lock nut. 070HH198012
13 Socket 24 mm To be used with pneumatic gun-rotor filter nut. 070HH198013
14 Aluminum Plug To block fuel pipe hose while removing from carburetor. 070HH198014
15 Average Testing Bottle with Fixture To measure fuel average. 070HH198015
16 Plastic Oil Seal Guide Kit (5 pcs.) To install stator plate oil seal. 070HH198016
17 GPD Holder To provide gear locking between GPD and clutch outer. 070HH198017
18 Front Fork Oil Seal Driver Body To drive in new oil seal. 070HH198018
To hold fork tube seat while opening the bottom
19 Front Fork Dismantling Tool 070HH198020
allen key bolt.
20 Compressor Rear Shock Absorber To compress spring for dismantling rear shock absorber. 070HH198021
21 Oil Pump Spindle Holder To remove and lock the oil pump spindle. 070HH198023
22 Swing Arm Pivot Nut Socket (17mm) To open and lock pivot nut. 070HH198024
23 Steering Bearing Adjusting Nut dual Spanner To adjust/remove/install the bearing adjusting nut. 070HH198025
24 Collet Bearing Remover (12mm) To remove bearing from crankcase. 070HH198026
25 Piston Slide Base To secure piston while assembling cylinder. 070HH198027
26 Race Steering Cone Inserter To insert ball race in steering pipe. 070HH198028
27 Socket Rotor Filter Nut (Pneumatic 24mm) To be used with pneumatic gun-rotor filter nut. 070HH198029
28 Ratchet Spring Inserter To insert kick shaft ratchet spring. 070HH198030
29 Driver 40x46 mm To seat on outer race surface and drive out/in the bearing. 070HH198031
30 Driver 31.8x34.8 mm To seat on outer race surface and drive out/in the bearing. 070HH198032
31 Pilot 17mm To seat in the inner race and drive out/in the bearing. 070HH198033
32 Pilot 11.8mm To seat in the inner race and drive out/in the bearing. 070HH198034
33 Cap, Muffler (100 CC series) To restrict water entry during washing. 070HH198035
34 Brake pad hanger pin remover To remove brake pad hanger pin from caliper assembly. 070HH198036
35 Main/Side Stand spring installer To install main and side stand spring. 070HH198037
36 Socket Steering Stem Nut (32 mm) To remove and tightening the steering stem nut. 070HHGBG004

1-16
 GENERAL INFORMATION

SPECIAL TOOLS

SL.
NO.
DESCRIPTION APPLICATION PART NUMBER 1
37 Front Fork Oil Seal Driver Attachment Dia 30 mm To drive in new oil seal. 070HHKCC001
38 Tappet Adjuster with Socket (10 mm) To adjust valve clearance. 070HHKFN001
39 Flywheel Puller (CBZ) To remove the flywheel from crankshaft. 070HHKFN002
To remove snap ring from master cylinder and
40 Pierer’s Plier 070HHKFN003
driven face bearing.
41 Front Fork Oil Seal Driver Attachment Dia 31mm To drive in new oil seal. 070HHKFN004
42 Crankcase Bearing Remover Collect (15mm) To remove bearing from crankcase. 070HHKFN005
43 Crankcase Bearing Remover shaft To remove bearing from crankcase. 070HHKFN006
44 Crankcase Bearing Remover weight To remove bearing from crankcase. 070HHKFN007
45 Handle Bearing Driver To hold pilot and driver outer to remove/insert bearing. 070HHKFN008
46 Driver Outer 22x24 To seat on outer race surface and drive out/in the bearing. 070HHKFN009
47 Driver Outer 32x35 To seat on outer race surface and drive out/in the bearing. 070HHKFN010
48 Driver Outer 42x47 To seat on outer race surface and drive out/in the bearing. 070HHKFN011
49 Pilot Driver 12 mm To seat in the inner race and drive out/in the bearing. 070HHKFN012
50 Pilot Driver 15 mm To seat in the inner race and drive out/in the bearing. 070HHKFN013
51 Pilot Driver 21 mm To seat in the inner race and drive out/in the bearing. 070HHKFN014
52 Pilot Driver 28 mm To seat in the inner race and drive out/in the bearing. 070HHKFN015
53 Pilot Driver 30 mm To seat in the inner race and drive out/in the bearing. 070HHKFN016
54 Remover Head 12mm To remove wheel bearing from wheel hub. 070HHKFN017
55 Steering Bearing Adjuster Nut Socket To adjust/remove the steering bearing adjuster nut. 070HHKFN018
56 Inspection Cap Driver (Timing) To remove/install timing inspection hole cap. 070HHKFN019
57 Inspection Cap Driver (Flywheel Nut) To remove/install flywheel inspection hole cap. 070HHKFN020
58 Driver 24x27 mm To seat on outer race surface and drive out/in the bearing. 070HHKFN021
59 TPS Test Connector To reset throttle position sensor. 070HHKRY001
60 Flywheel Puller To remove the flywheel from crankshaft. 070HHKRYH001
61 Flywheel puller Holder To hold the flywheel puller. 070HHKRYH002
To avoid the damage of crankshaft threads during
62 Crankshaft pilot 070HHKRYH003
removal of flywheel.
63 Magnet Holder (Clamp Type) To hold magnet while removing the lock nut. 070HHKRYH004
64 Oil Cooler Holder Cover To be used for protecting oil cooler fins during water wash. 070HHKRYH005
65 Hose Pipe Plier To pinch the fuel hose during fuel tank removal. 070HHKRYH006
66 Pin-out Box For diagnosing the Programmed-FI electrical system. 070HHKRYH007
67 Tester (MF Battery) To test the condition of a MF Battery 070HHKRYH008
68 T-Stem Cone puller To remove T-Stem bottom cone. 070HHKST001
69 Bottom Cone Race Driver To install T-Stem bottom cone. 070HHKST002
To install upper and bottom cone race to
70 Upper and Bottom Cone Installer 070HHKST003
steering head pipe.
71 Steering Bearing Adjusting Nut Socket (41 mm) To adjust the steering bearings. 070HHKST004

1-17
GENERAL INFORMATION

SPECIAL TOOLS

SL. DESCRIPTION APPLICATION PART NUMBER

NO.
1
72 Socket Wrench (Rotor Filter and Clutch) To remove lock nut clutch assembly and rotor filter. 070HHKTC001
73 Socket Clutch Nut (Pneumatic 20mm) To be used with pneumatic gun-clutch lock nut opening. 070HHKTC002
74 Clutch Pressure Plate Holder To hold clutch center while removing lock nut. 070HHKTC003
75 Flywheel Puller To remove the flywheel from crankshaft. 070HHKTC004
76 Crankshaft Bearing (RHS) Puller cum Inserter To install/remove RHS crankshaft bearing. 070HHKTC005
77 T-Stem Cone Puller To remove bottom cone race from the T-Stem. 070HHKTC006
78 Socket 19mm To open and lock pivot nut. 070HHKTC007
79 Cap, Muffler (Super Splendor) To be used for protecting oil cooler fins during water wash. 070HHKTC008
To protect the counter shaft while separating
80 Counter Shaft Oil Seal Guide 070HHKTC009
the crankcase.
81 Flywheel Puller To remove the flywheel from crankshaft. 070HHKTN001
82 Collet-17mm To remove bearing from crankcase. 070HHKTN002
83 Crankshaft Bearing (LHS) Puller To remove the bearing from crankshaft. 070HHKTN003
84 T-Stem Cone Inserter To insert new lower bearing inner race on T-Stem. 070HHKTN004
To remove top and bottom cone races from the
85 Bottom Cone Race Driver 070HHKTN005
steering head pipe.
86 Pilot 20mm To seat in the inner race and drive out/in the bearing. 070HHKTN006
87 Crankshaft Bearing (LHS) Inserter To install crankshaft LHS bearing. 070HHKTN007
To protect the counter shaft while separating
88 Counter Shaft Oil Seal Guide 070HHKTN009
the crankcase.
89 Rear Engine Foundation Bush Remover 8x20 To remove/install the rear engine foundation bush. 070HHKTP01
90 Front Engine Foundation Bush Remover 10x27 To remove/install the front engine foundation bush. 070HHKTP02
91 Drive Shaft Installer Extension To install the drive shaft into the left crankcase. 070HHKTP03
92 Drive Shaft Bearing Remover with Sleeve To remove the drive shaft bearing. 070HHKTP04
93 Drive Face Holder To hold the drive face for removal/installation. 070HHKTP05
94 Driven Face Nut Socket To remove/install driven face nut. 070HHKTP06
To compress the driven face spring for
95 Driven Face Spring Compressor 070HHKTP07
removal/installation.
96 Centrifugal Clutch Spring Remover To remove/install the centrifugal clutch spring. 070HHKTP08
97 Driven Face Bearing Remover & Installer To remove/install the driven face bearing. 070HHKTP09
98 Flywheel Puller To remove flywheel. 070HHKTP10
99 Flywheel Holder To hold the flywheel for removal/installation of flywheel. 070HHKTP11
100 Steering Bearing Adjuster Nut Socket 45.3 mm To adjust/remove/install the bearing adjustment nut. 070HHKTP12
101 Upper Cone Race Remover To remove the upper cone race. 070HHKTP13
102 Bottom Cone Race Remover Head To remove the bottom ball race from the steering head. 070HHKTP14
103 Bottom Cone Race Remover Shaft To remove the bottom cone race. 070HHKTP15
104 Bottom Cone Race Remover Weight To remove the bottom cone race. 070HHKTP16
105 Upper & Bottom Cone installer To install upper and bottom cone race 070HHKTP17

1-18
 GENERAL INFORMATION

SPECIAL TOOLS

SL.
NO.
DESCRIPTION APPLICATION PART NUMBER
1
106 T-Stem Cone Installer To install the T-Stem cone race. 070HHKTP18
To compress spring for dismantling front/rear
107 Shock Absorber Extractor 070HHKTP19
shock absorber.
108 Washing Kit (Pleasure) To restrict water entry during washing. 070HHKTP20
109 Cap, Muffler (Glamour) To restrict water entry during washing. 070HHKTR001
110 DLC Short Connector To read and erase the data from ECU. 070HHKTRF001
111 Fuel Pressure Gauge To check the fuel pressure in fuel delivery system. 070HHKTRF003
112 Multimeter Probe To check the wiring in Programmed-FI connectors. 070HHKTRF004
113 Fuel Pressure Gauge Adaptor To check the fuel pressure in fuel delivery system. 070HHKTRF005
114 Remover Head 15mm To remove wheel bearing from wheel hub. 070HHKVN001
115 Bearing Remover Head Shaft To remove the wheel bearing. 070HHKVN002
116 Swing Arm Bearing Remover/Installer To remove and install the swingarm bearing. 070HHKVN003
117 TPS Test Connector To reset throttle position sensor. 070HHKVN004
118 T-Stem Cone Remover To remove T-Stem bottom cone. 070HHKZJ001
119 Steering Race Remover To remove upper/bottom steering race. 070HHKZJ002
120 Steering Race Installer To install the bottom/upper steering races. 070HHKZJ003
121 Steering Adjuster Nut Socket To remove/adjust the steering adjusting nut. 070HHKZJ004
122 Swingarm Bearing Remover To remove the swingarm bearing. 070HHKZJ005
123 Swingarm Bearing Installer To Install the swingarm bearing. 070HHKZJ006
124 Mono-Shock Bearing Remover & Installer To remove/install the rear mono shock needle bearing. 070HHKZJ007
125 Wheel Bearing Remover Head (17mm) To remove wheel bearing from wheel hub. 070HHKZJ008
126 Wheel Bearing Remover Shaft To remove the wheel bearing. 070HHKZJ009
127 TPS Test Harness To reset throttle position sensor. 070HHKZJ010
To raise the rear wheel off the ground and
128 Swingarm Stand 070HHKZJ011
motorcycle in upright position
129 Frame Stand To support the motorcycle while doing major repairs 070HHKZJ012
130 Drive Shaft Installer Extension To install drive shaft into the crankcase. 070 HH KZN 001
To compress the driven face spring for
131 Driven Face Spring Compressor 070 HH KZN 002
removal/installation.
132 Collet 20 mm To remove driven face needle bearing. 070 HH KZN 003
133 Top Cone Race Holder To hold the steering stem lock nut. 070 HH KZN 004
134 Washing Kit (Maestro) To restrict water entry during washing. 71 HH KZN 005
135 Timing Sprocket Remover To remove the timing sprocket from the crankshaft 070 HH K06 001
136 Timing Sprocket Installer To install the timing sprocket on the crankshaft. 070 HH K06 002
137 Crankshaft Bearing Driver To install the crankcase bearing. 070 HH K06 003
138 Crankshaft Bearing Collar To install crankshaft bearing and timing sprocket. 070 HH KZA 001
139 Driver RHS Crankshaft Bearing To install the crankshaft bearing in RHS crankcase. 070 HH KZA 002
140 Crankshaft Installer Adapter To install the crankshaft in the RHS crankcase 070 HH KZA 003
141 Muffler Plug (Big) To restrict water entry during washing. 070HHKZA004
142 Muffler Plug (Small) To restrict water entry during washing. 070HHK06004

1-19
GENERAL INFORMATION

METER ASSEMBLY TOP VIEW

BOTTOM TO STOPPER

FRONT BRAKE HOSE

TURN SIGNAL SWITCH CORD

FRONT BRAKE HOSE

LAMP SWITCH CORD

CHOKE CABLE

20O 100+ 10

HANDLE BAND POSITION

CHOKE CABLE

1-20
 GENERAL INFORMATION

HANDLE BAR

1
CLUTCH CABLE THROTTLE CABLE
CHOKE CABLE

CHOKE LEVER
CLUTCH SWITCH

HANDLE BAR

CLUTCH SWITCH CORD

TURN SIGNAL SWITCH CORD

1-21
GENERAL INFORMATION

HEADLAMP WIRING

FRONT LEFT TURN SIGNAL CORD

TO WIRE HARNESS

HEADLAMP CORD

FRONT RIGHT TURN SIGNAL CORD

1-22
 GENERAL INFORMATION

VEHICLE FRONT VIEW

CABLE & HARNESS ROUTING
1
RIGHT HANDLE SWITCH CORD

PASSING RELAY CORD

COMBINATION SWITCH CORD

LEFT HANDLE SWITCH CORD

BRAKE HOSE THROTTLE CABLE
HEADLAMP SUB HARNESS

SPEED SENSOR CORD

HARNESS WIRE
CLUTCH CABLE

WIRE HARNESS INTO INSIDE

BRAKE HOSE OF PLATE WIRE HARNESS
GUIDE AND CLAMP IT THERE
CLAMPER A, FRONT BRAKE HOSE

1-23
GENERAL INFORMATION

LEFT FRONT VIEW

TURN SIGNAL SWITCH CORD CLUTCH CABLE

CHOKE CABLE

STAY FRONT COWL

SPEED SENSOR CORD

L CLIP HARNESS

CHOKE CABLE
THROTTLE CABLE

1-24
 GENERAL INFORMATION

BATTERY SIDE VIEW

TANK DRAIN TUBE

TANK BREATHER TUBE

AIR VENT TUBE

BATTERY NEGATIVE CORD

AIR SECTION VALVE

TUBE, B

CONNECTING TUBE BAND

CONNECTING TUBE

BRAKE HOSE
STARTER MOTOR CORD

CARBURETOR DRAIN TUBE

BATTERY NEGATIVE CORD
REAR STOP SWITCH CORD

1-25
GENERAL INFORMATION

RIGHT MIDDLE VIEW

HIGH TENSION CORD

ENGINE EARTH CORD

IGNITION COIL CORD

THROTTLE CABLE
EARTH POINT
CHOKE CABLE

WIRE HARNESS

CLUTCH CABLE

CLIP WIRE HARNESS

1-26
 GENERAL INFORMATION

LEFT CRANKCASE COVER INNER VIEW

NO BITE & INTERFERENCE

BEFORE ASSEMBLY CLAMPER, ACG CORD

PULSE GENERATOR

LOT NO.ACG LOT NO BE VISIBLE

WHEN ACG INSTALLING.

1-27
GENERAL INFORMATION

LEFT SIDE VIEW

CHOKE CABLE

THROTTLE CABLE
ENGINE EARTH CORD

AIR SECTION VALVE

PB TUBE WIRE HARNESS

CLIP WIRE HARNESS

THROTTLE SENSOR CORD SHOULD

BE CLAMPED WITH CARBURETOR

AIR VENT TUBE

AIR SECTION VALVE TUBE A
FUEL TUBE

THROTTLE SENSOR CORD

FIX COUPLER COVER WITH HES CLIP

ACG CORD
NEUTRAL SWITCH CORD
WIRE HARNESS
REAR STOP SW CORD

STARTER MOTOR CORD

CLIP

REAR STOP SWITCH CORD

AIR SECTION
VALVE TUBE, B

ACG CORD

NEUTRAL SWITCH CORD

1-28
 GENERAL INFORMATION

MAIN HARNESS TOP VIEW

CLIP WIRE HARNESS

WIRE HARNESS

CDI

AIR VENT TUBE

TO FUEL UNIT

ENTRY FOR AIR VENT TUBE END

1-29
GENERAL INFORMATION

REGULATOR/ RECTIFIER VIEW

REGULATOR/ RECTIFIER

REGULATOR/
RECTIFIER CORD
HARNESS WIRE

1-30
 GENERAL INFORMATION

REAR RIGHT SIDE VIEW

TAILLAMP CORD LICENCE LAMP

CORD REAR TURN SIGNAL CORD

FUSE

1-31
GENERAL INFORMATION

CABLE AND HARNESS ROUTING

L/ T SWITCH CORD

CHOKE CABLE

CLUTCH CABLE

STAY FRONT COWL

THROTTLE CABLE

FRONT BRAKE HOSE

1-32
 GENERAL INFORMATION

REAR RIGHT VIEW

REAR BRAKE STOPPER ARM COMP

REAR CALIPER

REAR BRAKE HOSE

CONTACT JOINT WITH STOPPER

AND TIGHTEN BOLT

1-33
GENERAL INFORMATION

EARTH CIRCUIT

FRAME ELECTRICAL PARTS

EARTH POINT y Å
(IGNITION COIL TIGHTENING AREA)

GENERAL CIRCUIT
EARTH POINT
M

ENG EARTH POINT

(STARTER MOTOR
TIGHTENING AREA)

EARTH POINT
(CYLINDER HEAD)
ENG-FRM EARTH POINT
(BOTTOM PLATE INSIDE)

1-34
 GENERAL INFORMATION

EMISSION CONTROL SYSTEM

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon 1
monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to form
photochemical smog when subjected to sunlight. 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.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emission into the atmosphere. Blow- by
gas is returned to the combustion chamber through the air cleaner and carburetor.

RESONATOR AIR
CHAMBER AIR CLEANER
HOUSING

CARBURETOR

CRANKCASE
BREATHER
TUBE

FRESH AIR

BLOW-BY GAS

EXHAUST GAS

1-35
GENERAL INFORMATION

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of an air injection system and lean carburetor settings.
No adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is
separated from the crankcase emission control system.
SECONDARY AIR SUPPLY SYSTEM
The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into exhaust port
by the function of ASV reed valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and
carbon monoxide into relatively harmless carbon dioxide and water vapor.
The ASV reed valve prevents reverse air flow through the system. The air suction valve reacts to high intake manifold vacuum and
will cut off the supply of fresh air during de- acceleration, thereby preventing after- burn in the exhaust system.
No adjustment to the air injection system should be made, although periodic inspection of components is recommended.

AIR SUCTION VALVE

AIR CLEANER
ASV CHECK HOUSING
RESONATOR
VALVE

VACCUM
TUBE

EXHAUST PORT

CARBURETOR

FRESH AIR
EXHAUST GAS
NEGATIVE PRESSURE

1-36