Thriller

PREFACE No : IB41A
Thank you for selecting a HMCL Niloy Bangladesh Ltd. THRILLER 160R
PROGRAMMED FI. We wish you many miles of continued riding pleasure in the years
ahead.
We, at HMCL Niloy Bangladesh Ltd., are committed to demonstrate excellence in our
environment performance on a continual basis, as an intrinsic element of our corporate
philosophy. To achieve this we commit ourselves to continue product innovations to improve
environment compatibility and strengthen the green supply chain. We are also using non
asbestos brake shoes and engine gaskets which are environment friendly in nature.
This booklet is your guide to the basic operation and maintenance of your new HMCL Niloy
Bangladesh Ltd. THRILLER 160R PROGRAMMED FI. Please take time to read it
carefully. As with any fine machine, proper care and maintenance are essential for trouble-
free operation and optimum performance.
Authorised Distributor or dealer(s) of the Distributor (‘‘Dealer’’) will be glad to provide you
further information or assistance and to handle your future service needs.
Let us make this world a safer, healthier and more environment friendly place.
NOTE
ALL INFORMATION, ILLUSTRATION, PHOTOGRAPH, DIRECTIONS,
SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS OWNER'S
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.
HMCL Niloy Bangladesh Ltd. 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 HMCL Niloy Bangladesh Ltd.
CONTENTS
Pg. No. Pg. No.
VEHICLE IDENTIFICATION 1 SPARK PLUG INSPECTION 36
VEHICLE VIEWS 2 ENGINE OIL 37
VEHICLE SPECIFICATION 7 OIL FILTER SCREEN & CENTRIFUGAL FILTER
VEHICLE SAFETY 9 CLEANING 38
• Important safety information 9 AIR CLEANER 39
• Protective apparel 10 VALVE CLEARANCE ADJUSTMENT 41
• Accessories & modifications 11 CLUTCH LEVER FREE PLAY 42
ANTI-THEFT TIPS 11 THROTTLE OPERATION 43
SAFE RIDING TIPS 12 DRIVE CHAIN SLACKNESS 44
TIPS FOR HEALTHY ENVIRONMENT 13 DRIVE CHAIN SLIDER INSPECTION 47
PART FUNCTION 14 BRAKES 47
• Ignition switch 14 SUSPENSION 51
• Instruments and indicators 15 WHEEL 52
• LCD panel 17 MAIN/SIDE STAND LUBRICATION 55
FEATURES 20 TUBELESS TYRES 55
HANDLEBAR SWITCHES CONTROL 20 NUT, BOLTS & FASTENERS 58
ABS INDICATOR 22 BATTERY 58
SIDE STAND INDICATOR/SWITCH 22 FUSE REPLACEMENT 60
FUEL TANK 24 STOP LAMP SWITCH 61
BS6 FUEL 25 HEADLAMP FOCUS ADJUSTMENT 62
SEAT LOCK 25 CATALYTIC CONVERTER 62
PRE-RIDE INSPECTION 25 EVAPORATIVE EMISSION CONTROL SYSTEM 63
STARTING THE ENGINE 26 POLISHING OF VEHICLE 63
RIDING 28 BASIC TROUBLESHOOTING 64
BRAKING 29 DELIVERY CERTIFICATE
PARKING 30 GENUINE PARTS
TOOL KIT 31 JOB APPLICABLE TO PERIODIC SERVICES
CLEANING AND WASHING OF VEHICLE 31 SERVICE RECORD SHEET
MAINTENANCE 31 SERVICE ADVICE SHEET
SAFETY PRECAUTION 32 OWNERSHIP RECORD AND DATA
MAINTENANCE SCHEDULE 33
VEHICLE IDENTIFICATION
PS1
KC
KC01AA#
U02
#######
####
####
#
Vehicle Identification Number (VIN) Engine No.
Location: Stamped on the right side of the Location: Stamped on the lower side of the
steering head tube. left crankcase.
VIN: PS1KCU02#########
PS1 KCU02 # # # # #####
Manufacturer Vehicle Check Model Year Plant Month of Production
code Description Digit Code Manufacturing Serial Number
Engine No.: KC01AA########
KC01AA # # # #####
Engine Year of Assembly Plant Month of Serial Number
Description Manufacturing Manufacturing
Model: THRILLER 160R PROGRAMMED FI
Variants VIN Engine
Electric start/Front disc with ABS/Rear disc/Cast wheel KCU02 KC01AA
Electric start/Front disc with ABS/Rear drum/Cast wheel KCU03 KC01AA
VIN and Engine No. may be required:
• During registration of the vehicle.
• For dealing with legal & insurance departments.
1
FRONT VIEW VEHICLE VIEWS
4
5
3 6
2 7
8
1
1. Front fender 5. Headlamp (Low beam)

2. Front right turn signal lamp 6. Left position lamp
3. Right position lamp 7. Front left turn signal lamp
4. Front visor 8. Headlamp (High beam)
*Accessories and features shown may not be part of standard fitment.
2
REAR VIEW
3
4
2 5
1
6
1. Rear reflex reflector 5. Right rear turn signal lamp

2. Left rear turn signal lamp 6. Rear brake fluid reservoir
3. Tail/Stop lamp 7. Rear fender
4. Licence plate lamp
3
TOP VIEW 8 9 10 11 12 13 14 15
7
16
6
5 17
18
4
3 19
20
2
21
1
(1) Neutral indicator (11) LCD panel of meter console, refer

(2) Programmed FI malfunction indicator instruments and indicators (page 15)
lamp (MIL) for fuel gauge, speedometer and other
(3) Side stand indicator features of console
(4) Horn switch (12) High beam indicator
(5) Turn signal switch (13) ABS indicator
(14) Mode button
(6) Clutch lever (15) Front brake master cylinder/Reservoir
(7) Passing switch (16) Front brake lever
(8) Headlamp dimmer switch (17) Throttle grip
(9) Hazard switch (18) Integrated start-kill switch
(10) Set button (19) Turn signal indicators
(20) Ignition switch with key
(21) Fuel tank cap
4
LEFT SIDE VIEW
13 12 11 10
1 2 3 4 5 6 7 8 9
(1) Side reflex reflector (5) Main stand (10) Rear grip
(2) Throttle body/ECU (6) Side stand (11) Seat lock
(inside) (7) Rider foot rest (12) Battery compartment (inside)
(3) Starter motor (8) Pillion foot rest (13) Side stand switch
(4) Gear shift pedal (9) Saree guard
5
RIGHT SIDE VIEW
10 9 8 7
11
12
13
1 2 3 4 5 6
(1) Rear master cylinder (8) Seat
(2) Brake pedal (9) Fuse box (inside)
(3) Kick starter pedal (10) Document & Tool kit compartment
(4) Oil level dipstick (11) Rear caliper assembly
(5) Front caliper assembly (12) Exhaust muffler
(6) Front disc (13) Rear disc
(7) Fuel tank cover
6
VEHICLE SPECIFICATION
ITEM SPECIFICATIONS
Dimensions
Overall length 2029 mm
Overall width 793 mm
Overall height 1052 mm
Wheelbase 1327 mm
Saddle height 795 mm
Ground clearance 165 mm
Weight
Kerb weight Disc-Disc 139.5 kg
Disc-Drum 138.5 kg
Capacities
Engine oil 1.3 litres at disassembly and 1.09 litres at draining
Fuel tank 12 litres (Minimum fuel to be maintained above
one segment blinking of fuel level indicator)
Hydraulic brake fluid DoT-3 or DoT-4
Engine
Maximum power 11.2 kW @ 8500±500 rpm
Maximum torque 14 N-m @ 6500±500 rpm
Bore and stroke 57.3x63.3 mm
Compression ratio 9.8:1
Displacement 163.23 cc
Spark plug NGK-CPR 8 EA 9, BOSCH UR5DC
Spark plug gap 0.8-0.9 mm
Valve clearance Intake (cold) 0.12 mm
Exhaust (cold) 0.13 mm
Idle speed 1400±100 rpm
Chassis and suspension
Front suspension Telescopic hydraulic
Rear suspension Rectangular swingarm with mono shock
Caster angle 25.5°
Trail length 98 mm
Tyre size Front 100/80 17 52 P (Tubeless tyre)
Rear 130/70 R17 62 P (Radial tubeless tyre)
7
VEHICLE SPECIFICATION
ITEM SPECIFICATIONS
Front (Disc type) Dia. 276 mm
Brakes Rear (Disc type) Dia. 220 mm
Rear (Drum type) Dia. 130 mm
Transmission
Primary reduction 3.136 (69/22)
Final reduction 3.077 (40/13)
Gear box st 5 Speed constant mesh
Gear ratio,1 nd 3.077 (40/13)
2 1.789 (34/19)
3rdth 1.304 (30/23)
4 1.1 (22/20)
5th 0.958 (23/24)
Electricals
Battery *MF Battery-12V-4 Ah/ETZ5
Alternator 120 W @ 5000 rpm (Single phase full DC system)
Headlamp (High/Low) LED
Position lamp LED
Tail/Stop lamp LED
Turn signal lamp LED
Meter illumination Module illuminated LCD
Neutral indicator LED
Turn signal indicator (RH/LH) LED
Hi beam indicator LED
ABS indicator LED
Service reminder indicator Module illuminated LCD
Licence plate lamp 12V-5W
Side stand indicator LED
Programmed-Fi Malfunction indicator lamp (MIL) LED
Starter magnetic switch 20A (Circuit fuse) & 20A (Spare fuse)
Fuse Fuse box 15A, 10A, 10A & 10A (Main fuse)
15A & 10A (Spare fuse)
*MF stands for Maintenance Free
**MFR stands for Multi-Focal Reflector
8
VEHICLE SAFETY
IMPORTANT SAFETY INFORMATION Ride defensively
Your vehicle can provide many years of Always pay due attention to other vehicles
service and pleasure if you take responsibility around you, and do not assume that other
for your own safety and understand the drivers see you. Be prepared to stop quickly or
challenges you can meet on the road. perform an evasive maneuver.
There is much that you can do to protect Make yourself easily visible
yourself when you ride. You will find many Some drivers do not see vehicles because they
helpful recommendations through out this are not looking for them. To make yourself
manual. Following are a few that we consider more visible, wear bright reflective clothing,
most important. position yourself so that others can see you,
Always wear a helmet signal before turning or changing lanes, and
It is a proven fact, helmet significantly reduces use horn which will help others to notice you.
the number and severity of head injuries. So Ride within your limits
always wear a helmet and make sure your Pushing the limits is another major cause of
pillion rider does the same. We also vehicle accidents. Never ride beyond your
recommend that you wear eye protection, personal abilities or faster than conditions
sturdy boots, gloves and other protective gear. demand. Remember that fatigue and
Before riding your vehicle negligence can significantly reduce your ability
Make sure that you are physically fit, mentally to make good judgements and ride safely.
focused and free of alcohol and drugs. Check Do not drink and ride
that you and your pillion are both wearing an Riding under the influence of alcohol or drugs
approved vehicle helmet and protective is dangerous. Alcohol can reduce your ability
apparel. Instruct your pillion on holding onto to respond to changing conditions and reduce
the grab rail or your waist, leaning with you in the reaction time. Do not drink and ride.
turns, and keeping their feet on the footrest, Keep your vehicle in safe condition
even when the vehicle is stopped. For safe riding, its important to inspect your
Take time to learn & practice your vehicle before every ride and perform all
vehicle recommended maintenance. Never exceed
Even if you have ridden other vehicles, load limits, and only use accessories that have
practice riding in a safe area to become been approved by HMCL Niloy Bangladesh
familiar with how this vehicle works and Ltd. for this vehicle. See (page 11) for more
handles, and to become accustomed to the details.
vehicle's size and weight.
9
If you are involved in a crash ! WARNING
Personal safety is your first priority. If you or • Not wearing a helmet increases the chance of
anyone else has been injured, take time to serious injury or death in a crash.
assess the severity of the injuries and whether • Be sure you and your pillion always wear a
it is safe to continue riding. Call for emergency helmet, eye protection and other protective
assistance if needed. Also follow applicable apparel when you ride.
laws and regulations if another person or
vehicle is involved in the crash. Helmets and eye protection
If you decide to continue riding, first evaluate Your helmet is your most important piece of
the condition of your vehicle. If the engine is riding gear because it offers the best
still running, turn it off. Inspect for fluid leaks, protection against head injuries. A helmet
check the tightness of critical nuts and bolts, should fit your head comfortably and securely.
and check the handlebar, brake levers, brakes, A bright coloured helmet can make you more
and wheels. Ride slowly and cautiously. Your noticeable in traffic, as can reflective strips.
vehicle may have suffered damage that is not An open-face helmet offers some protection,
immediately apparent. Have your vehicle but a full-face helmet offers more. Always
thoroughly checked at a qualified service wear face shield or goggles to protect your
facility as soon as possible. eyes and help your vision.
PROTECTIVE APPAREL Additional riding gear
For your safety, we strongly recommend that In addition to a helmet and eye protection, we
you always wear a helmet which should also recommend:
conform as per your country standards, in • Sturdy boots with non-slip soles to help
addition to eye protection, boots, gloves, long protect your feet and ankles.
pants and a long sleeve shirt or jacket • Leather gloves to keep your hands warm
whenever you ride. Take care of loose/ and help prevent blisters, cuts, burns, and
hanging clothes while solo/pillion riding. bruises.
Although complete protection is not possible, • A two wheeler riding suit or jacket for
wearing proper gear can reduce the chance of comfort as well as protection. Bright
injury when you ride. coloured reflective clothing can help make
Following are suggestions to help you choose you more noticeable in traffic. Be sure to
proper riding gear. avoid loose clothes that could get caught on
any part of your vehicle.
10
ACCESSORIES & MODIFICATIONS operation. Such changes could seriously
Modifying your vehicle or using non-genuine impair your vehicle's handling, stability and
accessories can make your vehicle unsafe. braking, making it unsafe to ride. Removing or
Before you consider making any modifications modifying your lamps, mufflers, emission
or adding an accessory, be sure to read the control system or other equipment can also
following information. make your vehicle illegal.
! WARNING
ANTI-THEFT TIPS
• Always lock the steering and never leave the
• Improper accessories or modifications can key in the ignition switch. This sounds
cause a crash in which you can be seriously simple but people do forgets.
hurt or killed. • Be sure the registration information for your
• Follow all instructions in this owner's manual vehicle is accurate and correct.
regarding accessories and modifications. • Park your vehicle in a locked garage
Accessories whenever possible.
• Make sure that the accessory does not • Use an additional anti-theft device of good
obscure any lamps, reduce ground quality.
clearance, limit suspension travel or steering • Never park your vehicle in an isolated area.
travel, affect your riding position or interfere Park as far as possible in a designated area.
with operating any controls. • Enter your name, address and phone
• Be sure electrical equipment does not number in this Owner's Manual and keep it
exceed the vehicle's electrical system in your vehicle at all times. Many times
capacity (page 8). A blown fuse can cause a stolen vehicles are identified by information
loss of lights. in the Owner's Manuals that are still with
• Do not pull a trailer or sidecar with your them.
vehicle. This vehicle was not designed for NAME: _____________________________________________
these attachments, and their use can ADDRESS: _______________________________________
seriously impair your vehicle's handling.
Modifications _______________________________________________________
We strongly advise you not to remove any _______________________________________________________
original equipment or modify your vehicle in _______________________________________________________
any way that would change its design or PHONE NO : _____________________________________
11
SAFE RIDING TIPS
Do's: Don'ts
• Always conduct simple pre-ride inspection • Never use cell phone while riding the vehicle.
(page 25). • Avoid sudden acceleration, braking and turning of
• Always wear a helmet with chinstrap securely your vehicle.
fastened and insist on a helmet for your pillion rider. • Never shift gears without disengaging the clutch
Helmet should conform as per safety standards and closing the throttle.
applicable in your country. • Never touch any part of the hot exhaust system like
• While riding, sit in a comfortable position with your muffler.
legs close to fuel tank. • Never ride under the influence of alcohol or drugs.
• Ride defensively and at a steady speed (between
40-50 km/hr). • Concentrate on the road and avoid talking to the
• For stopping vehicle, use both brakes simultaneously, pillion rider or others on the road.
keeping throttle in the close position. • Do not litter the road.
• During night time, dip headlamps of your vehicle for • Do not cross the continuous white/yellow line in
oncoming traffic, or when following another the center of the road, while overtaking.
vehicle. • Do not attach large or heavy items to the
• Give way to others on the road and signal before handlebars, front forks, or fenders.
you make a turn. • Never take your hands off the steering handle while
• To make yourself more visible, wear bright riding.
reflective clothing that fits well. • Do not attempt to apply the front brake lever
• Take care of loose/hanging clothes while
solo/pillion riding. intermittently for ABS vehicle.
• Get your vehicle serviced regularly by the • Do not panic by mechanical noises or slight pedal
Authorised Distributor/Dealer. pulses while applying the brake in vehicle. These
• Before riding make sure that integrated start-kill conditions are normal and indicates that ABS is
switch is in “ON” ( ) position. working.
• Keep checking the ABS indicator. At any point if • Don't apply hard braking on loose, wet or slippery
indicator remains on, then ABS is not working road surfaces.
(page 22). • Do not switch off the integrated start-kill switch
• Keep checking speedometer. In case of ABS ( ) while riding the vehicle (page 21).
malfunction, speed display may go to zero. • Do not move the side stand down while riding, as
• It is suggested to go through the do’s & dont’s of engine will stop while vehicle is in gear (page 23).
ABS (page 29) and practice your ABS vehicle
initially in low-traffic condition unless you are
thoroughly familiar with your vehicle and its
controls.
12
TIPS FOR HEALTHY ENVIRONMENT
The following tips shall ensure a healthy vehicle, healthy environment, and a healthy you.
• Healthy engine: The engine is the lifeline of every vehicle. To keep it healthy, it should be
tuned regularly, which will also help reduce pollution and improve vehicle performance &
fuel efficiency.
• Regular servicing: Get your vehicle serviced at an Authorised Distributor/Dealer, as per
the service schedule, for an optimum performance and keep the emission level under check.
• Genuine spares: Always insist on genuine parts as spurious or incompatible spares
and accessories can upset or deteriorate your vehicle’s running condition.
• Genuine engine oil: Hero 4T Plus SAE 10W 30 SL grade (JASO MA2) engine oil
recommended by HMCL Niloy Bangladesh Ltd. and make sure you change it every 6000
km. (with top up every 3000 kilometres) to keep the engine fit and environment healthy.
• Noise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or
defective mufflers, excessive noise will cause headaches and discomfort.
• Fuel saving & reduce pollution: Switch "OFF" the engine while waiting at traffic signal
points to save fuel and reduce pollution, if the waiting period is long.
• BS-VI grade fuel : Always use BS-VI grade fuel to adhere BS-VI norms (page 25).
13
PARTS FUNCTION 5 2
Ignition switch
“ON” ( )
Position 3
4
“OFF” ( )
Position/Lock Open
1
1. Ignition switch
2. Ignition key
3. “OFF” ( ) position
“LOCK” Position 4. Steering lock position
5. “ON” ( ) position
Key position Function Key removal
The LCD panel illuminates & initial display of
multi function digital segments are displayed.
The tachometer segment and the fuel gauge
segment will swing to the maximum scale once
“ON” ( ) and back to its normal position. Scroll message Key cannot be removed.
and odometer will appear. The engine can be
started. Turn signal lamp, horn, tail/stop lamp,
fuel gauge, passing switch, position lamp,
programmed FI malfunction indicator lamp
(MIL) illuminates continuously, neutral indicator
& hazard switch will be functional.
Engine cannot be started and no electrical Key can be removed.
“OFF” ( ) system will be functional.
“LOCK” Steering can be locked. Key can be removed.
14
Instruments and Indicators 1 2 3 4 5 67 8
The indicators are in the speedometer panel
above the headlamp. The functions are as 0 1
x 1000 RPM
2 3 4 5 6 7 8 9 10 11
below. TRIP
ODO
AM
PM
SERVICE
km/h E F
S M
16 15 1413 12 11 10 9
Sl. No. Description Function
Shows engine revolution per minute. The tachometer
1 Tachometer digital segments will swing to maximum scale on the meter
console once the ignition switch is turned “ON”.
2 Speedometer Indicates riding speed.
3 Odometer Shows accumulated distance travelled (page 20).
4 Tripmeter A & B Shows the distance travelled during a trip after setting
to zero (page 18).
5 Digital clock Indicates hours & minutes (page 17).
6 Scroll display Displays a scrolling “GET SET GO” message for few seconds
when the ignition switch is turned "ON" (page 18).
7 Service reminder Display when the next service is due (page 19).
indicator
Indicates approximate fuel quantity in the form of
8 Fuel gauge digital segments. The fuel gauge segments will display
its maximum scale on the fuel gauge LCD panel once
when the ignition switch it turned "ON" (page 19).
15
Sl. No. Description Function
9 Mode button Switches display between odometer, tripmeter-A & B.
This indicator normally comes on for approx 1.8 seconds
Anti-lock braking when the ignition switch is turned “ON” ( ) & then keeps
10 system (ABS) blinking until the vehicle attains speed of 5 km/h. If there
indicator is a problem with the anti-lock brake system, ABS
indicator turns on (page 22).
11 Turn signal indicators Flashes when turn signal switch is operated.
12 High beam indicator Light glows when headlamp is in high beam.
13 Neutral indicator Light glows when vehicle is in neutral position.
When the ignition switch is turned “ON” the programmed
FI malfunction indicator lamp (MIL) glows continuously
Programmed-FI and then should go “OFF” once the engine is started. It
14 malfunction indicator indicates that programmed FI system is OK. If it glows
lamp (MIL) continuously there is an abnormality in the programmed FI
system, it is recommended to reduce the speed and drive to
the Authorised Distributor/Dealer for check-up.
15 Side stand indicator Light glows when the vehicle is parked on the side stand.
16 Set button To adjust clock, date & tripmeter.
When long pressed resets tripmeter to zero.
16
LCD PANEL
(a) Digital clock
Digital clock (1) shows hour and minute. To
adjust the time, proceed as follows :
0 1 2 3 4 5 6 7 8 9 10 11
x 1000 RPM
TRIP
• Turn the ignition switch "ON" ( ).

ODO km
AM
PM
SERVICE
• Press and hold set button (2) and mode

km/h E F
button (3) simultaneously for more than 2

seconds. The clock will be set in the adjust S M
mode with the hour's digit display blinking.

3
(3) Mode button
• Press the set button (2). The minutes
0 1
x 1000 RPM
2 3 4 5 6
TRIP
ODO
7
AM
8 9 10
km
11
display starts blinking.

PM
SERVICE
km/h E F
S M 0 1 2 3 4 5 6 7 8 9 10 11
x 1000 RPM
TRIP
ODO km
AM
PM
SERVICE
km/h E F
2 1 3
(1) Digital clock (2) Set button
(3) Mode button
S M
• To set the hour, press mode button (3) until

the desired hour is displayed. 2
• The time is advanced by 1 hour (2) Set button
each time the button is pressed. • To set the minute press mode button (3)
• The time advances fast when the until the desired minute is displayed. The
button is pressed and held. minute display will return to " " when " "
• "AM" will change to "PM" after 12. is reached without affecting the hour
display.
• The time advances by 1 minute, each
time the button is pressed.
17
• The time advances fast when the button is If the tripmeter exceeds " " km it will
pressed and held. return to " " km automatically. When
tripmeter is selected long press the set button
to reset tripmeter to zero.
The odometer can be displayed from " to
0 1 2 3 4 5 6 7 8 9 10 11
x 1000 RPM
TRIP
ODO
AM
PM
SERVICE
km 2 3
km/h E F
TRIP B
S 0 1 2 3 4 5 6 7 8 9 10 11
M
x 1000 RPM
TRIP
ODO km
AM
PM
SERVICE
TRIP A
km/h E F
3
(3) Set button S M
TOTAL
• To end the adjustment press set button (2).

The display will stop flashing automatically 4 1
and it will return to its pervious value if the (1) Odometer (2) Tripmeter-A
button is not pressed for 30 seconds or (3) Tripmeter-B (4) Mode button
more. (c) Scroll message
NOTE The scroll (1) displays a message “GET SET
The clock will reset “AM: GO” for few seconds whenever the ignition
“ if the battery is switch
disconnected. is turned "ON".
1
(b) Odometer/Tripmeter
The odometer (1) shows accumulated
distance travelled. 0 1 2 3 4 5 6 7 8 9 10 11
The tripmeter shows distance travelled since x 1000 RPM

TRIP
ODO
trip meter was reset last time. There are two

AM
PM
SERVICE
km/h E F
tripmeters, tripmeter-A (2) and tripmeter-B

(3). S M
Push the mode button (4) to select odometer,

tripmeter-A or tripmeter-B. Tripmeter-A or
tripmeter-B can be displayed upto "
km. (1) Scroll
18
(d) Service reminder indicator The digital segments (2) will swing to
The service reminder indicator (1) is to maximum scale on the meter console once the
indicate the user to bring the vehicle to an ignition switch is turned “ON” ( ). If all the
Authorised Distributor/Dealer for service. The segments are displayed it means fuel quantity
indicator shall start blinking when the vehicle in the fuel tank is 12.0 litres.
covers kilometers as specified in the If only one segment (3) is displayed and
maintenance schedule. The indicator will keep blinks, this indicates the fuel quantity is low
on blinking throughout the kilometer interval and the fuel tank should be refilled as soon as
for a particular service and will stay ‘‘ON’’ possible.
thereafter. 3
The service reminder indicator can only be
reset at an Authorised Distributor/Dealer.
1
2 1
(1) Fuel gauge (2) Segments
(3) One segment
! CAUTION
(1) Service reminder indicator Please ensure the vehicle is not used
continuously when the fuel level indicator
NOTE reaches the one segment blinking. It will not only
result in the vehicle running out of fuel, it may
After getting the vehicle serviced, make sure also
that the service reminder indicator has been Please cause serious damage to the fuel pump.
reset. ensure fuel is filled up as soon as the fuel
level indicator reaches one segment blinking.
(e) Fuel gauge NOTE
The fuel gauge (1) indicates approximate fuel
available in the form of digital segments. To check the fuel level indication, the vehicle
should be on levelled surface and in stationary
condition.
19
FEATURES 4
Steering lock
Steering lock is with the ignition switch, turn 1
the key (1) to “OFF” ( ) position & turn the
handle bar towards left or right & push the key
downwards & turn towards "Lock" position.
After locking take out the key.
1
2 3
(1) Headlamp dimmer switch
(2) Turn signal switch (3) Horn switch
(4) Hazard switch
3. Horn switch ( )
Press the switch to operate the horn (3).
4. Hazard switch ( )
(1) Ignition key Press the hazard switch (4) in ignition "ON"
HANDLEBAR SWITCHES CONTROL condition whenever your vehicle becomes a
Left handlebar controls temporary hazard for other road users and it is
necessary to park the vehicle due to
1. Headlamp dimmer switch breakdown or other unavoidable problems.
The headlamp operates only when the engine Upon pressing the hazard switch, all turn
is running or when passing switch is operated. signal lamps start flashing simultaneously to
Press the switch (1) upwards for high beam warn other road users behind you of a hazard
“ ” downwards for low beam “ ”. or obstruction ahead.
2. Turn signal lamp switch ( ) To turn “OFF” the indicator lamps in hazard
switch “ON” condition, press the hazard
Shift the turn signal switch (2) sideways for switch again.
right/left indications and leave it to come NOTE
back to its normal position on its own.
IMPORTANT : To switch “OFF” the turn Use hazard lights only when your vehicle becomes
signal after completing the turn, gently push a temporary hazard for other road users.
the switch inside.
20
5. Passing switch ! CAUTION
Gives an indication for passing ahead. Never hold electric starter ( ) of integrated
Press passing lamp switch (5) to operate the start-kill switch continuously more than 5
passing lamp. seconds as continuous cranking of engine will
6. Clutch switch discharge the battery.
There is a clutch switch (6) provided for the 3 2
safety of the rider. The vehicle cannot be
started by electric starter switch until the clutch
lever is operated when the vehicle is engaged
in gear.
6
5 1
(1) Electric starter

(2) Integrated start-kill switch
(3) Engine stop (ON/OFF)
(b) Engine stop switch operation
(5) Passing switch (6) Clutch switch For engine stop operation (3) integrated
Right handlebar controls start-kill switch (1) has two positions. In
1. Integrated start-kill switch “ON” ( ) position, engine will operate and in
“OFF” ( ) position, engine will not operate.
(a) Electric starter operation ( ) The prime function of it is to stop the engine
Press the electric starter ( ) (1) of integrated during emergency (Vehicle tip over, throttle
start-kill switch (2) downwards to start the cable stuck etc.). The switch should normally
vehicle. Ensure the electric starter operation is remain in “ON” ( ) position. During
done when the vehicle transmission is in emergency, put the switch to “OFF” ( )
neutral. If the vehicle is engaged in gear, press
the clutch lever before electric starter ( ) position.
operation. Release switch after the engine has
started.
21
! WARNING SIDE STAND INDICATOR/SWITCH
While riding the vehicle in normal condition, do For the safety of the customer a side stand
not press the “Integrated start-kill switch to indicator (1) is provided.
“OFF” ( ) position to avoid any damage A side stand switch (2) is provided in the side
(Wheel locking leading to accident, part stand, when the side stand is down (ignition
damage, battery discharge etc.). switch “ON” ( )), the switch enables the side
ABS INDICATOR stand indicator lamp to glow on the
The ABS indicator (1) on speedometer come speedometer panel.
“ON” for approx 1.8 seconds when the
ignition switch is turned “ON” ( ) & then
keeps blinking until the vehicle attains a speed
of 5 km/h.
When the system functions normally indicator
goes “OFF” ( ) once vehicle speed exceeds
5 km/h.
At any point if ABS indicator remains “ON”
then ABS is not working, but the brakes still
work normally. Reduce your vehicle speed and 1
visit your Authorised Distributor/Dealer. (1) Side stand indicator
1 3
(1) ABS indicator (2) Side stand switch (3) Side stand spring
22
• Check the side stand for proper function To inspect the functionality of this feature,
and the spring (3) for damage or loss of park the vehicle on its main stand and check
tension and the side stand assembly for free all the conditions described in the inspection
movement. flow diagram:
• Check whether the side stand indicator (1)
glows when the side stand is down. INSPECTION FLOW DIAGRAM
• While the side stand is up, the side stand 1. Press the electric starter ( ) of integrated
indicator (1) should not glow. start-kill switch (with transmission in
• If the side stand indicator (1) does not neutral and side stand is down).
operate as described in above steps, please
visit your Authorised Distributor/Dealer. NO Visit Authorised
! CAUTION Does engine start? Distributor/Dealer
Ensure that adequate care should be taken YES
while cleaning the side stand switch.
Your vehicle is equipped with “Side 2. Then shift the transmission to gear (with
stand engine kill” feature for safety engine running and irrespective of clutch
lever operation).
purpose.
This feature has following functions: NO Visit Authorised
• It prevents starting the engine when Does engine stop?
transmission is in gear (irrespective of Distributor/Dealer
clutch lever operation) and side stand is YES
down. 3. Now press the electric starter ( ) of
• It stops the running engine when integrated start-kill switch (After engine
transmission is in gear (irrespective of has stopped).
clutch lever operation) and side stand is
moved down. YES Visit Authorised
! WARNING Does engine start? Distributor/Dealer
“Side stand engine kill” system is not affected NO
by clutch lever operation.
SYSTEM IS OK
23
If your vehicle doesn't operate as described in
above flow diagram, please visit your
Authorised Distributor/Dealer.
! WARNING 3
Regularly inspect the functionality of "Side stand
engine kill” feature and in case of any malfunction
visit Authorised Distributor/Dealer.
FUEL TANK
Fuel tank capacity is 12 litres (Minimum fuel
to be maintained above one segment blinking
of fuel level indicator). (3) Fuel tank cap
5 4
2
1
(1) Key hole cover (2) Ignition key (4) Fuel (5) Filler neck
Ÿ To unlock fuel tank cap, lift the key hole Remove the key and put back the keyhole
Ÿ
cover (1), insert key (2) turn it clockwise cover.
and lift open the cap (3). CAUTION
Ÿ Do not overfill the tank. There should be no Do not park the! vehicle
fuel (4) in filler neck (5). Fill the tank with as it causes evaporation under direct sunlight
of petrol due to heat
fuel as shown.
To lock fuel tank cap, close the cap back on and deterioration of paint gloss due to ultra
the opening and press gently. The key violet rays.
Ÿ
springs back to the normal position and cap

gets locked.
24
! WARNING
Petrol is extremely flammable and is explosive
under certain conditions. Refill in a well
ventilated area with the engine stopped. Do
not smoke or allow flames or sparks in the
area where the vehicle is refilled or where
petrol is stored.
BS6 FUEL
BS6 fuel specification are as follows:
PARAMETER VALUE 1
Vapour lock index: (1) Ignition key
Summers 1050
Other Months 1100 PRE- RIDE INSPECTION
Ethanol content % volume 10 You should conduct pre ride inspection before
Sulphur content, total, mg/kg 10 riding the vehicle to enhance riding comfort
and safety.
Oxygen content (% Concentration 3.7 (Regular) Clean your vehicle regularly. It protects the
by mass) 4.5 (Premium) surface finish. Avoid cleaning with products
NOTE that are not specifically designed for vehicle
• The octane number of gasoline is a measure
surfaces.
of fuel’s ability to resist auto-ignition, which Inspect your vehicle every day before you start
can lead to engine knocking and engine the engine. The items listed here will only take
damage. a few minutes, and in the long run they can
• Octane rating calculation: save time, expense, and possibly your life.
RON(Research Octane Number)+ Please follow the tips as given below:
MON (Motor Octane Number)/2 • Engine oil level-Check and top up engine
• Do not use less than 91 Octane fuel.
oil if required (page 37). Check for leaks.
SEAT LOCK • Programmed FI malfunction indicator
Location : On the left side of the rear cowl, lamp (MIL)-When the ignition switch is
above rear wheel. turned “ON” the programmed FI
Operation : Insert the ignition key (1) and malfunction indicator lamp (MIL) glows
turn in clockwise to unlock the seat. To continuously and then should go “OFF”
install, engage the seat hooks with frame once the engine is started.
and press the seat until the lock clicks.
25
• Fuel level-Ensure sufficient fuel is available • Steering-Check for smooth action and for
in the fuel tank for your journey. Fuel level easy maneuverability.
segment should be above one segment • Side stand-Check for proper functionality
blinking (page 19). Check for leaks. (page 22).
• Front brake-Check for correct brake fluid STARTING THE ENGINE
level in master cylinder/reservoir (page Always follow the proper starting procedure
47). described below :
• ABS indicator-Check ABS indicator for • To protect the catalytic converter in your
proper functioning of ABS (page 22). vehicle's exhaust system, avoid extended
• Rear brake (Disc type)-Check for correct idling and the use of leaded petrol.
brake fluid level in the reservoir (page 48). • Your vehicle's exhaust contains poisonous
• Rear brake (Drum type)-Check operation. carbon monoxide gas. High levels of carbon
Adjust free play, if necessary (page 50). monoxide can collect rapidly in enclosed
• Tyres-Check condition and pressure areas such as garage. Do not run the engine
(page 55). with the garage door closed.
• Clutch-Check for smooth operation.
Adjust free play if necessary (page 42). • Never hold electric ! CAUTION
starter ( ) of integrated
• Drive chain-Check condition and slackness start-kill switch continuously more than 5
(page 44). Lubricate if necessary. seconds as continuous cranking of engine
• Throttle-Check for smooth opening and will discharge the battery.
closing in all steering positions (page 43). • This vehicle is equipped with a side stand
• Lamps & Horn-Check that headlamp, engine kill feature (page 22).
position lamps, tail/stop lamp, turn signal Preparation
lamps, indicators and horn function Before starting insert the key and follow the
properly. below mentioned procedure :
• Rear view mirror-Ensure that the rear • Turn the ignition switch (1) to "ON" ( )
view mirror gives a good rear view when you position.
are sitting on the vehicle.
• Integrated start-kill switch-Check for Confirm that the programmed FI
•
proper functionality (page 21). malfunction indicator lamp (MIL) (2)
glows continuously and then should go
• Fitting & Fasteners-Check & tighten if “OFF” once the engine is started.
necessary.
26
1
2 4
(1) Ignition switch (4) Integrated start-kill switch
(2) Malfunction indicator lamp (MIL) Make sure that the integrated start-kill
•
NOTE switch (4) is at “ON” ( ) position.
• Electric start : Press the electric starter
If MIL remains “ON” even if the vehicle is ( ) of integrated start-kill switch with fully
started, there is an abnormality in the
programmed FI system. It is recommended to closed throttle.
reduce the speed and drive to the Authorised • Kick start : Depress the kick starter until
Distributor/Dealer for check-up. resistance is felt. Then let the kick starter
Ÿ Find neutral position & check neutral
return to the top of its stroke. Kick from the
top of the stroke through to the bottom with
N indicator (3) on instrument console a rapid, continuous
with ignition "ON". motion.
Starting procedure
At any ambient temperature, Press the electric
starter ( ) of integrated start-kill switch with
3 the throttle completely closed.
NOTE
This vehicle has a fuel-injected engine with an
idle air control valve (IACV).
Flooded engine
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
(3) Neutral indicator
27
• If the engine does not start wait for 15- RIDING
20 seconds, and try restarting the engine • After the engine has been warmed up, the
with throttle completely closed. vehicle is ready for riding.
• If the engine starts with unstable idle, open • While the engine is idling, press the clutch
the throttle slightly. lever and depress the gearshift pedal
Ignition cut off downwards using the toe to shift into 1st
Your vehicle is designed to automatically stop gear.
the engine & fuel pump, if vehicle falls down. • Slowly release the clutch lever and at the
(Bank angle sensor cuts off the ignition). same time, gradually increase engine speed
by opening the throttle. Coordination of the
NOTE throttle and clutch lever will assure a smooth
If the vehicle has fallen down, before restarting positive start.
the engine you must turn the ignition switch to • When the vehicle attains a moderate speed,
"OFF" ( ) position and then back to "ON" close the throttle, press the clutch lever and
( ) position. shift to 2nd gear by placing the toe on the
Running in underside of gear pedal and lift upwards.
• This sequence is repeated progressively to
Help assure your vehicle's future reliability and shift to 3rd, 4th and 5th gear.
performance by paying extra attention to how
you ride during the first 500 km. ! CAUTION
During this period, avoid full-throttle starts Do not shift gears without operation of clutch
and rapid acceleration. and without closing the throttle otherwise this
would lead to damage of gears.
NOTE
• To start the engine if any gear is engaged,
press the clutch lever and press the integrated 5
start-kill switch. 4
• Do not open the throttle during starting the 3
vehicle.
2
! WARNING N
Never run the engine in a closed area, the 1

exhaust contains poisonous gases.
28
BRAKING
Anti-lock braking system (ABS)
This model is equipped with Anti-lock braking
system (ABS). ABS enhances active safety by
helping to prevent the wheels from locking
under braking.
ABS is designed to meet two essential
requirements during every brake application:
• To help provide vehicle stability.
• To help maintain steering control and 3
manoeuvrability–on road surfaces. (3) ABS indicator
The ABS system is self-regulating and The system has a wheel speed sensor (1),
always active once vehicle speed exceeds hydraulic electronic control unit (HECU) (2),
5 km/h. and an ABS indicator lamp (3) on meter
• The ABS computer acts on the basis of the console.
comparative speeds of the front wheel. The Whenever you ride your vehicle, Wheel
use of non-approved tyres can affect the speed sensor monitors the speed of the
speed of the wheels and supply incorrect wheel and sends the input to Hydraulic
information to the ABS computer. Electronic control unit (HECU). Then
2 HECU monitors your bike and takes control
when vehicle speed exceeds 5 km/h.
Now whenever you will apply front brake,
ABS will come into picture and based on the
input from wheel speed sensor, HECU will
modulate the pressure at front caliper thus
avoiding wheel to lock and in turn resulting
safe stop of the vehicle.
Do's and Dont's
1 Do's
(1) Wheel speed sensor • Check your brake pads and be sure you
(2) Hydraulic electronic control unit (HECU) have clean brake fluid. ABS systems can
also fail due to worn brake pads or air or dirt
in brake fluid.
29
• Use the recommended brake fluid. • Do not adjust the wheel speed sensor air
• If brake gets wet, apply the brake while gap yourself.
riding at low speed to help them dry. • Do not attempt to correct the encoder teeth
• ABS should be serviced only at Authorised by bending manually or by using any other
Distributor/Dealer. mode. Do not use a different encoder teeth
• Read your owner's manual for additional • Do not insert any metallic part near wheel
riding instructions. speed sensor.
• Carefully remove the wheel during the • Don't try to service HECU or open to
puncture/tyre replacement to prevent the separate the parts.
Sensing ring damage/bend. • Don't use the non-genuine spares like pads,
• Use only the recommended make, type, size discs, tyres etc.
of tyre and maintain specified tyre pressure NOTE
(page 55). ABS may get activated without brake
• Keep checking speedometer. In case of •
ABS malfunction, speed display may go to application while riding on uneven road
zero. surfaces (sharp drop or rise on the road
• Always maintain sufficient distance from the level). This is normal functioning of ABS and
objects/vehicles ahead, for proper braking won’t be having any impact on performance.
and to match riding speed. • ABS may not work if the battery is discharged.
• On certain surfaces, such as rough road or • ABS operation is also affected by road
gravel road, brake lever may have hard/ conditions, vehicle handling and brake
operation. It is the rider’s responsibility to
pulsating feel. Apply full braking on the ride at reasonable speed and to leave a
lever even on the hard or pulsating feel of margin of safety.
the lever to get the optimum performance. • ABS consists of an electric motor, from
• In case of ABS malfunction, the brake which sound can be heard.
system will work as conventional (Non- PARKING
ABS) brake. Rider is recommended not to After stopping the vehicle, shift the
apply hard brake to prevent wheel lock and transmission to neutral, turn the ignition
visit Authorised Distributor/Dealer.
Don't's switch “OFF” ( ), park the vehicle on main
• Don't panic by mechanical noises or slight stand, lock the steering and remove the key.
lever pulses while applying the brake ! CAUTION
(whenever ABS actuates) in vehicle. These Park the vehicle on firm level ground to
conditions are normal and indicates that •
prevent overturning.
ABS is working. • While parking on side stand engage the first
• Don't apply the hard braking in wet or rainy gear.
conditions and while taking a turn.
30
TOOL KIT • Rub the soiled area gently rinsing it
The tool kit (1) is located below the seat in the frequently with fresh water.
rear. Some emergency repairs, minor • After cleaning spray water thoroughly.
adjustment and parts replacement can be • Dry the vehicle by wiping with dry soft cloth.
performed with the tools contained in the kit.
Kit consists of following tool: NOTE
Ÿ Tool bag • We at dealership take all above mentioned
Ÿ Driver No.2 + , - precautions like recommended detergents
Ÿ Grip and usage of muffler caps/plugs during
Ÿ Box wrench P16 x 14 wash to ensure quality wash.
• Do not use high pressure water (or air). It
Ÿ Handle pin spanner can damage certain parts of the vehicle.
Ÿ Pin spanner
Ÿ No.3 cross point screw driver MAINTENANCE
The importance of maintenance
A well-maintained vehicle is essential for safe
economical and trouble-free riding. It will also
help reduce pollution.
To help you, take proper care of your vehicle,
the following pages include a maintenance
1 schedule and a maintenance record for regular
scheduled maintenance.
These instructions are based on the
assumption that the vehicle will be used
(1) Tool kit
exclusively for its designed purpose. Sustained
high speed operation or operation in
CLEANING AND WASHING OF VEHICLE more unusually wet or dusty conditions will require
Follow the below mentioned steps for washing maintenancefrequent service than specified in the
the vehicle. schedule. Consult your
• Wet the vehicle with light water spray. Avoid Authorised Distributor/Dealer for
recommendation applicable to your individual
directing water to meter console, muffler needs
outlets and electrical parts. and use. If your vehicle overturns or is
• Clean the headlamp lens and other plastic involved in a crash, be sure your Authorised
parts using a cloth or sponge dampened Distributor/Dealer inspects all major parts,
with a solution of mild detergent and water. even if you are able to make some repairs.
31
! WARNING SAFETY PRECAUTIONS
• Improperly maintaining this vehicle or failing • Make sure the engine is “OFF” before you
to correct a problem before you ride can begin any maintenance or repair. This will
cause a crash in which you can be seriously help to eliminate several potential hazards:
hurt or killed. • Carbon monoxide poisoning from
• Always follow the inspection and maintenance engine exhaust.
recommendations and schedules in this
owner's manual. Be sure there is adequate ventilation
Maintenance safety whenever you operate the engine.
• Burns from hot parts.
This section includes instructions on some Let the engine and exhaust system cool
important maintenance tasks. You can before touching.
perform some of these tasks with the tools • Injury from moving parts.
provided (if you have basic mechanical skills). Do not run the engine unless instructed
Other tasks that are more difficult and require to do so.
special tools are best performed by • Read the instruction before you begin and
professionals. Wheel removal should normally
be handled only by a Authorised Distributor/ make sure you have the tools and skills
Dealer skilled technician or other qualified required.
technician; instructions are included in this • To help prevent the vehicle from falling
manual only to assist in emergency service. over, park it on a firm, level surface on the
You will come across some of the most main stand.
important safety precautions in the following • To reduce the possibility of a fire or
pages of this manual. explosion, be careful when working around
However, we cannot warn you of every petrol or batteries. Use only nonflammable
conceivable hazard that can arise in solvent, not petrol, to clean parts. Keep
performing maintenance. Only you can decide cigarettes, sparks and flames away from the
whether or not you should perform a given battery and all fuel-related parts.
task. Remember that your Authorised Distributor/
! WARNING Dealer knows your vehicle best and is fully
• Failure to follow maintenance instructions equipped to maintain and repair it.
and precautions properly can seriously To ensure best quality and reliability, use only
injure you. new genuine parts for repair and
• Always follow the procedures and replacement.
precautions in this owner's manual.
32
MAINTENANCE SCHEDULE
Perform the pre-ride inspection (page 25) at each scheduled maintenance period.
I: INSPECT C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE O: OIL CHANGE
T: TOP UP E: EMISSION CHECK
The following maintenance schedule specifies all maintenance required to keep your vehicle in
peak operating condition. Maintenance work should be performed in accordance with
standards and specifications of HMCL Niloy Bangladesh Ltd. by properly trained and
equipped technicians. Your Authorised Distributor/Dealer meets all of these requirements.
Ensure that each paid service is availed within 90 days or 3000 km from the date of previous
service, whichever is earlier.
To be serviced by your Authorised Distributor/Dealer unless the owner has the
relevant tools, technical information and is technically qualified.
In the interest of safety, we recommend that these jobs are carried out only by your
Note-1 : At higher odometer readings, repeat the frequency interval established here.
Note-2 : Replace air cleaner element once in every 15000 km or early replacement may
be required when riding in dusty areas.
Note-3 : Replace engine oil once in every 6000 km. Top up if the oil level is at or near the
lower level mark.
Note-4 : Visit Authorised Distributor/Dealer for inspection, cleaning, lubrication and
adjustment of drive chain at every 1000 km.
Note-5 : Replace brake fluid once in every two years or 30000 km, whichever is earlier.
Note-6 : Inspect & maintain specified torque.
Note-7 : Inspect the wheel bearings free play, replace if necessary.
Note-8 : Replace front fork oil once in a every 2 years or 30000 km, whichever is earlier.
Note-9 : Inspect rear suspension mounting bushes play, replace rear shock absorber if
necessary.
Note-10 : Check CO emission at idle.
Note-11 : Inspect the canister hoses for deterioration, damage or loose connections and
canister for cracks or other damages.
Note: Always wipe the water from the vehicle after washing. Use clean soft cloth or
pressurized air for completely drying the water.
33
MAINTENANCE SCHEDULE
Dear Customer,
We would strongly recommend the following schedule, to keep your vehicle in
perfect running condition and healthy environment. Vehicle subjected to severe use or ridden
in dusty area will require more frequent servicing.
SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
ITEMS DAYS 1st 60 90Next Next Next Next Next Next Next Next Next Next
90 90 90 90 90 90 90 90 90
KM Note-1 500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000- 30000-
750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500
Fuel Line I I I I I I I I I I I
Throttle Operation I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Air Cleaner Element Note-2 Do not open air cleaner element unless R R
there is a drivability problem
Spark Plug I, C, A I, C, A I, C, A I, C, A R I, C, A I, C, A I, C, A R I, C, A I, C, A
Valve Clearance I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Engine Oil Note-3 O I, T O I, T O I, T I, T O I, T O I, T
Engine Oil Strainer C C C C C C
Screen
Engine Oil Centrifugal C C C C C C
Filter
Electric Starter I I I I I I I I I I I
Oil Circulation I I I I I I I I I I I
Drive Chain Note-4 I,C,L,A at every 1000 km I,C,L,A at every 1000 km
Drive Chain Slider I I I I I I I I I I
Battery Voltage
Inspection with I I I I I I I I I I I
Midtronics tester
Brake Shoe I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
(Drum type)
34
SERVICE 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
ITEMS DAYS 1st 60 90Next Next Next Next Next Next Next Next Next Next
90 90 90 90 90 90 90 90 90
500- 3000- 6000- 9000- 12000- 15000- 18000- 21000- 24000- 27000-
KM Note-1 750 3500 6500 9500 12500 15500 18500 21500 24500 27500 30500 30000-
Disc Wear/ I I I I I I I I I I I
Pad Wear (Disc type)
Brake Fluid (Disc type) Note-5 I I I I I I I I I I I
Brake System (Brake C, L C, L C, L C, L C, L
Cam & Brake Pedal)
Stop Lamp Switch I, A I, A I, A I, A 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 I, A I, A I, A I, A
Clutch Lever Free Play I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A I, A
Side Stand/ L L L L L L L L L L L
Main Stand
Side Stand Switch I, C I, C I, C I, C I, C I, C I, C I, C I, C I, C I, C
Nut, Bolts & Fasteners Note-6 I I I I I I I I I I I
Wheels Bearings Note-7 I I I I I I I I I I I
Wheels/Tyres I I I I I I I I I I I
Steering Head Bearing I I, A I I, A I, L, A I I I, A I, L, A I I, A
Front Suspension/Oil Note-8 I I I I I I I I I I I
Rear Suspension Note-9 I I I I I I I I I I I
Muffler
(Catalytic Converter) Note-10 I, E I, E I, E I, E I, E
Evaporative Emission Note-11 I I I I I I I I I I I
Control System
35
SPARK PLUG INSPECTION Ÿ Make sure that the spark plug gap is
Recommended plugs: 0.8-0.9 mm using a wire-type feeler
NGK-CPR 8 EA9, BOSCH UR5DC gauge. If adjustment is necessary, bend the
For most riding conditions this spark plug heat side electrode carefully. Make sure the plug
range number is satisfactory. However, if the washer is in good conditions.
vehicle is going to be operated for extended
periods at high speeds or near maximum
power in hot climates, the spark plug should 0.8-0.9 mm
be changed to a cold heat range number,
consult Authorised Distributor/Dealer on this
if required.
Ÿ Clean dirt around the spark plug base.
Ÿ Disconnect the noise suppressor cap (1)
and remove the spark plug (2) with the help
of spark plug box wrench provided in the
tool bag.
Ÿ With the plug washer attached, thread the
spark plug in by hand to prevent cross-
threading.
Ÿ Tighten a new spark plug 1/2 turn
after the plug seats, with a spark plug box
wrench to compress the washer. If you are
reusing a plug, it should only take 1/8-
1/4 turn after the plug seats.
! CAUTION
2 1 • Do not remove the spark plug and test for
(1) Noise suppressor cap (2) Spark plug spark on the vehicle by cranking the engine
as this could lead to fire or explosion
Ÿ Visually inspect the spark plug electrodes for • Install a dummy spark plug in the cylinder
wear. The center electrode should have head and test for spark.
square edges and the side electrode should • Never use a spark plug with improper heat
not be eroded. Discard the spark plug if range.
there is apparent wear or if the insulator is • Always use resistor type spark plug.
cracked or chipped.
36
ENGINE OIL Ÿ Do top up if oil level reaches towards the
Use only genuine engine oil. lower level mark or every 3000 km
BRAND: Hero 4T plus whichever is earlier.
GRADE: SAE 10W 30 SL Grade Ÿ Park the vehicle on its main stand.
(JASO MA2). Ÿ Start the engine & let it idle for 3-5
Manufactured by: minutes.
Ÿ Tide Water Oil Co. (India) Ltd. Ÿ Slightly loosen the engine oil check bolt (4)
Ÿ Savita Oil Technologies Limited. and check the engine oil entry into the
Ÿ Bharat Petroleum Corporation Limited.
cylinder head cover.
OIL CAPACITY : 1.3 litres 4
Engine oil level inspection/
Top up process
Check engine oil level each day before
operating the vehicle. The oil level dipstick (1)
is on the right crankcase cover for measuring
oil level. Oil level must be maintained between
the upper (2) and lower (3) level marks on
the oil level dipstick.
UPPER
(4) Engine oil check bolt
LOWER
1 Ÿ After checking the oil circulation, tighten the
engine oil check bolt.
Ÿ Stop the engine and wait for 2-3 minutes.
Ÿ Remove the oil level dipstick, wipe it clean
2 and insert without screwing it in.
Ÿ Remove the oil level dipstick and check the
oil level.
3 Ÿ If required, add the specified oil up to the
(1) Oil level dipstick (2) Upper level mark upper level mark. Do not overfill.
(3) Lower level mark Ÿ Quantity of oil to be filled is 1.09 litres
(approx.) during oil change (when right
crankcase cover is not removed).
37
Ÿ Reinstall the oil level dipstick with new • Stop the engine and let the engine oil settle
O-ring and check for oil leaks. down.
Engine oil replacement/ • Recheck the oil level.
Oil circulation inspection • Make sure that oil level is at the “UPPER”
• Start the engine, warm it up for several level mark of the oil level dipstick with the
minutes and then turn it off. vehicle in an upright position and that there
• Wait a few minute until the oil settles down. are no oil leaks.
• To drain the oil, remove the oil level ! CAUTION
dipstick, drain bolt (1) and sealing washer • Running the engine with insufficient oil can
(2). cause serious engine damage.
2 • Running the engine with excessive oil can
cause spark plug fouling & loss in
performance.
• Engine oil is a major factor affecting the
performance and service life of the engine.
Non-detergent, vegetable or castor based
racing oils are not recommended.
OIL FILTER SCREEN & CENTRIFUGAL
FILTER CLEANING
• Drain the engine oil throughly.
1 • Remove the side stand switch bolts (1).
(1) Drain bolt (2) Sealing washer • Disconnect the clutch cable (2), remove the
• After the oil has completely drained, kick start pedal (3) and exhaust muffler (4).
reinstall the drain bolt (1) with a new • Remove the kick stopper with side stand
sealing washer (2). (5) and right crankcase cover (6).
• Fill the crankcase through the oil filler • Remove the dowel pins (7) and gasket (8).
hole with 1.09 liters (approximately) of • Remove the oil filter screen (9) and wash it
recommended grade oil during oil change in clean non flammable or high flash point
when right crankcase cover is not removed. solvent (kerosene).
• Reinstall the oil level dipstick with a new
O-ring.
• Start the engine and allow it to idle for few
minutes.
38
3 2
1
5
6 11
(1) Side stand switch bolts (2) Clutch cable (11) Centrifugal filter
(3) Kick start pedal (4) Exhaust muffler • Reinstall the centrifugal filter cover with new
(5) Kick stopper with side stand gasket.
(6) Right crankcase cover • Install the new dowel pins & gasket, right
crankcase cover and connect the clutch
cable.
7 • Install kick stopper with side stand, kick start
pedal and exhaust muffler.
10 • Install the side stand switch bolts.
• Fill the crankcase with clean engine oil as
8 per specification (page 36).
NOTE
• Clean filters as specified in the maintenance
9 schedule.
(7) Dowel pins (8) Gasket (9) Oil filter screen • Ensure to replace gasket & dowel pin with
(10) Centrifugal filter cover new one once removed
• Reinstall the filter screen with the tapered AIR CLEANER
end facing in. Air cleaner element inspection
• Remove centrifugal filter cover (10) & The air cleaner is wet paper pleated type filter
clean the centrifugal filter (11) with non which has enhances filtering efficiency. The
flammable or high flash point solvent air cleaner should be replaced at regular
(kerosene). intervals (page 33). When riding in dusty
39
areas, more frequent replacement may be NOTE
necessary.
• Remove the seat assembly (page 25). Align the tabs of air cleaner cover before
• Remove the air cleaner cover screws (1) installing screws & the cover.
and the cover (2). CAUTION
1 !
2
(1) Side cover screws (2) Side cover
• Never wash or clean the wet, paper pleated
• Remove the air cleaner element (3). type filter. Replace filter element once in
3 every 15000 km.
• Replace it earlier if it becomes very dirty,
damage on surface or on the sealing area.
• Clean the air cleaner housing using a shop
towel.
• Install the new air cleaner element.
• Install the air cleaner element cover.
• Install the seat (page 25).
Air cleaner drain tube cleaning
Remove the drain tube (1) and drain the
deposit into a container.
(3) Air cleaner element Follow the above process more frequently
when riding in rain or at full throttle.
40
2
1 1 4 3
(1) Drain tube (1) Crankshaft hole cap (2) Timing hole cap
(3) 'T' mark (4) Index mark
NOTE • Rotate the flywheel anticlockwise until the
Always ensure to reinstall the drain tube after “T” mark (3) on the flywheel coincides with
draining the deposit. the index mark (4) on the left crankcase
VALVE CLEARANCE ADJUSTMENT cover. In this position the piston will either
Excessive valve clearance will cause noise, and be on the compression or exhaust stroke.
little or no clearance will prevent the valve The adjustment must be made when the
from closing and cause valve damage and piston is at top dead center and both the inlet
power loss. Check valve clearance at the and exhaust valves are closed.
specified intervals (page 33). This condition can be determined by moving
the rocker arms. If they are free, it is an
NOTE indication that the valves are closed and the
The checking or adjustment of valve clearance piston is in compression stroke. If they are
should be performed while the engine is cold. tight, the valves are open, rotate the flywheel
The clearance will change as the engine 360° anticlockwise and realign the “T” mark
temperature rises. with the index mark.
• Remove the fuel tank cover (page 59). • Check the clearance by inserting the feeler
• Remove the crankshaft hole cap (1) and gauge (5) between the adjusting screw (6)
timing hole cap (2). and valve stem (7).
• Remove the cylinder head cover.
41
6 • After tightening the lock nut, check the
clearance again.
• Installation is in the reverse order of
removal.
8 NOTE
Before inserting the feeler gauge, smear a bit
of engine oil on the feeler gauge to avoid
damage to the feeler gauge.
CLUTCH LEVER FREE PLAY
5 7 Adjustment
(5) Feeler gauge (6) Adjusting screw Clutch adjustment may be required if the
(7) Valve stem (8) Lock nut vehicle stalls when shifting into gear or tends
to creep or if the clutch slips, causing
acceleration to lag behind engine speed.
Normal clutch lever free play (1) is 10-20
mm at the lever (2).
2
Standard clearance (cold condition)

Intake: 0.12 mm
Exhaust: 0.13 mm
• If adjustment is required, adjust by loosening
the lock nut (8) and turning the adjusting (1) Free play: 10-20 mm (2) Clutch lever
screw until there is a slight drag on the feeler • To adjust the free play, loosen the lock nut
gauge. (3). Turn the adjusting nut (4) to obtain the
specified free play. Tighten the lock nut and
check the adjustment.
42
3 4 THROTTLE OPERATION
Cable inspection
Check for smooth rotation of the throttle grip
A from the fully open to the fully closed position.
Check at full left and full right steering
positions. Inspect the condition of the throttle
B cable from the throttle grip down to the
throttle body. If the cable is kinked, chafed or
improperly routed, it should be replaced or
rerouted. Standard throttle grip free play (1)
is approximately 2-6 mm of grip rotation.
(3) Lock nut (4) Clutch cable adjusting nut 1
(A) Decrease free play (B) Increase free play
• Start the engine, press the clutch lever and
shift into gear. Make sure the engine does
not stall, and the vehicle does not creep.
Gradually release the clutch lever and open
the throttle. The vehicle should start
smoothly and accelerate.
NOTE
If proper adjustment cannot be obtained or the
clutch does not work correctly, visit your
Authorised Distributor/Dealer. (1) Free play 2-6 mm
Other checks Free play adjustment
• Check the clutch cable for kinks or signs of To adjust the free play, slide the boot (2), then
wear that could cause sticking or failure. loosen the lock nut (3). Turn the adjuster (4)
• Check for clutch cable model. Use genuine to adjust free play. After adjustment, tighten
clutch cables. the lock nut and slide the boot on the adjuster
• Check for clutch cable routing. and locknut securely.
43
2 4 • Rotate the wheel and check the drive chain
slack. Repeat this procedure several times.
Drive chain slack should remain constant
A (20-25 mm). If the chain is slack only in
3 certain sections, some links are kinked or
binding. Binding and kinking can be
B eliminated by frequent lubrication.
(2) Boot (3) Lock nut (4) Adjuster

(A) Decrease free play (B) Increase free play
DRIVE CHAIN SLACKNESS
The service life of the drive chain depends
upon proper lubrication and adjustment.
Poor maintenance can cause premature wear 1 2
or damage to the drive chain and sprockets. (1) Drive chain
The drive chain (1) should be checked and (2) Drive chain slack: 20-25 mm
lubricated as part of the pre-ride inspection
(page 24). Under severe usage, or when the NOTE
vehicle is ridden in unusually dusty areas, more Drive chain slack should be adjusted at your
frequent maintenance will be necessary. Authorised Distributor/Dealer as per the
Inspection specification.
• Turn the engine “OFF”, park the vehicle on
its main stand and shift the transmission to • Turn the chain to view chain lock plate (3).
neutral. Ensure that the chain lock plate open end
• Drive chain slack (2) should be checked in (4) is installed in the opposite direction of
the lower run midway between the the chain rotation.
sprockets. Move the drive chain up and • Rotate the rear wheel slowly and inspect the
down by hand and chain slack should be drive chain and sprockets for any of the
adjusted to 20-25 mm vertical movement following conditions.
by hand.
44
Sprocket Teeth
orn
W
3
Da
maged Sprock
4
th
e
Te
et
tT ck
e
eet p ro
h
N o r m al S
(3) Chain lock plate (4) Open end

! CAUTION
Drive chain Always replace the drive chain and sprockets
• Damaged rollers as a set. Otherwise the new part will wear
• Loose pins prematurely.
• Dry or rusted links Adjustment
• Kinked or binding links Drive chain slack should be checked and
• Excessive wear adjusted, if necessary at every 1000 km.
• Improper adjustment When operated at sustained high speeds or
• Damaged or missing O-rings. under conditions of frequent rapid
Sprockets acceleration, the chain may require more
• Excessively worn teeth frequent adjustments.
• Broken or damaged teeth. If the drive chain requires adjustment, follow
If the drive chain has damaged rollers, loose the procedures below:
links or missing O-rings, replace it. If the • Park the vehicle on its main stand with the
chain is dry or rusted, it should be lubricated. transmission in neutral and the ignition
Lubricate the chain if the links are kinked or switch in “OFF” position.
binding. If the problem is not solved after • Loosen the rear axle nut (1).
lubrication, replace the chain. • Loosen the drive chain lock nut (2).
If the drive chain or sprockets are excessively • Turn the adjusting nut (3) in an equal
worn or damaged, they should be replaced. number of turns until the correct drive chain
slack is obtained. Turn the adjusting nut
clockwise to decrease the slack or
45
anticlockwise to increase the slack of the • Check the drive chain slack again.
chain. • If after adjustment of drive chain slack, axle
• Align the chain adjuster index mark (4) with (5) touches to the rear edge of adjustment
the rear edge (5) of the adjusting slots on slot (6). Chain kit has to be replaced.
both sides of the swingarm equally.
1 ! WARNING
If a torque wrench is not used for installation,
see your Authorised Distributor/Dealer as
soon as possible to check for proper assembly.
Cleaning and Lubrication
Lubricate every 1000 km or sooner if the
chain appears dry.
• Turn the engine off, park the vehicle on its
main stand and shift the transmission into
neutral. Open side stand to facilitate
cleaning.
(1) Rear axle nut • Spray a commercially available chain
5 2 cleaner for cleaning the drive chain over its
entire length.
NOTE
Ensure that the chain cleaner and lubricant
used is the one recommended for use on an
O-ring chain, otherwise the O-rings may
deteriorate, fail and lose their sealing
properties.
• Rotate the rear wheel backwards to expose
4 6 3 the next section of the drive chain and
(2) Drive chain lock nut repeat second step until all of the drive chain
(3) Drive chain adjusting nut (4) Index mark is cleaned.
(5) Axle (6) Rear edge of adjusting slot • Let the spray dry for about five minutes.
• Tighten the rear axle nut. • To remove stubborn dirt, scrub the rollers
Torque: 6.8 kgf-m and side plates with soft nylon brush.
46
• Apply SAE 90 grade oil on the hanger side of DRIVE CHAIN SLIDER INSPECTION
the entire length of the chain using an oil can. (Refer to “Maintenance schedule” on page
• Wait for 7-10 minutes for penetration of 32).
lubricant inside the bush and roller wipe the Check the chain slider (1) for wear, The chain
excessive lubricant from the chain and slider must be replaced if wear limit is reached.
nearby parts using a clean rag. For replacement, see your Authorised
NOTE Distributor/Dealer.
Excessive lubricant if not wiped off, will aid in
accumulation of dust, sand and dirt on the drive
chain, increasing its wear and will also be
sprayed on the vehicle as well due to chain
movement.
! CAUTION 2
• Steam cleaning, high pressure washers and
certain solvents can damage the drive chain
O-rings. 1 CUTOUT
• While lubricating and cleaning hold the rear

wheel with one hand to prevent the (1) Chain slider (2) Wear limit
possibility of your finger being trapped
between the chain and sprocket. BRAKES
• Clean and lubricate the chain, whenever Refer to the safety precautions on (page 31).
possible, after riding the vehicle under rain or (a) Front brake
in terrain with excessive dust, mud or sand.
• The drive chain is fitted with O-rings Master Cylinder/Reservoir (1)
between the link plates. These O-rings Location : Right handlebar.
retain grease inside the chain to improve its
service life. However, special precautions
Brake fluid recommended:
must be taken when adjusting, lubricating, DoT3 or DoT-4.
washing and replacing the chain. Fluid level - Ensure that the brake fluid level
• If the chain is excessively dirty, it should be does not fall below “LWR” (lower) mark (2)
removed and cleaned before lubrication. For on master cylinder, when checked with the
your own safety, we recommend that service master cylinder parallel to the ground. The
be performed by an Authorised Distributor/ level decreases gradually due to piston
Dealer. movement to compensate pad wear. If the
47
level decreases abruptly, check for the • Always contact your Authorised Distributor/
leakages in the brake system and consult your Dealer for refilling of master cylinder/
Authorised Distributor/Dealer. reservoir when necessary. Do not mix DoT 3
1 and DoT 4 brake fluid.
• Always use recommended tyres (page 55)
for better braking performance.
(b) Rear brake (Disc type)
Refer to the safety precautions on (page 32).
Reservoir (1)
Location : Near pillion footrest.
Brake fluid recommended:
DoT3 or DoT-4.
2 Fluid level - Ensure that the brake fluid level
(1) Master cylinder (2) "Lower" mark does not fall below "LOWER" mark (2) on the
4 5 reservoir parallel to the ground. The level
decreases gradually due to piston movement
to compensate pad wear. If the level decreases
abruptly, check for the leakages in the brake
system and consult your Authorised
Distributor/Dealer.
3
(3) Brake pad (4) Caliper (5) Disc LOWER
NOTE
• Clean the dirt and mud accumulation
between the front brake caliper (3), brake 2 1
pads (4) and the disc (5) by using a water jet.
(1) Reservoir (2) “Lower” mark
48
3
5
4 1
(3) Rear caliper (4) Brake pads (5) Disc (1) Wear indicator groove
Rear brake (Disc type)
NOTE Check the wear indicator groove (1) in each
• Clean the dirt and mud accumulation pad.
between the rear brake caliper (3), brake If either pad is worn to the bottom of the
pads (4) and the disc (5) by using a water jet. groove, replace both as a set. Visit your
• Always contact your Authorised Distributor Authorised Distributor/Dealer for this service.
/Dealer for refilling of reservoir when
necessary. Do not mix DoT 3 and DoT 4
brake fluid.
(c) Brake pad wear
Brake pad wear depends upon the severity of
usage, type of riding & road conditions.
Generally, the pads will wear faster on wet &
dirty roads. Inspect the pads at each regular
maintenance interval.
Front brake
• Check the brake pads for wear by 1
examining the wear indicator groove (1) on (1) Wear indicator groove
each pad.
• If either pad is worn to the bottom of the ! WARNING
Always apply front and rear brakes
grooves replace both pads as a set. Visit simultaneously
your Authorised Distributor/Dealer for this to avoid skidding of vehicle.
service.
49
(d) Rear brake (Drum type) Ÿ If adjustment is necessary, turn the rear
Ÿ Park the vehicle on its main stand. brake adjusting nut (3).
Ÿ Measure the distance brake pedal (1) Ÿ Make sure that the cut-out on the adjusting
moves before the brake starts to take hole. nut is seated on the brake arm pin (4) after
Free play (2) should be 20-30 mm. the final adjustment has been made.
2 Ÿ Apply the brake several times and check for
free wheel rotation when released.
X ü
1 3 4 3 4
(1) Rear brake pedal (A) Cut-out not seated (B) Cut-out seated
(2) Free play 20-30 mm
(3) Adjusting nut (4) Brake arm pin
(A) Decrease free play (CW)
NOTE
If proper adjustment cannot be obtained by
B this method, visit your Authorised Distributor
/Dealer.
4 (e) Brake wear indicators (Drum type)
Rear brake wear indication
A When the brake is applied, an arrow (1), fixed
to the brake arm (2), moves towards a
(B) Increase free play (ACW) reference mark (3) on the brake panel (4).
3
(3) Adjusting nut (4) Brake joint pin If the arrow aligns with the reference mark on
CW- Clockwise ACW- Anticlockwise mustapplication
full of the brake, the brake shoes
be replaced.
50
1 4 • Check the rear mono shock absorber by
pushing hard downwards on rear grip while
the vehicle is not parked on stand. The
suspension action should be smooth and
there should be no oil leakage.
Rear mono shock absorber adjustment
Rear shock absorber adjustment can be made in
any position from 1st to 7th according to the
load/road conditions or owner’s requirement.
Recommend adjustment
3 2 • Solo rider : 3rd position
(1) Arrow (2) Brake arm • Rider + Pillion: 7th position
(3) Reference mark (4) Brake panel 3 1 2
SUSPENSION
Front and rear suspension inspection
• Check the front forks by locking the front
brake and pumping the front fork up and B
down vigorously. The suspension action
should be smooth and there should be no oil A
leakage.
Front Rear
(1) Rear mono shock absorber
(2) Pin spanner (3) Pin spanner handle
(A) Softer (B) Stiffer
• In direction A: Softer
• In direction B: Stiffer
NOTE
To adjust the rear mono shock absorber (1),
use the rear shock absorber adjustment tool
[Pin spanner (2) with handle (3)] available in
the tool kit.
51
WHEEL 3
(a) Front wheel
Removal
• Support the vehicle securely on the main
stand and raise the front wheel off the
ground.
• Remove the wheel speed sensor bolt (1)
from right fork leg and disconnect the wheel
speed sensor cable (2). 4 5
2 (3) Axle nut (4) Axle (5) Wheel
6 6
1
(1) Wheel speed sensor bolt
(2) Wheel speed sensor cable
(6) Side collars
• Remove the front axle nut (3), remove the Installation
axle (4) and wheel (5). • Install the side collars (1) to both sides of
! CAUTION the wheel hub.
Do not operate front brake lever when the • Insert the disc (2) between the pads in the
wheel is removed. caliper assembly (3). When installing the
• Remove the side collars (6) from both sides
wheel, carefully fit the brake disc between
from the wheel. the brake pads to avoid damage to the pads.
• Tighten the front axle nut (4) to the
specified torque.
TORQUE : 5.9 kgf-m
52
• After installing the wheel apply the brake 1
several times and then check if the wheel
rotates freely. Recheck the wheel if the 5
brake drags or if the wheel does not rotate
freely. 2
1 3
3
4
(1) Rear axle nut (2) Indicator plate (3) Axle
(4) Side collar (5) Caliper assembly
2 Installation
• Install the side collar (1) to the right side of
4 the wheel hub.
(1) Side collar (2) Disc (3) Caliper • Tilt the vehicle and position the rear wheel
(4) Front axle nut between the swingarm.
(b) Rear wheel (Disc type) • Insert the disc (2) between the pads in the
Removal caliper assembly. When installing the wheel,
Refer safety precautions on (page 32). carefully fit the brake disc between the brake
• Support the vehicle securely on the main pads to avoid damage to the pads.
stand and raise the rear wheel off the • Align the rear caliper holder (3) with the
ground. swingarm (4).
• Remove the rear axle nut (1) and indicator • Insert the axle (5) from the left side through
plate (2). the swingarm, wheel hub, collar and rear
• Remove the axle (3) and the right side caliper holder.
collar (4).
• Move the caliper assembly (5) upwards.
• Remove the wheel.
53
4 7
2 6
3 5
3
1
1 2
(1) Side collar (2) Disc (3) Caliper holder (1) Rear brake adjusting nut
(4) Swingarm (5) Rear axle (2) Rear brake rod (3) Brake arm
(6) Indicator plate (7) Rear axle nut 6 4
• Install the indicator plate (6) and tighten the
rear axle nut (7) to the specified torque.
TORQUE : 6.8 kgf-m
• Adjust the drive chain slack (page 44).
(c) Rear wheel (Drum type)
• Support the vehicle securely on the main
stand and raise the rear wheel off the
ground.
• Remove the rear brake adjusting nut (1)
and disconnect the brake rod (2) from the 5
brake arm (3) by pushing down the brake (4) Axle nut (5) Axle (6) Collar
pedal. Installation
• Remove the rear axle nut (4). • Reverse the removal procedure
• Pull out the axle (5) and collar (6). Axle nut torque: 6.8 kgf-m.
• Remove the wheel. • Adjust the rear brake free play (page 50)
and drive chain slackness (page 44).
• After installing the wheel, apply the brake
several times and check for free wheel
rotation when released.
54
MAIN/SIDE STAND LUBRICATION ! WARNING
• Park the vehicle on the level surface. • Using tyres that are excessively worn or
• Check the main/side stand return spring for improperly inflated can cause a crash in which
damage or loss of tension. you can be seriously hurt or killed.
• Check the main stand (1)/side stand (2) • Follow all instructions in this owner's manual
for freedom of movement. regarding tyres inflation and maintenance.
• Lubricate the side stand pivot if necessary. Air pressure
• Make sure the main/side stand is not bent. Keeping your tyres properly inflated provides
the best combination of handling, tread life
and riding comfort.
Generally, under-inflated tyres wear unevenly,
adversely affect handling and are more likely
to fail from being overheated.
Under inflated tyres can also cause wheel
damage in rocky terrain.
Over-inflated tyres make your vehicle ride
harshly, are more prone to damage from road
2 1 hazards, and wear unevenly.
(1) Main stand (2) Side stand We recommend that you visually check your
TUBELESS TYRES tyres before every ride and use a gauge to
The tyres fitted on your vehicles are of any measure air pressure at least once a month or
TUBELESS type. time you think the tyres pressure might be
low. Tubeless tyres have some self-sealing
To safely operate your vehicle, your tyres must ability
be of the proper type and size, in good if they are punctured. However, because
condition with adequate tread, and correctly leakage is often very slow, you should look
inflated for the load you are carrying. closely for punctures whenever a tyre is not
The following pages give more detailed fully inflated.
information on how and when to check the air Always check air pressure when your tyres are
pressure, how to inspect your tyres for "cold"-when the vehicle has been parked for
damage, and what to do when your tyres need at least three hours. If you check air pressure
to be repaired or replaced. when your tyres are "warm"-when the vehicle
55
has been ridden for even a few km-the Look for:
readings will be higher than if the tyres were • Bumps or bulges in the side of the tyre or the
"cold". This is normal, so do not let air out of tread. Replace the tyre if you find any bumps
the tyres to match the recommended cold air or bulges.
pressures given below. If you do, the tyres will • Cuts, splits or cracks in the tyre. Replace the
be under-inflated. tyre if you can see fabric or cord.
The recommended “cold” tyre pressures are:
Rider only Rider and Pillion
Front 1.75 kgf/cm2 (25 psi) 1.75 kgf/cm2 (25 psi)
Rear 1.96 kgf/cm2 (28 psi) 2.10 kgf/cm2 (30 psi)
1
• Excessive tread wear.
(1) Air pressure gauge

! CAUTION
Over inflation/Under inflation will affect the
performance.
Inspection
Whenever you check the tyre pressure, you • Carefully inspect the tyres for any damage,
should also examine tyre treads & side walls if the vehicle hits a pothole or hard object.
for wear, damage & foreign objects.
56
Tread wear speeds and riding conditions. If a temporary or
Replace tyres immediately when the wear emergency repair is made to a tyre, you should
indicator (1) appears on the tyre. The tread ride slowly cautiously to your Authorised
limits are: Distributor/Dealer and have the tyre replaced.
MINIMUM TREAD DEPTH: If possible you should not carry a pillion or
Front: 0.8 mm Rear: 1.0 mm load until a new tyre is installed.
Check the tread wear indicator for tyre wear. Even if a tyre is professionally repaired with a
permanent internal patch plug, it will not be as
good as a new tyre.
You should not exceed 70 km/hour for the
1st 24 hours or 105 km/hour at any time
thereafter. In addition you may not be able to
2 safely carry as much load as with a new tyre.
Therefore, we strongly recommend that you
1 replace a damaged tyre.
I
TW
If you decide to have a tyre replace be sure the
wheel is balanced before you ride.
Tyre replacement
The tyres that were installed on your vehicle
(1) Tread wear indicator (2) Arrow mark were designed to match the performance
capabilities of your vehicle and provide the
Unidirectional tyres best combination of handling, braking,
Whenever the tyre is removed and put back in durability and comfort.
case of puncture, ensure the arrow mark (2) The recommended tyre for your vehicle are:
on the tyre is in the same direction as that of
forward rotation of wheel. Front 100/80 17 52 P (Tubeless tyre)
Tyre repair Rear 130/70 R17 62 P (Radial tubeless tyre)
If a tyre is punctured or damaged, you should
replace it, not repair it. As mentioned below, a NOTE
tyre that is repaired either temporarily or For repair and replacement of tyre it is advised
permanently, will have lower speed and to visit your Authorised Distributor/Dealer.
performance limits than a new tyre.
A temporarily repaired, such as an external
tubeless tyre plug, may not be safe for normal
57
! WARNING
• Operation with excessively worn tyres is
hazardous and will adversely affect traction
and handling.
• Under-inflation may result in the tyre
slipping on or tyre coming off the rim.
• Always use the size and type of tyres
recommended in this owner's manual.
Important safety reminders
• Do not install a tube inside a tubeless tyre on
this vehicle. Excessive heat buildup can
cause the tube to burst. BATTERY
• Use only tubeless tyres on this vehicle. The Refer to the safety precautions on (page 32).
rims are designed for tubeless tyres, and Location
during hard acceleration or braking, a tube- The battery is located behind the left
type tyre could slip on the rim and cause the side of fuel tank cover.
tyre to rapidly deflate. Specification
NUTS, BOLTS & FASTENERS *MF Battery-12V-4 Ah/ETZ5
• Tighten bolts and nuts at regular interval It is not necessary to check the battery
shown in the maintenance schedule. electrolyte level or add distilled water as the
• Check that all chassis nuts and bolts are battery is a Maintenance-Free (sealed)
tightened to correct torque values. type. If your battery seems weak and/or
• Check that all cotter pins, safety clips, hose electrolyte is leaking (causing hard starting or
clamps and cable stays are in place. other electrical troubles), contact your
58
NOTE Ÿ Ensure the battery leads are properly
connected to the battery terminals during
This symbol on the battery means that installation.
this product must not be treated as Battery removal
household waste. • Make sure the ignition switch is “OFF” ( ).
This symbol on the battery means the • Remove the seat (page 25).
old battery must be returned to your • Remove the screws (1) from the both the
Authorised Distributor/Dealer as it sides.
must be treated as recyclable material.
• Battery is a maintenance-free (sealed) type
and can be permanently damaged if the
sealing strip is removed.
• An improperly disposed battery can be
harmful to the environment and human
health. Always confirm local regulations for
battery disposal.
Battery charging
Always visit your Authorised Distributor 1 1
/Dealer if you see any symptom of battery
discharge as earliest as possible to get the •(1)Remove
Screws
the bolts (2) from the both rear
battery charged. The battery has a tendency to
discharge rapidly if additional electrical and front side of the fuel tank.
accessories are fitted on the vehicle.
Battery storage
• If in case your vehicle is not used for more
than a month remove the battery, fully
charge and store in a cool and dry place.
Ÿ If the battery is expected to be stored for
more than two months, ensure to fully
charge the battery once in a month.
Ÿ Always ensure the battery is fully charged
before installation. 2 2
(2) Bolts
59
• Remove the fuel tank cover (3). • Pullout the battery (8) from the battery box.
3
8
(3) Fuel tank cover (8) Battery
• Disconnect the (-)ve terminal lead (4) from Battery installation
the battery first, then disconnect the (+)ve Ÿ Reinstall in the reverse order of removal. Be
terminal lead (5). sure to connect the (+)ve terminal first, then
• Remove the battery clamp bolt (6) and the (-)ve terminal.
battery clamp (7). Ÿ Check all fasteners are secure.
4 5 FUSE REPLACEMENT
The fuse box (A) is below the seat.
Main fuse (1) : 15A, 10A, 10A & 10A
Spare fuse (2) : 15A & 10A
7 6
(4) (-)ve terminal (5) (+)ve terminal
(6) Battery clamp bolt (7) Battery clamp
60
1
! WARNING
Never use a fuse with a different rating from
•
that specified. It may lead to serious damage
to the electrical system or a fire due to short
2 • circuit.
Battery gives off explosive gases. Keep
sparks, flames & cigarettes away.
! CAUTION
1A
• Do not attempt to start or ride the vehicle
without a charged battery, it can cause
(A) Fuse box fusing of the bulbs and permanent damage
(1) Main fuse:15A, 10A, 10A & 10A to certain electrical components.
(2) Spare fuse:15A & 10A • Turn the ignition switch "OFF" before
Starter magnetic switch (B) checking or replacing the fuse to prevent
accidental short-circuiting.
Location : Inside left side of fuel tank cover,
below the starter magnetic switch.
Fuse Type: Blade fuse GOOD FUSE BLOWN FUSE
Main fuse (1) : (20A)
Spare fuse (2) : (20A)
1
STOP LAMP SWITCH
The stop lamp switch (1) must be adjusted so
2 that stop lamp glows when rear brake is
B applied. The procedure for adjusting stop
(B) Starter magnetic switch lamp is as follows :
(1) Main fuse (20A) (2) Spare fuse (20A) • Turn the ignition switch to the “ON” ( )
position.
61
• Turn the adjusting nut (2) to position stop 1
lamp switch at a point where the stop lamp
glows once the brake pedal is depressed.
Turn the adjusting nut in direction (A) to
advance switch timing or in direction (B) to
retard switch timing.
1
A B
(1) Headlamp adjusting bolt
• Tighten the bolt after adjustment.
! WARNING
2 An improperly adjust headlamp may blind
(1) Stop lamp switch (A) Advance oncoming rider/driver or it may fail to light
(2) Adjusting nut (B) Retard the road for a safe distance.
HEADLAMP FOCUS ADJUSTMENT CATALYTIC CONVERTER
Headlamp is preset. However in case of This vehicle is equipped with a catalytic
adjustment required, please follow the steps converter (1) in the muffler to meet the
as given below: emission norms.
• Headlamp adjustment is done by the The catalytic converter contains precious
loosening the bolt (1) located below the metals that serve as catalysts, promoting
headlamp. chemical reactions to convert the exhaust
• Park the vehicle on it main stand on level gasses without affecting the metals. The
ground. catalytic converter acts on HC, CO and NOx.
• Turn the ignition switch to “ON” position The catalytic converter must operate at a high
( ) and start the engine. temperature for the chemical reactions to take
• Adjust the headlamp beam by loosening the place. It can set on fire any combustible
bolt (1) and moving the headlamp unit material that come near it. Park your vehicle
forward and backward for correct focus away from high grasses, dry leaves, or other
adjustment. flammable material.
62
A defective catalytic converter contributes to The canister (1) collects the fuel vapour from
air pollution and can impair your engine’s the fuel tank and then the fuel vapour is drawn
performance. into the engine for re-burning to avoid
Follow these guidelines to protect your pollution caused by the fuel vapour diffused
vehicle’s catalytic converter. into the air.
• Always use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
converter ineffective.
• Keep the engine tuned up.
1
(1) Canister
POLISHING OF VEHICLE
After washing your vehicle, wax all painted
1 surfaces (except matte painted surfaces) using
(1) Catalytic converters a commercially available polish/quality liquid
or paste wax to finish the job. Use only a non
EVAPORATIVE EMISSION CONTROL abrasive polish or wax made specifically for
SYSTEM automobiles. Apply the polish or wax
This vehicle is equipped with an evaporative according to the instructions on the container.
emission control system to meet emission NOTE
standards. During warm weather, the petrol
vapours which contain HC evaporates easily Polishing or waxing is not applicable for
into the atmosphere from the fuel tank, if the models having matte paint.
fuel system is unsealed or open.
The evaporative emission control system is
used to prevent petrol vapours from escaping
into the atmosphere from fuel tank.
63
BASIC TROUBLESHOOTING
1. STARTING TROUBLE - ENGINE DOES NOT START
A. Integrated Start-Kill Switch
Check engine stop switch position “OFF” Turn to “ON” ( ) position
“ON” ( ) position
Consult Authorised Distributor/Dealer
B. Side Stand Engine Kill System

Check side stand in gear condition (page 22) Side stand“Down” Move the side stand up
Side stand “Up”
C. Fuel System
Check fuel gauge Refill the fuel tank
Key “ON” position Only one segment displayed
Check fuel lines Leakage Consult Authorised Distributor/Dealer
Refill
OK
Check for operating sound of fuel pump Broken fuel pump wire connector Secure connections
OK
D. Electric Starter Not Working

Check fuse Fused Replace fuse (page 60)
OK
Inspect battery Weak Consult Authorised Distributor/Dealer
Refill
OK
Check connections, ignition switch/integrated start-kill switch Loose Secure connections
OK
64
E. No Spark At Spark Plug
Check ignition switch “OFF” ( ) position Turn ignition switch “ON” ( )
OK
Check spark plug for fouling/ Replace spark plug/adjust
improper electrode gap No spark spark plug gap (0.8-0.9 mm)
OK
Check for poorly connected Secure properly
or loose spark plug wire Loose contact
OK
2. ENGINE STARTS BUT STALLS

Check fuel lines Leakage Consult Authorised Distributor/Dealer
OK
Check air cleaner element Dirty Replace
OK
3. POOR PICK UP
Spark plug loose in cylinder head Loose Tighten the spark plug
OK
Check air cleaner element Clogged Replace
OK
Check brake binding Consult Authorised
Improper functioning Distributor/Dealer
OK
Check tyre inflation pressure Under inflated Correct tyre pressure
OK
65
4. ELECTRICAL SYSTEM
Feeble Horn Sound or No Light
Check fuse Fused Replace fuse
OK
Inspect battery Weak Consult Authorised Distributor/Dealer
OK
Check bulbs Fuse/wrong wattage Replace bulbs
OK
Check connections Loose Secure connections
OK
66
CU
ST
OM
ER
HMCL Niloy Bangladesh Ltd.
’S
CO
PY
DELIVERY CERTIFICATE
No.: IB41A
I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

THRILLER 160R PROGRAMMED FI Vehicle bearing the following
particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.
Customer’s Copy
Alongwith the vehicle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool kit
Tool bag, +, - No. 2 Driver, Grip, Box wrench P16 x 14, Handle pin
spanner, Pin spanner, No. 3 Cross point screw driver.
DIS
TR
IBU AU
TO THO
R/ RI
DE SE
HMCL Niloy Bangladesh Ltd. AL D
ER
COP
Y
DELIVERY CERTIFICATE
No.: IB41A
I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

THRILLER 160R PROGRAMMED FI Vehicle bearing the following
particulars:-
Engine No.
VIN
Colour/Model Key No.
Allotment No. Date of Sale
Customer’s Name
I have been explained by the dealer about correct and safe driving habits,
warranty terms and conditions, service schedules and maintenance tips.
Authorised Distributor/Dealer copy

Alongwith the vehicle I have also received the following:-
1. Owner’s Manual
2. 2 Nos. Keys
3. 1 Set of tools (for details see below)
4. Standard Accessories
5. Battery Make Sr. No.
6. Tyre Front Make Sr. No.
Rear Make Sr. No.
The vehicle has been delivered in factory fresh conditions to my satisfaction & I
have understood all terms and conditions of warranty and shall abide by them.
Customer’s Name
Customer’s Address
Customer’s Signature
Authorised Distributor/Dealer Name
Authorised Distributor/Dealer Address
Details of Tool kit
Tool bag, +, - No. 2 Driver, Grip, Box wrench P16 x 14, Handle pin
spanner, Pin spanner, No. 3 Cross point screw driver.
WHAT ARE THE BENEFITS OF GENUINE SPARE PARTS ?
• Assures long life
• Ensures economy for a long time
• Safety of vehicle and rider
• Peace of mind
• Value for money
• Assured quality
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
• Material used is inferior
• Damages other parts of clutch like, clutch center and
Clutch Plate outer clutch
• Affects fuel efficiency
• Poor acceleration
Cam Chain Kit

• Poor performance
• Reduced life
• Improper sealing
Gasket Cylinder Head • Engine knocking
• Leads to leakage and smoky exhaust
• Higher emission level
CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS
• Improper air filtration resulting in premature engine failure
Element Air Cleaner • Affects fuel efficiency
• Poor engine performance
• Frequent stalling of engine

Spark Plug • Higher emission level
• Poor engine performance
• Affects fuel efficiency
• Poor braking efficiency
Brake Pads/Shoes • Rider safety-an issue
• Discs/Drum wear out, resulting in subsequent repair cost
Chain Sprocket Kit • Noisy Operation

• Failure of chain can cause fatal accident
JOBS APPLICABLE TO PERIODIC SERVICES
• Test drive the vehicle if required for reported troubles, if any.
• Wash the vehicle, blow dry with air at every service.
• Fuel line inspection at every service.
• Inspect throttle free play and operation at every service, adjust if necessary.
• Replace air cleaner element at every 15000 km.
• Inspect, clean the spark plug at every service, adjust if necessary. (replace at every 12000 km).
• Inspect the valve clearance at every service, adjust if necessary.
• Engine oil top up or change as per the maintenance schedule.
• Clean engine oil strainer screen at first service then every 6000 km.
• Clean engine oil centrifugal filter at first service then every 6000 km.
• Inspect oil circulation at every service.
• Inspect electric starter operation at every service.
• Inspect, clean, lubricate and adjust the drive chain at every 1000 km.
• Inspect the drive chain slider.
• Inspect battery voltage at every service and charge if required.
• Inspect brake shoe wear at every service, adjust if necessary.
• Inspect brake pad and brake fluid level at every service, adjust brake pad if necessary.
• Clean and lubricate brake pedal at second service, then every 6000 km.
• Inspect all lamps, horn and switches at every service, adjust if necessary.
• Inspect headlamp focus at every service, adjust if necessary.
• Inspect clutch lever free play at every service, adjust if necessary.
• Lubricate the side stand and main stand at every service.
• Inspect and clean the side stand switch at every service.
• Inspect fasteners and tighten to the specified torque (if required).
• Inspect the bearings free play, replace if necessary.
• Inspect wheels/tyres. Inflate tyre to specified pressure at every service.
• Inspect steering for smooth operation, adjust (if necessary) in every alternate service and lubricate at every
12000 km.
• Inspect front suspension at every service, replace oil once in every 2 year or 30000 km whichever is earlier.
• Inspect rear suspension mounting bushes play, replace if necessary.
• Inspect the canister hoses for deterioration, damage or loose connections and canister for cracks or other
damages at every service.
• Test drive the vehicle for repair of problems reported.
• Polish entire vehicle.
SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km. Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
I 500 - 750
II 3000 - 3500
III 6000 - 6500
IV 9000 - 9500
V 12000 - 12500
VI 15000 - 15500
VII 18000 - 18500
VIII 21000 - 21500
IX 24000 - 24500
X 27000 - 27500
XI 30000 - 30500
XII 33000 - 33500
XIII 36000 - 36500
XIV 39000 - 39500
XV 42000 - 42500
XVI 45000 - 45500
XVII 48000 - 48500
NOTE
It is mandatory to avail all free and paid services as per the recommended schedule to be eligible for
the warranty benefits. Please ensure that each paid service is availed within 90 days from the date of
previous service or as per the recommended schedule, whichever is earlier.
SERVICE RECORD SHEET
To be Filled in by Supervisor
Free/Paid Km. Job Card Engine Oil Authorised
Service Km Range Date Reading No. Top-up/ Distributor/Dealer
Replace (Sig. & Stamp)
XVIII 51000 - 51500
XIX 54000 - 54500
XX 57000 - 57500
XXI 60000 - 60500
XXII 63000 - 63500
XXIII 66000 - 66500
XXIV 69000 - 69500
XXV 72000 - 72500
REMARKS (IF ANY)
SERVICE ADVICE SHEET
Normal wear and tear components replacement advice
Km Authorised Completion Dt.
Date Advice Distributor/Dealer
Job Card No. (Sig. & Stamp) Job Card No.
OWNERSHIP RECORD AND DATA
VIN
AUTHORISED DISTRIBUTOR/DEALER NAME

ADDRESS
AUTHORISED DISTRIBUTOR/DEALER
STAMP AND SIGNATURE

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PREFACE No : IB41A

1. Front fender 5. Headlamp (Low beam)

1. Rear reflex reflector 5. Right rear turn signal lamp

(1) Neutral indicator (11) LCD panel of meter console, refer

• Turn the ignition switch "ON" ( ).

• Press and hold set button (2) and mode

button (3) simultaneously for more than 2

mode with the hour's digit display blinking.

display starts blinking.

• To set the hour, press mode button (3) until

• To end the adjustment press set button (2).

The tripmeter shows distance travelled since x 1000 RPM

trip meter was reset last time. There are two

tripmeters, tripmeter-A (2) and tripmeter-B

Push the mode button (4) to select odometer,

(1) Electric starter

springs back to the normal position and cap

Never run the engine in a closed area, the 1

Standard clearance (cold condition)

(2) Boot (3) Lock nut (4) Adjuster

(3) Chain lock plate (4) Open end

• While lubricating and cleaning hold the rear

• Excessive tread wear.

(1) Air pressure gauge

B. Side Stand Engine Kill System

D. Electric Starter Not Working

2. ENGINE STARTS BUT STALLS

I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

I certify having taken delivery of one HMCL Niloy Bangladesh Ltd.

Authorised Distributor/Dealer copy

Cam Chain Kit

• Frequent stalling of engine

Chain Sprocket Kit • Noisy Operation

AUTHORISED DISTRIBUTOR/DEALER NAME

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