Introduction

1. This GMI is guide to the basic operation and maintenance of new Motor Cycle HERO Honda CD-100. Please take time to read it carefully, as with fine machine proper care and maintenance are essential for trouble-free operation and optimum performance.

2. To prolong the life of your vehicle and reduce maintenance cost, the periodic maintenance must be carried out according to the ‘periodic maintenance schedule. Periodic maintenance is essential for preventing trouble and accident to ensure your satisfaction and safety. Daily care and inspection is essential for prolonging the operating life of the vehicle and for safe driving. It also reduces the wear and tear of vehicle, prolongs its life, give more mileage, if failure of the guide lines it can result in personal injury or serious damage to the vehicle. All information and instruction in this GMI is base on the latest Owner’s manual and service booklet.

AIM:- The instruction are issued as guide lines for schedule of preventive maintenance, lubrication of Motor Cycle Hero Honda CD100 manufactured by Hero Honda Motors Ltd for regular attention to keep the vehicle in good mechanical condition and it must be strictly followed.

Action by

	User Unit:
a)	To carry out periodic inspection and monitor regular/periodical maintenance as laid down in this instruction and record the tasks done in the log book.
b)	Field Wksp (GREF)
	i)	To carry out and monitor, maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instructions and to check the record of maintenance including lubrication.
	ii)	To advise the user unit in respect of any lapses noticed.
c)	Mobile maintenance team
	To ensure that proper maintenance is carried out and report accordingly to Task Force Commander and OC Fd Wksp for necessary action.

3. Details: The details of maintenance and lubrication with their periodicity are as under:-

a)	Safe riding rule	:	Appx ‘A’
b)	Daily inspection	:	Appx ‘B’
c)	Basic Trouble shooting	:	Appx ‘C’
d)	Technical data	:	Appx ‘D’
e)	Lubricants	:	Appx ‘E’
f)	Maintenance schedule	:	Appx ‘F’

5. Please ack receipt.

				Sd x x x x
				(VK Sharma)
				EE (E&M)
				Dy Dir (Tech)
Distribution				For Dir Gen Border Roads
Normal

				Appx- ‘A’
SAFE RIDING RULES

1.	Always make a pre-ride inspection before you start the engine, you may prevent an accident or equipment damage.
2.	Many accidents involve inexperienced riders. Make sure you are qualified before you ride. Never lend your motor cycle to an inexperienced rider.
3.	Make yourself conspicuous to help avoid accident that wasn’t your fault.
	a)	Wear bright or reflective clothing.
	b)	Don’t ride in another motorist’s ‘Blind spot’.
	c)	Don’t ride on the road way shoulder.
4.	Obey all national and local laws and regulations.
5.	Excessive speed is a factor in many accidents, obey the speed limits and never travel faster than condition warrant.
6.	Do not let other motorist’s surprises you, use extra caution at intersections, parking lot entrances and exits, and drive-ways.
7.	Never shift gear without applying the clutch.
8.	Most of the motor cycle accident – fatalities are due to head injuries. Always wear a good quality helmet. You should also wear a face shield or goggles as well as boots, gloves and protective clothing.
9.	Do not wear loose clothing which could catch on the control levers, kick starter, foot rests or wheels.
10.	Keep cargo and accessory weight low and close to the centre to the motor cycle load weight equally on both sides to minimize in balance. If weight is located away from the motor cycles centre of gravity, handling is affected.
11.	All cargo and accessories must be secured for stable handling.
12.	Do not attach large or heavy items to the handle bars, front forms or fender causing unstable handling ort slow steering response may result.

						Appx ‘B
DAILY INSPECTION
1.	Inspect your vehicle every day before you start the vehicle engine.
2.	Check engine oil level and top up if necessary.
3.	Check fuel level.
4.	Check front and rear brake.
5.	Check tyre pressure and condition. Proper air pressure will provide maximum traction, stability, riding and tyre life.
6.	Check drive chain condition and slackness adjust and lubricate if necessary.
7.	Check throttle for smooth opening and closing in all steering positions.
8.	Check all lights and horn for functioning properly.
9.	Check the air suction valve and ensure the proper tube connections correct.
10.	When the engine is cool, to start the engine with the help of choke.
11.	When warm engine, choke is not required for start the engine.
12.	Change the engine oil with the engine warmed up.
13.	Remove the oil filter screen and wash it in clean petrol.
14.	Always use NGK, CR7HSA & Mico UR4A Spark plug.
15.	Clean any dirt from around the spark plug base.
16.	Air should be serviced at regular intervals, when riding in dirty areas.
17.	Check cable for smooth rotation of the throttle grip from the fully open to the fully closed position.
18.	Check valve clearance at the specified intervals.
19.	Check the clutch free play and adjust if necessary.
20.	Service life of the drive chain is dependent upon proper lubrication and adjustment. It should be checked and lubricated as part of the pre-ride inspection under service usages or when motor cycle is ridden in unusually dust areas.
21.	Inspect the sprocket teeth for wear or damage. If the drive chain and sprocket are excessively worn or damaged they should be replaced. Never use a new chain with worn sprocket since this will result in rapid chain wear.
22.	Check the front and rear brake adjust if necessary.
23.	When checking battery electrolyte level or adding distilled water, make sure that Breather tube is connected to the battery breather outlet.
24.	Always use distilled water in the battery. Tap water may shorten the service life of the battery.
25.	Never use a fuse with a different rating from that specified.

							Appx- ‘C’
BASIC TROUBLE SHOOTING
1.	No fuel is getting to the carburetor		1. Inspect fuel in the fuel tank: refill the fuel tank necessary. 2. Clear fuel tube is clogged.
2.	Air filter choked		Clean the air filter.
3.	Air suction valve		Check and ensure for proper tube connections.
4.	Ignition system		Make sure that the ignition switch is in ‘ON’ position and the high tension wire connection.
5.	Try spark plug test, If no sparking, spark plug clogged or porcelain part cracked		1. Check loose connection of wire, terminals. 2. Clean the spark plug, or replace the spark plug.
6.	Engine start but stalls		1. Check the choke lever is in ‘fully open’ position and fuel valve is open. 2. Consult your authorized dealer if the trouble persists.
7.	poor pick up
	a) Air filter clogged		Clean the air filter.
	b) Spark plug loose in cylinder head		Tighten the spark plug securely.
	c) Clutch slipping		Adjust the clutch lever free play.
	d) Brakes binding		Adjust the brake lever/pedal free play.
	e) Too low tyre pressure		Fill correct pressure.
	f) Fuel leakage		Check fuel lines.
	g) Worn out spark plug		Replace the spark plug.
	h) Faulty carburetor, fuel gauge improper valve timing poor compression		Check and over haul carburetor, replace fuel gauge and set the valve timing
8.	Abnormal noise from engine, drive chain, front and rear suspension poor braking		Check engine, drive chain, front and rear suspension and brakes and rectify the all faults properly.
9.	Electric system
	a) Feeble horn sound		Check the battery connection and clean the battery terminal.
	b) No light		Check the fuse / bulb, if found faulty replace them.
	c) Terminals loose or wrongly connection		Check the terminals and correct it properly.

					Appx ‘D’

TECHNICAL DATA

DIMENSIONS
Overall length	:	1925.
Over all width	:	720.
Over all height	:	1040.
Wheel base	:	1220.
Weight	:	107 Kg.
CAPACITY
Engine oil	:	0.9 Ltr.
		0.75 Ltr at draining.
Fuel tank	:	10.1 Ltr.
Fuel reserve capacity	:	1.3 Ltr.
Front fork oil at disassembly	:	82.5 ml.
ENGINE
Bore stroke	:	50x49.5 mm.
Compression ratio	:	8.8:1.
Displacement	:	97.2 cm².
Spark plug	:	NGK: CR&HAS, MICO UR4 A.
Valve clearance	:	IN: 0.05mm EX: 0.05mm.
Chassis and suspension Caster	:	26⁰.
Trail	:	80mm.
Tyre- front	:	2.5-80-4PR.
rear	:	2.75-18-6PR.
POWER TRANSMISSION
Primary reduction	:	3.722
Final reduction	:	3.000
Gear ratio - 1^st	:	3.181
2^nd	:	1.70
3^rd	:	1.238
4^th	:	0.958
ELECTRCAL
Battery	:	12V 2.5AH.
Alternator	:	Fly wheel AC generator.
LIGHTS
Head light	:	12V 25W.
Tail/ Stop light	:	12V 5/10W.
Turn signal	:	12V 10W.
Meter light	:	12V 3.4W.
Neutral indicator	:	12V 3.4W.
Tur signal indicator	:	12V 1.7W.

			Appx- ‘E’
LUBRICANTS
ENGINE OIL
SAE 20W 40 (SF/SG grade) “HERO HONDA 4 t Plus” OR
SAE 20W 40 (SC grade) Servo super IOC’ AOTOMOL’
GEAR OIL – SAE 80W 90

								Appx- ‘F’
MAINTENANCE SCHEDULE
Items	Kms
Items	500 to 750	2500 to 2800	5000 to 5500	7000 to 7500	9000 to 9500	11000 to 11500	13000 to 13500		15000 to 15500	17000 to 17500
Check Fuel line	x	x	x	x	x	x	x		x	x
Check throttle operation	x	x	x	x	x	x	x		x	x
Check carburetor	x	x	x	x	x	x	x		x	x
Check air cleaner filter Clean & replace	x	x	x	x	x	Replace every 30,000 Kms
Check spark plug	x	x	x	x	x	x	x		x	x
Check valve clearance	x	x	x	x	x	x	x		x	x
Check engine oil level and Top up if necessary	x	x	x	x	x	Engine oil should be changed every 4000 Kms in case 4T Plus is used.
Check engine oil strainer screen	x		x		x		x			x
Check engine oil rotor filter	x		x		x		x			x
Check oil pump for proper function	x		x		x		x			x
Check drive chain for looseness & breakage	x	x	x	x	x	x	x		x	x
Check battery electrolyte	x	x	x	x	x	x	x		x	x
Check brake shoe wear	x	x	x	x	x	x	x		x	x
Check brake system for proper function		x		x		x			x
Check brake light switch	x	x	x	x	x	x	x		x	x
Check head light focus	x	x	x	x	x	x	x		x	x
Check clutch transmission	x	x	x	x	x	x	x		x	x
Check side stand & main stand	x	x	x	x	x	x	x		x	x
Check fasteners	x	x	x	x	x	x	x		x	x
Check wheel/ tyres	x	x	x	x	x	x	x		x	x
Check steering head bearing	x	x	x	x	x	x	x		x	x
Check front suspension	x	x	x	x	x	x	x		x	x
				______

BRO TECHNICAL

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