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PREFACE

Thank you for selecting a 

 

. We wish you many miles of 

Hero MotoCorp

Karizma ZMR

continued riding pleasure in the years ahead.

Let us make this world a safer, healthier and more environment friendly place.

This  booklet  is  your  guide  to  the  basic  operation  and  maintenance  of  your  new 

 

. Please take time to read it carefully. As with any fine 

Hero  MotoCorp

Karizma ZMR

machine, proper care and maintenance are essential for trouble-free operation and optimum 

performance.

We  at 

  are  committed  to  demonstrate  excellence  in  our  environment 

Hero  MotoCorp

,

performance on a continual basis, as an intrinsic element of our corporate philosophy. To 

achieve this we commit ourselves to continue product innovations to improve environment 

compatibility,  comply  with 

  and 

all  applicable  legislation  including  environment  legislation

strengthen the green supply chain.  

Your 

 is conforming to latest (Bharat stage-  norms) regulation for emission, safety & 

vehicle

IV

noise levels. We are also using non asbestos brake shoes/pads and engine gaskets which are 

environment friendly in nature.

This vehicle is fitted with a lighting feature known as “Automatic Headlamp ON”. The feature 

is mandated for all 2 Wheelers by Ministry of Road Transport & Highways (Government of 

India) vide notification GSR 188 (E) dated 22nd February 2016. This feature helps in 

conspicuity for improving rider safety. The headlamp of this vehicle will always be lit ON when 

the engine gets ON.

Your  Authorised 

  dealer  will  be  glad  to  provide  further  information  or 

Hero  MotoCorp

assistance and is equipped to handle your future service needs.

Summary of Contents for Karizma ZMR

Page 1: ...t innovations to improve environment compatibility comply with and all applicable legislation including environment legislation strengthenthegreensupplychain Your is conforming to latest Bharat stage...

Page 2: ...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 P...

Page 3: ...TIPS 9 VEHICLE SAFETY 10 VEHICLE VIEWS 2 TIPS FOR HEALTHY ENVIRONMENT 13 Maintenance schedule 33 Air cleaner 39 Drive chain slider inspection 45 Brakes 46 Main Side stand lubrication 51 Oil cooler 39...

Page 4: ...N Engine Variants XXXXEJ Y Z X YYYYY Engine Description Year of Manufacturing Assembly Plant Month of Manufacturing Serial Number Vehicle Identification Number VIN Engine No Electric start Front disc...

Page 5: ...right turn signal lamp 1 Front fender 4 Front visor 1 7 6 Front left turn signal lamp 8 Headlamp Hi beam 7 Left position lamp guide 9 Oil cooler Accessories and features shown may not be part of stan...

Page 6: ...2 Tail stop lamp 1 Left rear turn signal lamp 4 Licence plate lamp 3 Right rear turn signal lamp 1 2 Accessories and features shown may not be part of standard fitment REAR VIEW 3 3 4 VEHICLE VIEWS...

Page 7: ...Dimmer switch 6 Rear view mirror 8 Ignition switch with steering lock 13 Fuel tank cap 9 Front brake lever 12 Electric starter switch 10 Dynamic handlebar damper 11 Throttle grip Accessories and featu...

Page 8: ...d 11 Document tool kit 10 Rear grip 12 Fuel pump 13 Fuel injector compartment 1 Starter motor 3 Side stand switch 4 Main stand 2 Gearshift pedal 5 Rider foot rest 5 7 5 LEFT SIDE VIEW Accessories and...

Page 9: ...14 Rear brake fluid reservoir 15 Fuse box 16 Rear shock absorber 17 Rear hugger fender 1 Rear disc 3 Rear master cylinder 4 Rider foot rest 5 Brake pedal 6 Oil level dipstick 2 Pillion foot rest 5 7...

Page 10: ...es at disassembly and 1 10 litres at draining 15 3 litres Minimum Castrol Q stop DoT 3 or DoT 4 171 2 5 ml 14 9 kW 20BHP 8000 r min 19 N m 00 7 65 r min 65 5 x66 2 mm 9 6 1 223 cc Capacities Engine Sp...

Page 11: ...nd 2 Battery 12V 6Ah MF Battery Electricals MF stands for Maintenance Free MFR stands for Multi Focal Reflector 12V 0 2W 2 1W LED Alternator Starting system Headlamp High Low Tail Stop lamp Turn signa...

Page 12: ...braking makingitunsafetoride Removingor modifying your lamps mufflers emission control system or other equipment can also makeyourvehicleillegal Use an additional anti theft device of good quality Ent...

Page 13: ...ice riding in a safe area to become familiar with how this vehicle works and handles and to become accustomed to the vehicle ssizeandweight Riding under the influence of alcohol or drugs is dangerous...

Page 14: ...injured take time to assess the severity of the injuries and whether itissafetocontinueriding Callforemergency assistance if needed Also follow applicable laws and regulations if another person or veh...

Page 15: ...hanging clothes while solo pillionriding Ride defensively and at a steady speed between40 50km hr Always wear a helmet ISI marked with chin strap securely fastened and insist on a helmetforyourpillio...

Page 16: ...MotoCorp and make sure you change it every 6000 kms with topupevery3000kilometres tokeeptheenginefitandenvironmenthealthy Noise pollution Noise beyond a certain decibel is pollution Whether it is fro...

Page 17: ...amps Horns Tail Stop lamp Passlamp Headlamp Neutral indicator will befunctional Programmed FI Malfunction Indicator lamp illuminatesforfewsecondsandgoes OFF SIDE STAND IS ON scroll message will be dis...

Page 18: ...canbesuretheLCDdisplayisfunctioningproperly 2 Digital clock 1 Combination meter console 3 Tachometer 4 Real Time Mileage Indicator RTMI 5 Scroll message or 9 Speedometer 6 Tripmeter 8 Fuel gauge 7 Odo...

Page 19: ...ingdisplay ToselectTrip A Trip Bontripmeterorodometer Lamp glows when the engine is running Position lamp TaillampandLicenceplatelamparefunctional Indicates approximate quantity of fuel available in t...

Page 20: ...pending upontheridingcondition page20 Displays a scrolling Welcome Message when the ignition switch is turned ON if the side stand is up and Sign Off message whentheignitionswitchisturned OFF Displays...

Page 21: ...meadvancesfastwhenthebuttonis pressedandheld Tosetthehour pressResetButton 3 until thedesiredhourisdisplayed Press the Select Button 2 The minute displaystartsblinking SEL RESET km h AM PM TOTAL TRIP...

Page 22: ...n 3 until the desired minute The minute display will return to when is reached withoutaffectingthehourdisplay To end the adjustment press Select Button 2 or turn the ignition switch OFF The display wi...

Page 23: ...tion Press the SEL button 2 and turn the ignition switch to ON 5 under bars 3 st out of 6will be displayed with the 1 under barblinking SEL RESET 0 1 2 3 4 5 6 7 8 9 10 x1000r min x1000r min Press Res...

Page 24: ...turn the ignition switch to ON mode display will beflashed Press RESET button toselectmode Press SEL button 2 to SAVE the selected MODE and END SEL RESET 0 1 2 3 4 5 6 7 8 9 10 x1000r min x1000r min...

Page 25: ...When the ignition switch is turned ON the Real Time Mileage Indicator will temporarily show the digit which indicates that all the digital LCD segments are working The displayrangeisfrom km litre The...

Page 26: ...ch turn the key 1 to OFF position turn the handlebartowardsleftorright pushthekey downwards turn towards LOCK position Afterlockingtakeoutthekey FEATURES 1 Ignition key 1 Press the passing switch 1 to...

Page 27: ...e tank There should be no fuel 4 infillerneck 5 5 4 4 Filler Neck 5 Fuel 4 Horn switch Pressthehornswitch 4 tooperatethehorn 5 Clutch switch There is a clutch switch 5 provided for the safety of the r...

Page 28: ...due to ultra violet rays Petrol is extremely flammable and is explosive undercertainconditions Refillinawellventilated area with the engine stopped Do not smoke or allowflamesorsparksintheareawherethe...

Page 29: ...stallation 1 Helmet hanger 1 Clean your vehicle regularly It protects the surface finish Avoid cleaning with products that are not specifically designed for vehicle surfaces Inspect your vehicle very...

Page 30: ...operly Fitting Fasteners Check tighten if necessary STARTINGTHEENGINE Throttle Check for smooth opening and closinginallsteeringpositions page41 Steering Check for smooth action and for easymaneuverab...

Page 31: ...utions till 1000 km will reduce initial wear of engine components and increase its servicelife If the engine does not start wait for 10 seconds thenfollowsteps1 3again Your vehicle is designed to auto...

Page 32: ...re flammable materials such as dry grassorleavesdonotcomeincontactwiththe exhaust system when riding idling or parking yourvehicle 2 3 4 N 1 5 CAUTION Do not shift gears without operating clutch and w...

Page 33: ...ntitfromfallingover While parking on side stand ensure the vehicleisinfirstgear Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking yo...

Page 34: ...TENANCE A Well maintained vehicle is essential for safe economical and trouble free riding It will also helpinreducingairpollution To help you take proper care of your vehicle the following pages incl...

Page 35: ...o MotoCorp workshop knows your vehicle best and is fully equipped to maintain and repair it To ensure best quality and reliability it is recommended to use Hero MotoCorp genuinepartsforrepairandreplac...

Page 36: ...technicalinformationandistechnicallyqualified In the interest of safety we recommend that these jobs are carried out only by yourAuthorisedHero MotoCorp workshop Ensurethateachpaidserviceisavailedwit...

Page 37: ...trifugal Filter Oil Circulation Electric Starter WHICHEVER COMES FIRST ITEMS DURING FREE SERVICE PERIOD SERVICE st 1 nd 2 rd 3 th 4 th 5 AFTER FREE SERVICE ONCE IN EVERY 6000 9000 12000 15000 DAYS 500...

Page 38: ...t Bolts Fasteners Wheels Tyres Wheels Bearings Steering Head Bearing Front Suspension Oil I I I I I I I I I I I I I I I I I I I I I I I I I L A I A I I L A I A I I A I I I I I I I Side Stand Main Stan...

Page 39: ...d have square edges and the side electrode should notbeeroded Disconnect the noise suppressor cap 3 andremovethesparkplug 4 withthehelp ofboxwrenchprovidedinthetoolkit Cleandirtaroundthesparkplugbase...

Page 40: ...heoilremovethescrews 1 from thefrontleftandthebellypan 2 Reinstall the oil level dipstick with a new O ring checkforoilleaks Replace engine oil once in every 6000 Km 6monthswhicheverisearlier If requi...

Page 41: ...useseriousenginedamage Engine oil is a major factor affecting the performance and service life of the engine Non detergent vegetable or castor based racingoilsarenotrecommended Running the engine with...

Page 42: ...cous type paper filter whichhasenhancedfilteringefficiency Remove the pillion and rider seats page 25 Remove the left side rear grip by removing thenuts 1 andbolts 2 asmarked The air cleaner should be...

Page 43: ...ircleanerelement 9 7 Cover 8 Screw 9 Air cleaner element Install a new air cleaner element in the reverse orderofremoval 10 Wire mesh side 5 6 9 7 8 10 CAUTION Never wash or blow air to clean the elem...

Page 44: ...it becomes very dirty damagedonsurfaceoronthesealingarea 1 Free play 10 20 mm 2 Clutch lever 3 Dust cover 4 Lock nut 5 Adjuster 1 A B 2 4 3 5 Cableinspection The standard free play should be approxim...

Page 45: ...nance can cause premature wear or damage to the drive chain and sprockets The drive chain 1 should be checked and lubricated as part of the Pre ride inspection page 26 Under severe usage or when the v...

Page 46: ...d in the opposite direction of thechainrotation Damagedrollers Excessivewear Rotate the rear wheel slowly inspect the drive chain and sprockets for any of the followingconditions Drivechain Damagedorm...

Page 47: ...6 8kgf m If the drive chain slack is excessive when the rear axle is moved to the furthest limit of adjustment thedrivechainiswornandmust bereplaced Tightentherearaxlenutandsleevenut Checkthedrivecha...

Page 48: ...dryshoptowel Regular adjustment and lubrication as per the maintenance schedule would ensure highperformanceandlongerlife The drive chain is fitted with O rings between the link plates These O rings...

Page 49: ...MotoCorp workshop Brakefluidrecommended DoT3orDoT4 Front Master Cylinder 1 Location Front handlebar Rear Reservoir 1 A Location Inside rightsidecovernexttothebattery Wearlimit 4mm For replacement visi...

Page 50: ...a set Visit your AuthorisedHero MotoCorp workshop Brake pad wear depends upon the severity of usage type of riding road conditions Generally the pads wear faster on wet dirty roads Inspect the pads at...

Page 51: ...eload roadconditions Check the rear shock absorber by pushing hard downwards on rear grip while the vehicle is not parked on stand The suspension action should be smooth and thereshouldbenooilleakage...

Page 52: ...ely Recheck the wheel if the brake drags or if the wheel does not rotate freely TORQUE 5 9kgf m NOTE 49 If a torque wrench was not used for installation visit your Authorised Hero MotoCorp workshop as...

Page 53: ...wheel off the ground Removetherearaxlenut 1 alongwiththe rearaxlewasher 2 Tiltthevehicleandremovethewheel Tilt the vehicle and position the rear wheel betweentheswingarm Insert the disc between the pa...

Page 54: ...kingforce 1 Main stand 2 Side stand Parkthevehicleonthelevelsurface Checkthemain sidestandreturnspringfor damageorlossoftension Main Sidestandlubrication 2 1 Checkthesidestandforproperfunction Check w...

Page 55: ...mend that you visually check your tyres before every ride and use a gauge to measure air pressure at least once a month or any time you think the tyre pressure might be low Over inflated tyres make yo...

Page 56: ...treads side walls forwear damage foreignobjects Lookfor Cuts splitsorcracksinthetyre Replacethe tyreifyoucanseefabricorcord Excessivetreadwear Carefullyinspectthetyresforanydamage if thevehiclehitsap...

Page 57: ...cy repair always have the tyre inspected replaced at our authorised dealer andreplacethetyreifsuggested You should not exceed 70 km hour for the 1st 24 hours or 105 km hour at any time thereafter In a...

Page 58: ...cautionson page33 Location The battery 1 is located behind the right sidecover Specification MF Battery 12V 6Ah It is not necessary to check the battery electrolyte level or add distilled water as the...

Page 59: ...ro MotoCorp workshop if you see any symptom of battery discharge as earliest as possible to get the batterycharged Thebatteryhasatendencyto discharge rapidly if additional electrical accessoriesarefit...

Page 60: ...the positive terminal first thenthenegative terminal Check all bolts and other fasteners are secure 6 11 8 7 10 9 Remove the right side cover under screws 5 Removetherightsidecoverscrews 6 6 Right sid...

Page 61: ...to prevent accidentalshort circuiting Stop lamp switch The stop lamp switch 1 must be adjusted so that stop lamp glows when rear brake is applied The procedure for adjusting stop lampswitchisasfollow...

Page 62: ...as possible A defective catalytic converter contributes to air pollution and can impair your engine s performance Follow these guidelines to protectyourvehicle scatalyticconverter Keep the engine in...

Page 63: ...urfaces using a commercially available polish quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for automobiles Apply the polish or wax accordingtot...

Page 64: ...Check Spark Plug for Fouling Improper Electrode Gap Replace Spark Plug Adjust page 36 Spark Plug Gap 0 8 0 9 mm LooseContact Check for Poorly Connected or Loose Spark Plug Wire Secure Properly Check...

Page 65: ...Battery OK OK Check Bulbs Fuse Wrong Wattage Replace Fuse page 57 Weak Fuse Feeble Horn Sound or No Light Replace Bulbs 4 ELECTRICAL SYSTEM OK Check Connections Loose Secure Connections Consult Author...

Page 66: ...signs as theyhelpavoidaccidents TheirviolationcanbepenalisedundertheMotorVehicleAct Mandatory Speed Limit No Hand Craft No Pedestrians No Right Turn No U Turn Overtaking Prohibited No Parking Length L...

Page 67: ...information about road directions are maps of specific destinations On highways they provide information about the location of public telephones restaurants hospitals parking petrol pumps resting pla...

Page 68: ...ervices from the Hero MotoCorp s authorized workshop as per the recommended schedule to be eligible for warranty benefits Each paid service should be availed within 90 days from the date of previous s...

Page 69: ...ormisalignment bend 10 Ifanymaintenance repairsrequiredduetobadroadconditionsormisuseof KarizmaZMR vehicle 11 Ifanydefectcropsorrepairsneededasaresultof meetingtosomeaccident KarizmaZMRvehicle 9 Ifany...

Page 70: ...Customersaredeemedtohaveread understoodandagreedtotheseconditionsatthetimeofpurchaseofthevehicle 3 12 The leviableonthebatteryunderrepairorreplacementwillbebornebythecustomer applicabletaxeswhichis 9...

Page 71: ...ards as specified in S No of table in item i of sub rule 2 of Rule 115 of Central Motor Vehicles Rules 5 1989 which stipulates that Idle CO Carbon monoxide emission limit for all two wheeled petrol dr...

Page 72: ...lfunctionIndicatorLamp MIL Warrantytermsandconditions Procedureofremoving installingseat sidecoversandfueltanklid Tubelesstyreandimportanceoftyrepressure Waterwashprecautions LocationofToolKit First A...

Page 73: ...Value for money CONSEQUENTIAL DAMAGES ON USING NON GENUINE PARTS Clutch Plate Affects fuel efficiency Material used is inferior Poor acceleration Damages other parts of clutch like clutch center and...

Page 74: ...ine performance Affects fuel efficiency Poor engine performance Higher emission level Frequent stalling of engine Affects fuel efficiency Poor braking efficiency Rider safety an issue Discs Drumwearou...

Page 75: ...2623774 2623775 E mail chandigarh heromotocorp com HeroMotoCorpLtd S C O 367 368 FirstFloor Sector 34A Chandigarh 160022 India Tel 0135 2714661 2713662 2714663 E mail dehradun heromotocorp com HeroMot...

Page 76: ...heromotocorp com HeroMotoCorpLtd D NO 54 11 18E 2ndFloor SaiOddesseyBuilding OppExecutiveClub NearNH 5 HeroMotoCorpLtd 3 6 289 3rdFloor KareemManzil Hyderguda Hyderabad 500029 India Tel 91 40 2322373...

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