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PREFACE

Your vehicle is conforming to latest (Bharat stage-

) regulation for emission, safety & 

VI 

norms

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

environment friendly in nature.

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

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.

We  at 

Hero  MotoCorp

,

  are  committed  to  demonstrate  excellence  in  our  environment 

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

To 

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

compatibility,  comply  with 

  and 

all  applicable  legislation  including  environment  legislation

strengthen the green supply chain. 

Thank you for selecting a 

 

. We wish 

Hero MotoCorp

X

TREME 160R PROGRAMMED FI

you many miles of continued riding pleasure in the years ahead.

Your Authorised 

 dealer will be glad to provide further information or 

Hero  MotoCorp

assistance and is equipped to handle your future service needs.

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

 

. Please take time to read it carefully. 

Hero MotoCorp

XTREME 160R PROGRAMMED FI

As  with  any  fine  machine,  proper  care  and  maintenance  are  essential  for  trouble-free 

operation and optimum performance.

Summary of Contents for XTREME 160R PROGRAMMED FI

Page 1: ...mitted 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 innovat...

Page 2: ...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 WRIT...

Page 3: ...per Ministry of Road Transport Highways Government of India vide Notification G S R 540 E Hemostatic agent is excluded from first aid kit in reductionfromexistingkiteffectivefrom31stAugust2020 ADDEND...

Page 4: ...NUT BOLTS FASTENERS 58 EVAPORATIVE EMISSION CONTROL SYSTEM 63 POLISHING OF VEHICLE 63 BASIC TROUBLESHOOTING 64 HERO GENUINE PARTS ZONAL REGIONAL AREA OFFICES VEHICLE IDENTIFICATION 1 VEHICLE VIEWS 2...

Page 5: ...A KC01AA Engine Description Year of Manufacturing Assembly Plant Month of Manufacturing Serial Number Duringregistrationofthevehicle VINandEngineNo mayberequired Fordealingwithlegal insurancedepartmen...

Page 6: ...rn signal lamp 3 Right position lamp 4 Front visor 5 Headlamp Low beam 7 Front left turn signal lamp 8 Headlamp High beam 6 Left position lamp 1 3 2 Accessories and features shown may not be part of s...

Page 7: ...and features shown may not be part of standard fitment REAR VIEW 2 Left rear turn signal lamp 1 Rear reflex reflector 3 Tail stop lamp 5 Right rear turn signal lamp 4 Licence plate lamp 6 Rear fender...

Page 8: ...gswitch 9 Headlampdimmerswitch 10 Hazardswitch 11 Setbutton 12 LCD panel of meter console refer instruments and indicators page 15 for fuel gauge speedometer and other featuresofconsole 15 Modebutton...

Page 9: ...eflex reflector 2 Throttle body ECU inside 3 Starter motor 4 Gear shift pedal 7 Rider foot rest 6 Side stand 9 Saree guard 5 Main stand 8 Pillion foot rest 13 Side stand switch 10 Rear grip 11 Seat lo...

Page 10: ...Rear master cylinder 3 Brake pedal 4 Kick starter pedal 5 Oil level dipstick 7 Front disc 6 Front caliper assembly 8 Fuel tank cover 10 Fuse box inside 11 Document Tool kit compartment 12 Rear calipe...

Page 11: ...g gap Valve clearance Idle speed Front suspension Rear suspension Caster angle 1 3 litres at disassembly and 1 09 litres at draining 12 litres DoT 3 or DoT 4 1 kW 8 00 1 2 5 500 r min 1 N m 00 4 65 50...

Page 12: ...mesh 3 077 40 13 1 789 34 19 1 304 30 23 1 1 22 20 0 958 23 24 MF Battery 12V 4 Ah ETZ5 120 W 5000 r Single phase full DC system min LED LED LED Module illuminated LCD LED LED LED LED LED Module illum...

Page 13: ...and handles and to become accustomed to the vehicle ssizeandweight Always wear a helmet Beforeridingyourvehicle VEHICLE SAFETY Pushing the limits is another major cause of vehicle accidents Never ride...

Page 14: ...long sleeve shirt or jacket whenever you ride Take care of loose hanging clothes while solo pillion riding Although complete protection is not possible wearing proper gear can reduce the chance of in...

Page 15: ...ormation in the Owner s Manuals that are still with them _______________________________________________________ PHONE NO _____________________________________ ADDRESS ________________________________...

Page 16: ...start kill switchisin ON position It is suggested to go through the do s dont s of ABS page 29 and practice your ABS vehicle initially in low traffic condition unless you are thoroughly familiar with...

Page 17: ...ASO MA engine oil recommended by and make sure you change it every 6000 km with top Hero MotoCorp upevery3000kilometres tokeeptheenginefitandenvironmenthealthy Fuel saving reduce pollution Switch OFF...

Page 18: ...gauge passing switch position lamp programmed FI malfunction indicator lamp MIL illuminates continuously neutral indicator hazardswitchwillbefunctional Key cannot be removed Engine cannot be started a...

Page 19: ...the next service is due page 19 Speedometer Indicates riding speed Odometer Shows accumulated distance travelled page 20 Tripmeter A B Shows the distance travelled during a trip after setting tozero...

Page 20: ...aking system ABS indicator This indicator normally comes on for approx 1 8 seconds whentheignitionswitchisturned ON thenkeeps blinking until the vehicle attains speed of 5 km h If there is a problem w...

Page 21: ...tton 2 Set button Digital clock 1 shows hour and minute To adjustthetime proceedasfollows Turntheignitionswitch ON Press and hold set button 2 and mode button 3 simultaneously for more than 2 seconds...

Page 22: ...A 0 1 2 3 4 5 6 7 8 9 10 11 AM PM km h E F SERVICE km TRIP ODO x 1000 RPM S M Thetimeadvancesfastwhenthebuttonis pressedandheld If the tripmeter exceeds km it will return to km automatically When trip...

Page 23: ...aximumscaleonthemeterconsoleoncethe ignition switch is turned ON If all the segments are displayed it means fuel quantity inthefueltankis12 0litres If only one segment 3 is displayed and blinks this i...

Page 24: ...ignallampswitch 2 Turnsignalswitch 3 Hornswitch 4 Hazardswitch 1 Headlampdimmerswitch 3 Hornswitch To turn OFF the indicator lamps in hazard switch ON condition press the hazard switchagain 4 Hazardsw...

Page 25: ...dstart killswitch 1 Electric starter 2 Integrated start kill switch 3 Engine stop ON OFF 2 5 Passing switch 6 Clutch switch 6 For engine stop operation 3 integrated start kill switch 1 has two positio...

Page 26: ...ally indicator goes OFF once vehicle speed exceeds 5km h 1 Side stand indicator 2 Side stand switch 3 Side stand spring 3 1 A side stand switch 2 is provided in the side stand when the side stand is d...

Page 27: ...urehasfollowingfunctions It prevents starting the engine when transmission is in gear irrespective of clutch lever operation and side stand is down INSPECTION FLOW DIAGRAM 2 Then shift the transmissio...

Page 28: ...rt key 2 turn it clockwise andliftopenthecap 3 2 1 WARNING Regularly inspect the functionality of Side stand engine kill feature and in case of any malfunction visit Authorised Hero MotoCorp workshop...

Page 29: ...k and top up engine oilifrequired page37 Checkforleaks ABS indicator Check ABS indicator for properfunctioningofABS page22 Inspect your vehicle every day before you start the engine The items listed h...

Page 30: ...operation Adjustfreeplayifnecessary page42 Drive chain Check condition and slackness page44 Lubricateifnecessary Lamps Horn Check that headlamp position lamps tail stop lamp turn signal lamps indicato...

Page 31: ...ll switch NOTE If MIL remains ON even if the vehicle is started there is an abnormality in the programmed FI system It is recommended to reduce the speed and drive to the Authorised Hero MotoCorp work...

Page 32: ...ing While the engine is idling press the clutch lever and depress the gearshift pedal st downwards using the toe to shift into 1 gear Slowly release the clutch lever and at the same time gradually inc...

Page 33: ...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 safestopoftheve...

Page 34: ...to preventoverturning While parking on side stand engage the first gear The tool kit 1 is located below the seat in the rear Some emergency repairs minor adjustment and parts replacement can be perfor...

Page 35: ...nvolved in a crash be sure that you visit your Authorised Hero MotoCorp workshop for detailedinspections WARNING Always follow the inspection and maintenance recommendations and schedulesinthisowner s...

Page 36: ...he instruction before you begin and make sure you have the tools and skills required Burns from hot parts Let the engine and exhaust system cool before touching To help prevent the vehicle from fallin...

Page 37: ...nicalinformationandistechnicallyqualified Note 1 Athigherodometerreadings repeatthefrequencyintervalestablishedhere Note 4 Visit Authorised Hero MotoCorp workshop for inspection cleaning lubrication a...

Page 38: ...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 KM Note 1 500 750 O C C I I I I I I I I I I I I C C C C C C I...

Page 39: ...Converter 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 I I I I I I I E I E I E Wheels Bearings I I I I I I Rear Suspension Evaporative Emission Control System I I I I I I Note 6...

Page 40: ...he side electrode should not be eroded Discard the spark plug if there is apparent wear or if the insulator is crackedorchipped Make sure that the spark plug gap is 0 8 0 9 mm using a wire type feeler...

Page 41: ...ipstick 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 theoilleveldipstick ENGINEOIL BRAND Hero4Tplus GRADE SAE10...

Page 42: ...ately of recommended grade oil during oil change whenrightcrankcasecoverisnotremoved Reinstall the oil level dipstick with a new O ring Start the engine and allow it to idle for few minutes 2 1 1 Drai...

Page 43: ...bolts 2 Clutch cable 3 Kick start pedal 4 Exhaust muffler 5 Kick stopper with side stand 6 Right crankcase cover Remove centrifugal filter cover 10 clean the centrifugal filter 11 with non flammable...

Page 44: ...ver 1 2 CAUTION wet paper pleated Never wash or clean the type filter Replace filter element once in every15000km Replace it earlier if it becomes very dirty damageonsurfaceoronthesealingarea Installt...

Page 45: ...derheadcover This condition can be determined by moving the rocker arms If they are free it is an indication that the valves are closed and the piston is in compression stroke If they are tight the va...

Page 46: ...justment may be required if the vehicle stalls when shifting into gear or tends to creep or if the clutch slips causing accelerationtolagbehindenginespeed After tightening the lock nut check the clear...

Page 47: ...k nut 4 Clutch cable adjusting nut A Decrease free play B Increase free play 3 4 Cableinspection THROTTLEOPERATION Check for smooth rotation of the throttle grip fromthefullyopentothefullyclosedpositi...

Page 48: ...idway between the sprockets Move the drive chain up and down by hand and chain slack should be adjusted to 20 25 mm vertical movement byhand 2 3 Drive chain slack should be adjusted at your Authorised...

Page 49: ...p k e S t l T a e m e r t o h N o r p c S k d e e t g T a ee m t a h D CAUTION Always replace the drive chain and sprockets as a set Otherwise the new part will wear prematurely Adjustment Drive chai...

Page 50: ...thastobereplaced Checkthedrivechainslackagain Spray a commercially available chain cleaner for cleaning the drive chain over its entirelength CleaningandLubrication park the vehicle on its Turn the en...

Page 51: ...rear wheel with one hand to prevent the possibility of your finger being trapped betweenthechainandsprocket If the chain is excessively dirty it should be removed and cleaned before lubrication For yo...

Page 52: ...rDoT 4 Location Nearpillionfootrest Brakefluidrecommended reservoir parallel to the ground The level decreases gradually due to piston movement tocompensatepadwear Iftheleveldecreases abruptly check f...

Page 53: ...both pads as a set Visit your Authorised Hero MotoCorp workshop forthisservice c Brakepadwear Frontbrake Brake pad wear depends upon the severity of usage type of riding road conditions Generally the...

Page 54: ...for freewheelrotationwhenreleased 2 B A 4 A Decrease free play CW B Increase free play ACW 3 3 Adjusting nut 4 Brake joint pin CW Clockwise ACW Anticlockwise 3 Adjusting nut 4 Brake arm pin X A Cut o...

Page 55: ...ock absorber by pushing hard downwards on rear grip while the vehicle is not parked on stand The suspension action should be smooth and thereshouldbenooilleakage Solorider 3rdposition Rearshockabsorbe...

Page 56: ...front axle nut 3 remove the axle 4 andwheel 5 CAUTION Do not operate front brake lever when the wheelisremoved 3 Axle nut 4 Axle 5 Wheel 4 3 5 Remove the side collars 6 from both sides fromthewheel 6...

Page 57: ...thewheel Refersafetyprecautionson page32 Movethecaliperassembly 5 upwards b Rearwheel Disctype Removal Installation Install the side collar 1 to the right side of thewheelhub Tilt the vehicle and posi...

Page 58: ...tothespecifiedtorque Remove the rear brake adjusting nut 1 and disconnect the brake rod 2 from the brake arm 3 by pushing down the brake pedal Pullouttheaxle 5 andcollar 6 Removethewheel 1 7 6 5 3 2 4...

Page 59: ...uctions in this owner s manual regardingtyresinflationandmaintenance WARNING Over inflated tyres make your vehicle ride harshly are more prone to damage from road hazards andwearunevenly Always check...

Page 60: ...ct the performance CAUTION Bumpsorbulgesinthesideofthetyreorthe tread Replacethetyreifyoufindanybumps orbulges Lookfor Cuts splits or cracks in the tyre Replace the tyreifyoucanseefabricorcord Excessi...

Page 61: ...ur at any time thereafter In addition you may not be able to safelycarryasmuchloadaswithanewtyre Tyrereplacement The tyres that were installed on your vehicle were designed to match the performance ca...

Page 62: ...lydeflate NUTS BOLTS FASTENERS Tighten bolts and nuts at regular interval showninthemaintenanceschedule Check that all chassis nuts and bolts are tightenedtocorrecttorquevalues Check that all cotter p...

Page 63: ...hebatteryonceinamonth Battery charging If in case your vehicle is not used for more than a month remove the battery fully chargeandstoreinacoolanddryplace Always visit your Authorised Hero MotoCorp wo...

Page 64: ...e veterminal FUSEREPLACEMENT Thefusebox A isbelowtheseat Checkallfastenersaresecure Sparefuse 2 15A 10A Mainfuse 1 15A 10A 10A 10A 4 ve terminal 5 ve terminal 6 Battery clamp bolt 7 Battery clamp 4 5...

Page 65: ...gases Keep sparks flames cigarettesaway B CAUTION Do not attempt to start or ride the vehicle without a charged battery it can cause fusing of the bulbs and permanent damage tocertainelectricalcompone...

Page 66: ...A to advance switch timing or in direction B to retardswitchtiming A B 1 Stoplampswitch A Advance 2 Adjustingnut B Retard 2 WARNING An improperly adjust headlamp may blind oncoming rider driver or it...

Page 67: ...SION CONTROL SYSTEM This vehicle is equipped with an evaporative emission control system to meet emission standards During warm weather the petrol vapours which contain HC evaporates easily into the a...

Page 68: ...A Integrated Start Kill Switch Consult Authorised Hero MotoCorp Workshop Turn to ON position ON position Key ON position Check for operating sound of fuel pump Broken fuel pump wire connector Refill t...

Page 69: ...toCorp Workshop 65 OK Check air cleaner element OK Replace Dirty Leakage Consult Authorised Workshop Hero MotoCorp 2 ENGINE STARTS BUT STALLS Consult Authorised Workshop Hero MotoCorp Check fuel lines...

Page 70: ...OK Check bulbs Fuse wrong wattage Replace fuse Weak Fused Feeble Horn Sound or No Light Replace bulbs 4 ELECTRICAL SYSTEM OK Check connections Loose Secure connections Consult Authorised Hero MotoCorp...

Page 71: ...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 72: ...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 73: ...m the advised that the purchaser avails 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...

Page 74: ...rease gasketetctobeusedduringfreeservicesand orwarrantyrepairs 2 Ifanyotherengineoilwhichis noncompatiblewithproductisusedotherthanSAE10W30SLGrade JASOMA2 3 To normal wear tear components including bu...

Page 75: ...nce from the date of sale of the original battery as stated in the originalwarrantycard 7 This warranty does not cover damage to the battery caused by faulty electrical systems incorrect charging and...

Page 76: ...clepurchase c The method s of examination to determine the warranty conditions of the emission warranty related component will be at the sole discretion of and or Channel Partners service center and r...

Page 77: ...lty levied on you on account of non compliance with the emission standards m Hero MotoCorp Ltd All decisions regarding emission warranty settlement shall be taken by and shall be final binding on all...

Page 78: ...Value for money CONSEQUENTIAL DAMAGES ON USING NON GENUINE PARTS Clutch Plate Affects fuel efficiency Material used is inferior Damages other parts of clutch like clutch center and outerclutch Poor a...

Page 79: ...ine performance Affects fuel efficiency Higher emission level Poor engine performance Frequent stalling of engine Affects fuel efficiency Poor braking efficiency Rider safety an issue Discs Drumwearou...

Page 80: ...2623774 2623775 E mail chandigarh heromotocorp com HeroMotoCorpLtd S C O 367 368 FirstFloor Sector 34A Chandigarh 160022 India HeroMotoCorpLtd KapoorTowers PlotNo 284 15 B RajpurRoad Dehradun 248001 I...

Page 81: ...H 5 Vijayawada 520008 AndhraPradesh India Tel 91 866 2546859 2546860 E mail vijayawada heromotocorp com HeroMotoCorpLtd 3 6 289 3rdFloor KareemManzil Hyderguda Hyderabad 500029 India Tel 91 40 2322373...

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