3.

MAINTENANCE
Service Information 3-1 Oil Filter Rotor Cleaning 3-12
Specification 3-1 Drive Chain 3-13
Torque Values/ Special Tools 3-2 Battery Voltage 3-15
Maintenance Schedule 3-3 Electric Starter Switch 3-15
Throttle Operation 3-4 Brake Fluid 3-16
Fuel Lines/ Fuel Strainer Screen 3-5 Brake Pad Wear/ Brake System 3-17
Fuel Strainer 3-5 Headlamp Focus 3-19
Engine Idle Speed/ Air Cleaner 3-6 Clutch System/ Side/ Center Stand 3-19
3
Crankcase Breather/ Drain Tube 3-7 Suspension 3-20
Spark Plug 3-8 Nuts, Bolts, Fasteners 3-20
Valve Clearance 3-9 Wheels/ Tyres 3-21
Engine Oil 3-10 Steering Head Bearings 3-22
Oil Strainer Screen Cleaning 3-11 Exhaust Emission 3-22
SERVICE INFORMATION
GENERAL
! WARNING
• If the engine is running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area
The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run
the engine in an open area or with an exhaust evacuation system in an enclosed area.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Petrol is extremely inflammable and is explosive under certain condition. Work in a well ventilated area with the engine in
stop condition. Do not smoke, allow flames, sparks in the work area where petrol is stored.
• Park the motorcycle on ramp before starting any work.
• The oil filter screen, oil filter rotor cleaning and oil pump servicing can be done with engine in the frame.
• Some maintenance jobs requires removal of body panels. Refer to (SECTION- 2) for the removal/ installation of required body panels.
SPECIFICATIONS Unit: mm
MAINTENANCE
ITEM SPECIFICATIONS
Throttle grip free play 2 - 6 mm
Spark plug NGK - CPR 8 EA9
Spark plug gap 0.8 - 0.9 mm
Intake 0.08 mm
Valve clearance
Exhaust 0.12 mm
At oil change 1.0 Litre
Engine oil capacity
At disassambly 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.
Engine idle speed 1400 ±100 rpm
Cylinder compression 12.0 ± 2.0 kgf/ cm2
Drive chain slack 30 mm
Recommended brake fluid DOT 3 or DOT 4
Clutch lever free play 10 - 20 mm

3-1
MAINTENANCE

Front 80/ 100 x 18 - 47 P (Tubeless)

Tyre size
Rear 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
Front 2.00 kgf/cm2 (29 psi)
Rider & pillion
Rear 2.25 kgf/cm2 (33 psi)
Front 1.5 mm
Minimum tyre tread depth
Rear 2.0 mm

TORQUE VALUES

SPARK PLUG : 1.6 kgf-m

TAPPET ADJUSTING SCREW LOCK NUT : 1.4 kgf-m
OIL DRAIN BOLT : 3.0 kgf-m
REAR AXLE NUT : 6.8 kgf-m
REAR AXLE SLEEVE NUT : 5.9 kgf-m
CRANKSHAFT HOLE CAP :1.5 kgf-m
For other nuts, bolts, fasteners etc. refer to standard torque values (SECTION- 1).

SPECIAL TOOLS

TAPPET ADJUSTER
WITH SOCKET (10 mm)
PART NO: 070 HH KFN 001

GPD HOLDER
PART NO: 070 HH 198 017

3-2
 MAINTENANCE SCHEDULE
The Maintenance schedule is based upon average riding conditions. Motorcycle subjected to severe use or ridden in dusty area will require more frequent servicing.
WHICH EVER
COMES FIRST AFTER FREE SERVICE,
SERVICE 1st 2nd 3rd 4th 5th 6th ONCE IN EVERY
ITEMS
DAYS 1st to 60 Next 100 Next 100 Next 100 Next 100 Next 100
12000- 15000-
KMS. 500-750 3000-3500 6000-6500 9000-9500 3000 6000 9000 12000 15000
12500 15500
Fuel Line I I I I I I I
Throttle Operation I,A I,A I,A I,A I,A I,A I,A
Carburetor C,A A C,A A C,A A A C,A
Air Cleaner* C C C C R C C R
Spark plug I,C,A I,C,A I,C,A I,C,A R I,C,A I,C,A R
Valve Clearance I,A I,A I,A I,A I,A I,A I,A
Engine Oil** O I,T O I,T O I,T I,T O
Engine Oil Strainer Screen C C C C
Engine Oil Centrifugal Filter C C C C
Electric Starter I I I I I I I
Oil Circulation I I I I I I I
Drive Chain@ I,C,L,A at every 2000 kms. I,C,L,A at every 2000 kms.
Battery I I I I I I I
Brake Shoe/ Pad Wear I,A I,A I,A I,A I,A I,A I,A
Brake Fluid**** I I I I I I I
Brake system (Brake Cam
- C,L - C,L - C,L - C,L
& Brake Pedal)
Stoplamp Switch I,A I,A I,A I,A I,A I,A I,A
Headlamp Focus I,A I,A I,A I,A I,A I,A I,A
Clutch I,A I,A I,A I,A I,A I,A I,A
Side Stand/Main Stand L L L L L L L
Fasteners*** I I I I I I I
Wheels/ Tyres I I I I I I I
Steering Head Bearing I I,A I I,A I,L,A I I I,A L
Front Suspension/ Oil*** I I I I I I I
Secondary Air Injection - - I - I - - I
Muffler (Catalytic Converter) - - I,E - I,E - - I,E
More frequent cleaning may be required when riding in dusty areas.
Replace engine oil once in every 6000 kms. Top up once in every 3000 kms.
Inspect & maintain specified torque.
Replace once in every two years or 30,000 kms. whichever is earlier.
Check idle CO emission along with idle rpm/ idle CO adjustment (if required)
@ Visit Authorised Hero MotoCorp workshop for inspection, cleaning, lubrication and adjustment of drive chain at every 2000 kms.
NOTE:- Always wipe the water from the motorcycle after washing. Use clean soft cloth or pressurized air for completely drying the water.

3-3
MAINTENANCE

I: INSPECT R: REPLACE C: CLEAN L: LUBRICATE A: ADJUST IF REQUIRED O: OIL CHANGE T:TOP UP E: EMISSION CHECK
3
MAINTENANCE
HOSE JOINT HOSE
FUEL LINES
Check the fuel line for:
- Leakage.
- Loose or improperly positioned line clip.
CORRECT
- Deteriorated or damaged line.
Replace any part which shows signs of deterioration
damage or leak.

NOTE
• Insert the hoses deeply to the joint so that the clips past
INCORRECT
the protruding area.
CLIP
FUEL VALVE
FUEL STRAINER SCREEN
! WARNING
Petrol is extremely inflammable and is explosive under
certain condition. Work in a well ventilated area with the
engine stopped. Do not smoke or allow flames or sparks in
the work area or where petrol is stored.
Turn the fuel valve “OFF”.
Remove the left side cover (page2-2).
Remove the fuel strainer cup and drain the fuel into a suitable
container.
Remove the O-ring and fuel strainer screen. STRAINER CUP
Wash the fuel strainer cup and screen in nonflammable or
high flash point solvent(kerosene).
Install the fuel strainer screen, a new O-ring and cup into the
fuel valve body.
Tighten the strainer cup.
CAUTION
Do not over tighten the cup or it may cause fuel leak due- to
deformation of the O-ring.
After installation turn the fuel valve “ON” and check that
there are no fuel leaks.
Install the left side cover (page2-2).

O-RING STRAINER SCREEN

LOCKNUT
FUEL STRAINER
Make sure that there is no fuel in the fuel tank.
Remove the fuel tank (page 2-6).
Remove the fuel valve assembly from the fuel tank by
loosening its lock nut.
Clean the strainer if fuel flow is restricted.
Installation is in the reverse of the removal.
NOTE
• After assembly, make sure there is no fuel leak.

STRAINER

3-4
 MAINTENANCE

THROTTLE OPERATION 2.6 mm

Check for any deterioration or damage to the throttle cable.
Check the throttle grip for smooth operation. Check that the
throttle grip returns from the full open to the full closed
position smoothly and automatically in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle grip housing.
For cable lubrication: Disconnect the throttle cable at its 3
upper end and thoroughly lubricate the cable and its pivot
points with silicon grease or equivalent.
If the throttle grip still does not return properly, replace the
throttle cable.
! WARNING
Reusing a damaged or abnormally bent or kinked throttle
cable can prevent proper throttle slide operation and may
lead to a loss of throttle control while riding.
With the engine idling, turn the handlebar all the way to the
right and left to ensure that idle speed does not change.
A
If idle speed increases, check the throttle grip free play and
the throttle cable connection.
Measure the throttle grip free play at the throttle grip flange.
FREE PLAY: 2-6 mm B
If the throttle grip free play is not correct, adjust as follows:
A- DECREASE FREE PLAY ADJUSTER LOCKNUT
Slide the dust cover off the adjuster.
B- INCREASE FREE PLAY LOCKNUT
Loosen the lock nut and turn the adjuster as required.
(Replace the throttle cable if the above procedure is no
longer effective.)
B
After adjustment, tighten the lock nut and reposition the dust
cover. A
Recheck the throttle operation in all steering positions.
Major adjustment can be made with the lower adjusting nut
at the carburetor.
Remove the throttle cable drum cover (page 5-6).
Loosen the lock nut and turn the adjusting nut.
After adjustment is complete, tighten the lock nut while
holding the adjusting nut.
ADJUSTMENT NUT
Recheck the throttle operation. CHOKE LEVER
BI- STARTER OPERATION
This motorcycle is equipped with a fuel enriching circuit
controlled bi- starter valve.
The Bi- Starter valve opens the enriching circuit via a choke
cable when the choke lever is pulled back.
Check for smooth operation of the choke lever. Lubricate the
choke cable if the operation is not smooth.
Inspect the cable for cracks which could allow moisture to
enter
Replace the cable if necessary.

3-5
MAINTENANCE

ENGINE IDLE SPEED

NOTE
• Inspect and adjust the idle speed after all engine
maintenance have been performed and are within
specifications.
• Before checking the idle speed inspect the following B
items. A
- Spark plug condition (page3-8).
- Air cleaner condition.
• The engine must be warm for accurate idle speed
inspection and adjustment.
A- INCREASE RPM THROTTLE STOP SCREW
! WARNING
B- DECREASE RPM
If the engine is running make sure the area is well-ventilated.
Never run the engine in an enclosed area.
Place the motorcycle on its center stand on level ground and
shift the transmission into neutral.
Start the engine and warm it up to the normal operating
temperature (60 to 65°C).
Stop the engine and connect a tachometer and start the
engine let it idle.
Check the idle speed and adjust by turning the throttle stop
screw.
If the idle speed is out of specification, check the following:
• Throttle operation and throttle grip free play (page3-4).
• Intake air leak or engine top- end problems. SCREWS AIR CLEANER HOUSING COVER
ENGINE IDLE SPEED: 1400±100 rpm
AIR CLEANER
NOTE
• If the motorcycle is used in wet or dusty areas, more
frequent inspections are required.
• Replace the air cleaner in accordance with the
maintenance schedule (page3-3) or any time it is
excessively dirty or damaged.
Remove the left side cover(page 2-2).
Remove the screws and air cleaner housing cover.

SCREWS
Remove the screws of air cleaner element.
Remove the air cleaner element.

AIR CLEANER ELEMENT

3-6
 MAINTENANCE
AIR CLEANER ELEMENT SEAL
First clean the element by tapping it lightly to remove dust
particle.
Check air cleaner element seal for deterioration or damage
and replace if necessary.

AIR CLEANER ELEMENT

Blow away the dust by compressed moisture- free air from the I II
wire mesh side 30 mm away from the body in an up and
down motion vertically and then left and right motion
horizontally, alternately for 2- 3 minutes. Repeat the process
for 5 times.
To finish cleaning and to remove any dust particle on the filter
element, blow compressed air from the paper filter side III IV
keeping the air nozzle 50 mm away and at 45° angle and
moving it up and down along the paper fold line for 30
50 mm
seconds. Air Nozzle at
450 approx.

CAUTION
• Never wash the paper filter. Only blow air in the paper
filter for cleaning dust, as explained. Replace paper
filter element every 12000 kms. 45O
• Replace it earlier if it becomes very dirty, damaged on
surface or on the sealing area.
Installation is in the reverse order of removal.

NOZZLE

CRANKCASE BREATHER / DRAIN

TUBE
Check the crankcase breather tube for deterioration,
damage or loose connection. Make sure that the tubes are
not kinked, pinched or cracked.
Remove the drain tube from the air cleaner housing and
drain deposit into a container.
Service more frequently when ridden in rain at full throttle, or
after the motorcycle is washed.
Reinstall the drain tube.
CRANKCASE BREATHER TUBE DRAIN TUBE

3-7
MAINTENANCE
NOISE SUPPRESSOR CAP
SPARK PLUG
Disconnect the noise suppressor cap and clean any dirt
around the spark plug area.
NOTE
• Clean around the spark plug area with compressed air
before removing, and be sure that no debris is allowed
to enter the combustion chamber.
Remove the spark plugs using the spark plug wrench.
Inspect, clean or replace as described in the maintenance
schedule (page3-3).
RECOMMENDED SPARK PLUG: NGK- CPR 8 EA 9
SPARK PLUG
INSPECTION
Check the following and replace if necessary
• Insulator for damage
• Electrodes for wear
• Burning condition and coloration

INSULATOR
REUSING A SPARK PLUG
0.8- 0.9 mm
Clean the spark plug electrodes in a spark plug cleaner.
Check the gap between the center and side electrodes with a
wire-type feeler gauge. If necessary, adjust the gap by
bending the side electrodes carefully.
SPARK PLUG GAP: 0.8- 0.9 mm
CAUTION
To prevent damage to the cylinder head, hand tighten the
spark plug before using a wrench to tighten to the specified
torque.
TORQUE ELECTRODE
SPARK PLUG: 1.6 kgf-m SPARK PLUG NOISE SUPPRESSOR CAP
REPLACING A SPARK PLUG
Set the plug gap to specification with a wire-type feeler
gauge.
CAUTION
Do not overtighten the spark plug.
Hand tighten the spark plug to the cylinder head before
tightening with wrench to the specified torque to prevent
damage/cross threading.
If reusing plug, it should take 1/8 - 1/4 turns after sealing
washer contacts the seat of the plug hole.

3-8
 MAINTENANCE
CYLINDER HEAD COVER
VALVE CLEARANCE
NOTE
• Inspect and adjust the valve clearance when the
engine is cold (below 350C/ 950F).
Remove the cylinder head cover (page 7-3).

TIMING HOLE CAP

Remove the crankshaft hole cap and timing hole cap. INDEX MARK
Rotate the crankshaft counterclockwise and align the"T" mark
on the flywheel with the index mark on the left crankcase
cover.
Make sure that the piston is at TDC (Top Dead Centre) on the
"T" MARK
compression stroke. (The rocker arms should be free in this
condition).
If the rocker arms are not free, it is because the piston is
moving through the exhaust stroke to TDC. Rotate the
crankshaft one full turn and the match then "T" mark again

CRANKSHAFT HOLE CAP

LOCK NUT
Apply clean engine oil on the feeler gauge.
Check the valve clearance by inserting a feeler gauge
between the valve adjusting screw and the valve stem.
VALVE CLEARANCE
INTAKE: 0.08 mm
EXHAUST: 0.12 mm
Adjust the valve clearance by loosening the lock nut and
turning the adjusting screw until there is slight drag on the
feeler gauge.
Hold the adjusting screw and tighten the lock nut.
FEELER GAUGE ADJUSTING SCREW
VALVE ADJUSTER
TAPPET ADJUSTER WITH SOCKET, 10 mm
PART NO: 070 HH KFN 001
Recheck the valve clearance.
TORQUE
TAPPET ADJUSTING SCREW LOCK NUT: 1.4 kgf-m
NOTE
• An improperly tightened lock nut may cause damage to
the engine.

FEELER GAUGE

3-9
MAINTENANCE
O- RING
Install new O-rings to the crankshaft hole cap and timing
hole cap.
Apply clean engine oil to the O-rings.

O- RING
TIMING HOLE CAP
Install and tighten the timing hole cap.
Install and tighten the crankshaft hole cap to the specified
torque.
TORQUE
CRANKSHAFT HOLE CAP: 1.5 kgf-m

CRANKSHAFT HOLE CAP

OIL LEVEL DIPSTICK
ENGINE OIL
OIL LEVEL INSPECTION
1. Park the motorcycle on its main stand.
2. Start the engine and let it idle for 3-5 minutes.
3. Stop the engine and wait for 2-3 minutes.
4. Remove the oil level dipstick, wipe it clean and insert
without screwing it in.
5. Remove the oil level dipstick and check the oil level.
6. If required add the specified oil up to the upper level
mark. Do not overfill.
7. Quantity of the oil to be filled is approximately 1.0 litre
during oil change when right crankcase cover is not O-RING OIL LEVEL DIPSTICK
removed.
8. Reinstall oil level dipstick and check for oil leaks.

UPPER

LOWER

3-10
 MAINTENANCE
OIL LEVEL DIPSTICK
OIL CHANGE
NOTE
• Drain engine oil while engine is warm and the
motorcycle is on the main stand or held upright. This
ensures complete and rapid draining.
• While inspecting the oil level do not screw in the oil level
dipstick in the right crankcase cover.
3
1. To drain the oil, remove oil level dipstick and drain plug.

2. After the oil has completely drained, reinstall the drain

plug with new sealing washer and tighten it to the
specified torque. WASHER
Torque : 3.0 kgf-m
3. Fill the crankcase with recommended engine oil
(Approx.1.0 litre when right crankcase cover is not
removed).
Engine Oil Capacity : 1.0 litre at oil change
1.2 litres at disassembly of right crankcase cover
4. Reinstall the oil level dipstick with a new O-ring.
5. Make sure that the oil level is till the upper level mark and
there are no oil leaks.

DRAIN PLUG

OIL STRAINER SCREEN CLEANING

Drain the engine oil.
Remove the under cowl and stay (page 2- 5).
Remove the right crankcase cover (page 9-3).
Pull the strainer screen out of the crankcase.
NOTE
• Be careful not to damage the oil strainer screen.

STRAINER SCREEN

Wash the oil strainer screen thoroughly in nonflammable or

high flash point solvent until all accumulated dirt has been
removed.
Check the screen and the sealing rubber for damage/
deterioration and replace if necessary
Blow dry it with compressed air to clean completely.
CRANKCASE
Coat the oil strainer screen rubber with engine oil.
Install the oil strainer screen with the thin sharp edge facing
inwards towards the crankcase.
Install the right crankcase cover (page9-5).

3-11
MAINTENANCE
GASKET
OIL FILTER ROTOR CLEANING
Drain the engine oil (page 3-11).
Remove the right crankcase cover (page 9-3).
Remove the oil filter rotor cover and gasket (page 9-6).

NOTE :
• Always use an impact driver to remove rotor oil filter cover
screws.
• Do not use GPD holder when using impact driver.

SCREWS COVER
OIL FILTER ROTOR
Clean the oil filter rotor at the periphery using a clean lint-free
cloth.
Then clean the oil filter rotor in side and oil filter rotor cover
with non flammable or high flash point solvent (Kerosene)

OIL THROUGH COVER OIL THROUGH

While pressing down the oil through from the reverse side,
remove the slip pin.
CAUTION
• Do not allow dust or dirt to enter the crankshaft oil
passage.
• Do not use compressed air to clean the filter rotor.
Remove the oil through and spring. Blow and clean the oil
through with compressed air.
Apply clean engine oil to the oil through surface and install
the spring, oil through and slip pin.

SLIP PIN SPRING SLIP PIN

GASKET
Install the oil filter rotor cover with a new gasket aligning the
screw holes in the cover and gasket.
Install and tighten the three screws.
Install the right crankcase cover (page 9-5).
Fill the crankcase with recommended engine oil (page 3-11).

NOTE :
• Always use an impact driver to remove rotor oil filter cover
screws.
• Do not use GPD holder when using impact driver.

COVER SCREWS

3-12
 MAINTENANCE

DRIVE CHAIN
! WARNING
Inspecting the drive chain while the engine is running can
result in serious hand or finger injury. 30 mm

DRIVE CHAIN SLACK INSPECTION

Turn the ignition switch "OFF", park the motorcycle on main
stand and shift the transmission in neutral. 3
Drive chain slack should be checked in the drive chain lower
run midway between the sprockets.
To check remove the drive chain hole cap. Move the drive
chain up and down by hand and measure the amount of DRIVE CHAIN HOLE CAP
slack.
Rotate the wheel and repeat the process at 4 to 5 different
chain locations.
DRIVE CHAIN SLACK: 30 mm
Lubricate the drive chain.
ADJUSTMENT
CAUTION
If the adjustment is not the same, the wheel is out of alignment
and can cause excessive sprocket and chain wear.
Park the motorcycle on its main stand with the transmission in
neutral and the ignition switch “OFF” position.
Loosen the rear axle nut and the sleeve nut. REAR AXLE NUT
Loosen the drive chain adjuster lock nut. REAR AXLE LOCK NUT
Turn both the adjusting nuts in an equal number of turns until
the correct drive chain slack is obtained. Turn the adjusting
nut clockwise to decrease the slack or anticlockwise to
increase the slack of the chain.
Align the rear index mark with the rear edge of the adjusting
slots on both the sides of the swing arm equally.
If the drive chain slack is excessive when the rear axle is
moved to the farthest limit of adjustment, the drive chain is
worn and must be replaced.
NOTE
• When the rear axle is moved towards the rear for chain
adjustment, the rear index marks start getting hidden over a SLEEVE NUT ADJUSTING NUT
period of time on further adjustment. A stage would come CHAIN ADJUSTER
when the front index marks are to be used/ referred for further
adjustment of the chain.
Tighten the rear axle nut.
TORQUE
REAR AXLE NUT: 6.8 kgf-m
Tighten the sleeve nut.
TORQUE
REAR AXLE SLEEVE NUT: 5.9 kgf-m
Recheck the chain slack and free wheel rotation.
Adjust brake pedal free play if required (page3-18).
INDEX MARK REAR EDGE

3-13
MAINTENANCE
BOLTS
DRIVE CHAIN REMOVAL
Remove the left crankcase rear cover (page 6-3).
Remove the drive chain cover bolts.
Slide out the upper cover upwards and under cover
downwards.

RETAINING CLIP MASTER LINK

Remove the chain clip master link.
Remove the drive chain.
DRIVE CHAIN CLEANING INSPECTION
AND LUBRICATION
If the drive chain becomes extremely dirty, it should be
removed and cleaned prior to lubrication.
Clean the chain with suitable solvent and wipe it dry.
Be sure the chain has dried completely before lubricating.
Inspect the drive chain for possible damage or wear. Replace
any chain that has damaged rollers, loose fitting links, or
other wise appears unserviceable. Installing a new chain on
badly worn sprockets will cause the new chain to wear RETAINING CLIP LINK PLATE
quickly. Inspect and replace sprockets as necessary.
Lubricate the drive chain with SAE# 90 grade oil. Wipe off (1) SOLVENT
the excess chain lubricant.

CAUTION
• The open end of the retaining clip should face towards (2) CLEAN
the opposite direction of rotation.
• Never install a new drive chain on a worn sprocket or a
worn chain on new sprocket. Both chain and sprockets (3) WIPE AND
must be in a good condition or the new replacement DRY
chain or sprocket will wear rapidly (SAE #90 GRADE)
(4) LUBRICATE

SPROCKET
Inspect the drive and driven sprocket teeth for damage or
WORN SPROCKET TEETH
wear. Replace if necessary.
Never use a new drive chain on worn sprockets. Both chain
and sprockets must be in good condition, or the new
replacement chain will wear rapidly.
Check the attachment bolt and nuts on the drive and driven DAMAGED NORMAL
sprockets. If any are loose, torque them. SPROCKET TEETH SPROCKET TEETH

3-14
 MAINTENANCE
LEFT CRANKCASE REAR COVER
DRIVE CHAIN SLIDER
Remove two bolts and the left crankcase rear cover.

BOLTS
CHAIN SLIDER CUT OUT
Wipe the drive chain slider clean.
Check the drive chain slider for wear or damage.
If the slider is worn replace it with new one (page13-21).

BATTERY (-)VE TERMINAL

BATTERY VOLTAGE
It is not necessary to check the battery electrolyte level or add
distilled water as the battery is an Maintenance- Free (sealed) type.
Remove the right side cover (page 2-2).
Measure the battery voltage using a MF- Battery Tester (page
16-6).
VOLTAGE: 12.4V min
For battery charging procedure (page 16-12).
! WARNING

This vehicle is equipped with a Maintenance- Free Battery and can

be permanently damaged if the cap sealing strip is removed. BATTERY (+)VE TERMINAL

ELECTRIC STARTER SWITCH

Check for the operation of electric starter switch for stickey
moment.
NOTE
• Do not operate the electric starter for more than 10
seconds, to avoid drainage of battery.

ELECTRIC STARTER SWITCH

3-15
MAINTENANCE
MASTER CYLINDER RESERVOIR
BRAKE FLUID
CAUTION
• Do not remove the cover or cap unless the reservoir is in
level or else fluid may spill out.
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system when
filling the reservoir.
• Avoid spilling of fluid on painted, plastic or rubber parts.
Place a rug over these parts whenever the system is
serviced.
RESERVOIR CAP
When the fluid level is low, check the brake pads for wear
(page 3-17).
A low fluid level may be due to wear of the brake pads.
If brake pads are worn, the caliper piston is pushed out, and
this accounts for low reservoir level. If the brake pads are not
worn and the fluid level is low, check the entire system for
leaks.

MINIMUM LEVEL MARK

DIAPHRAGM UPPER LEVEL MARK
FRONT BRAKE
Turn the handlebar so that the reservoir is in level and check
the front brake reservoir level through the sight glass.
If the level is near mark, check the brake pad wear (page 3-17).
To top up the brake fluid, remove the cover, set plate and
diaphragm and fill the reservoir to the casting edge with DOT
3 or DOT 4 brake fluid from a sealed container.
NOTE
Replace brake fluid once in every 2 years or 30000 kms.
whichever is earlier.
MASTER CYLINDER
UPPER LEVEL MARK LOWER LEVEL MARK
REAR BRAKE
Park the motorcycle on a level surface, and support it an
upright position.
Check the rear brake fluid level.
If the level is near the lower level line, check the brake pad
wear (page3-17).

REAR MASTER CYLINDER RESERVOIR

3-16
 MAINTENANCE
RESERVOIR COVER
To top up the brake fluid, remove the cover, set plate and
diaphragm and fill the reservoir with DOT 3 or DOT 4 brake
fluid from a sealed container.

DIAPHRAGM

BRAKE PAD WEAR

FRONT BRAKE PADS
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the bottom of
wear limit line.
Brake pad replacement (page 15-8).
CAUTION
Always replace the brake pads in pairs to assure even
pressure is applied on disc.

BRAKE PAD WEAR LIMIT LINES

REAR BRAKE PADS

Check the brake pads for wear.
Replace the brake pads if either pad is worn to the bottom of
wear limit line.
Brake pad replacement (page 15-10).
CAUTION
Always replace the brake pads in pairs to assure even
pressure is applied on disc.

BRAKE PAD WEAR LIMIT LINES

FRONT BRAKE HOSE REAR BRAKE HOSE
BRAKE SYSTEM
INSPECTION
Firmly apply the brake lever or pedal, and check that no air has
entered the system.
If the lever or pedal feels soft or spongy when operated, bleed the air
from the system (page 15-4).
Inspect the brake hose and fittings for deterioration, cracks and
signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.
For brake air bleeding (page 15-4).

3-17
MAINTENANCE
PUSH ROD
BRAKE PEDAL HEIGHT ADJUSTMENT
REAR DISC MODEL
Loosen the lock nut and turn the push rod until the correct
pedal height is obtained.
Adjust the push rod length so that the distance between the

67+1 mm
center of the master cylinder lower mounting bolt hole and
joint pin hole is 67± 1 mm. After adjustment, tighten the lock
nut.

LOCK NUT LOCK NUT BRAKE PEDAL

BRAKE PEDAL FREE PLAY

REAR DRUM MODEL
NOTE
• Perform brake pedal free play adjustment after
adjusting brake pedal height. 20- 30 mm
Check the brake pedal free play at the tip of the pedal.

FREE PLAY: 20- 30 mm

Adjust the brake pedal free play by turning the adjusting nut.

NOTE
• Make sure that the cut away in the adjusting nut is seated
on the brake arm joint.
• After adjusting the brake pedal free play, check the rear
brake lamp switch operation and adjust if necessary. CUT-OUT IMPROPERLY INSTALLED CUT-OUT PROPERLY INSTALLED

• Apply brake several times and check for free wheel

rotation when releasing.

ADJUSTING NUT
REAR BRAKE LAMP SWITCH
STOP LAMP SWITCH
NOTE
• Perform stop lamp switch adjustment after adjusting the
brake pedal height and free play.
• The front stop lamp switch does not require adjustment.
Check that the stop lamp comes “ON” when the brake pedal
is depressed and the brake engagement begins.
To adjust, hold the switch body and turn the adjusting nut.
NOTE
• Do not turn the stop lamp switch body.
ADJUSTING NUT

3-18
 MAINTENANCE

HEADLAMP FOCUS
! WARNING
An improperly adjusted headlamp may blind oncoming
drivers, or it may fail to light the road for a safe distance.
HEADLAMP ADJUSTMENT
Headlamp adjustment is done by loosening the headlamp
adjuster bolt located below the headlamp. 3
Park the motorcycle on level ground.
Adjust the headlamp beam vertically by loosening the bolt &
moving the headlamp unit forward & backward for correct
focus adjustment. ADJUSTING BOLT

CLUTCH SYSTEM
Measure the clutch lever free play at the end of the lever.
10- 2
FREE PLAY: 10- 20 mm 0 mm

LOCK NUT
Adjustments are made by adjusting the nut of the clutch cable
mounted at the engine. Loosen the lock nut and turn the B
adjusting nut for adjusting the clutch lever free play.
After the adjustment is complete, tighten the lock nut while
holding the adjusting nut securely. A
If the proper free play cannot be obtained, or the clutch slips
during the drive, disassemble and inspect the clutch.
NOTE
• Check the cable routing and any signs of cable damage
that could cause improper clutch operation.

A- INCREASE FREE PLAY ADJUSTING NUT

B- DECREASE FREE PLAY
SIDE STAND/MAIN STAND
Support the motorcycle on the level surface.
Check the side/main stand return spring for damage or loss
of tension.
Check the side/main stand for freedom of movement.
Lubricate the side stand pivot with grease if necessary.
Make sure the side stand is not bend.

BOLT SIDE STAND MAIN STAND

3-19
MAINTENANCE

SUSPENSION
! WARNING
Loose, worn, or damaged suspension parts impair
motorcycle stability and control. Repair or replace any
damaged components before riding. Riding a motorcycle
with faulty suspension increases your risk of an accident
and possible injury.

FRONT
Check the action of the forks by applying the front brakes
and compressing the front suspension several times.
Check the entire fork assembly for signs of leaks,
scratches, damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.

REAR
Support the motorcycle securely and raise the rear wheel off
the ground.
Check for worn swing arm bush by grabbing the rear wheel
and attempting to move the wheel side to side.
Replace the bush if found loose.
Check the action of the shock absorbers by compressing
them several times.
Check the entire shock absorber assembly for signs of leaks,
damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.

NOTE
• Rear suspension adjustment should be done equal on
both sides

NUTS, BOLTS, FASTENERS

Tighten bolts and nuts at regular interval shown in the
maintenance schedule.
Check that all chassis nuts and bolts are tightened to correct
torque values (page 1-10)
Check that all cotter pins, slip pins, hose clamps and cable
stays are in place.

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 MAINTENANCE

WHEELS/TYRES
Make sure the fork is not allowed to move, raise the front
wheel and check for play. Turn the wheel and check that it
rotates smoothly with no unusual noise.
If faults are found, inspect the wheel bearings.

Support the motorcycle securely and raise the rear wheel off
the ground.
Check for play in either the wheel or the swing arm pivot. Turn the
wheel and check that it rotates smoothly with no unusual noise.
If abnormal conditions are suspected, check the rear wheel
bearings.
NOTE
• As the swing arm pivot is included in this check, be sure
to confirm the location of the play; i.e. from the wheel
bearings or the swing arm pivot.

Check and adjust the tyre pressure

NOTE
• The tyre pressure should be checked when the tyres are
COLD.

Cold tyre pressure

Front Rear
kgf/ cm2 (psi)

Rider only 2.00 (29 psi) 2.00 (29 psi)

Rider & pilliion 2.00 (29 psi) 2.25 (33 psi)

TYRE WEAR INDICATOR

Check the tyre treads and side wall for cuts, imbedded nails,
or other damage.
Measure the tread depth at the centre of tyre. Replace the tyre
when the tread depth reaches the following limits:
MINIMUM TREAD DEPTH
FRONT: 1.5 mm
REAR: 2.0 mm
Tyre wear indicators are distributed at several locations
around the tyre for easy inspection. Replace tyres
immediately when the tyre wear indicator contacts the road.

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MAINTENANCE

STEERING HEAD BEARINGS

NOTE
• Check that the control cables do not interfere with the
handlebar rotation.
Raise the front wheel off the ground by placing a jack or other
support under the engine.
Check that the handlebar rotates freely from side to side. If the
handlebar moves unevenly, binds, or has play, inspect and
adjust the steering head bearings.
If the operation is not smooth check for any interference of
cable or wiring harness.
Check for misalignment of front wheel with respect to
handlebar. 4 GAS ANALYZER
EXHAUST EMISSION
MEASUREMENT AT IDLE
1. Check the following items before inspection;
- Air cleaner
- Spark plug
- Crankcase breather
- Ignition timing 30 cm
2. Park the motorcycle on the main stand on a level surface (12 in)

3. Warm up the engine to the normal operating temperature

(Engine oil temperature: Approx. (60° to 65°C).
4. Connect an appropriate pipe or hose (heat resistant, RESONATOR AIR CHAMBER
chemical resistant) to the muffler so that the probe can be AIR CLEANER HOUSING

inserted by more than 30 cm (12 inch). CARBURETOR

5. Check the engine idle speed.
IDLE SPEED: 1400± 100 rpm
6. Insert the probe into the muffler and measure the carbon
monoxide (CO%) and hydrocarbon (HC ppm) concentration.
CO MEASUREMENT AT IDLE: 0.02- 0.4 % CRANKCASE
BREATHER
TUBE
HC MEASUREMENT AT IDLE: Below 4500
FRESH AIR
BLOW-BY GAS
EXHAUST GAS

CRANKCASE BREATHER
Check the crankcase breather tube for deterioration, damage
or loose connection. Make sure that the tubes are not kinked
pinched or cracked.
Remove the drain tube from the air cleaner assembly and
drain the deposit into a suitable container. Reinstall the drain
tube. Follow the above process more frequently when riding
in rain or at full throttle.
NOTE
• Always ensure to reinstall the drain tube after draining the
deposit.
DRAIN TUBE

3-22