EasyManua.ls Logo

HERO DAWN-150 User Manual

HERO DAWN-150
300 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
A FEW WORDS ABOUT SAFETY
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Hero MotoCorp, must determine the risks to their personal safety and the safe
operation of the vehicle.
If you need to replace a part, use genuine Hero MotoCorp parts with the correct
part number or an equivalent part. We strongly recommend that you do not use
replacement part of inferior quality.
FOR YOUR CUSTOMER’S SAFETY
Proper service and maintenance are essential to the customer’s safety and the
reliability of the vehicle. Any error or oversight while servicing a vehicle can result in
faulty operation, damage to the vehicle, or injury to others.
FOR YOUR SAFETY
Because this manual is intended for the professional service technician, we do not
provide warnings about many basic shop safety practices (e.g., Hot parts-wear
gloves). Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can arise in
performing service and repair procedures. Only you can decide whether or not you
should perform a given task.
IMPORTANT SAFETY PRECAUTION
Make sure you have a clear understanding of all basic shop safety practices and
that you are wearing appropriate clothing and using safety equipment. When
performing any service task, be especially careful of the following:
Read all of the instructions before you begin and make sure you have the tools, the replacement or repair parts and the skills
required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire of explosion, be careful
when working around gasoline or batteries.
Use only a nonflammable solvent, not gasoline, to clean parts.
Never drain or store gasoline in an open container.
Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an
unsafe condition that can cause your
customer or others to be seriously hurt or
killed. Follow the procedures and
precautions in this manual and other
service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in
this manual carefully.
!
WARNING
!
WARNING
Question and Answer IconNeed help?

Do you have a question about the HERO DAWN-150 and is the answer not in the manual?

HERO DAWN-150 Specifications

General IconGeneral
Displacement149.2 cc
Bore x Stroke57.3 mm x 57.8 mm
Compression Ratio9.1:1
Fuel SystemCarburetor
Transmission5-speed
ClutchWet multi-plate
Frame TypeTubular diamond
Front SuspensionTelescopic hydraulic fork
Rear SuspensionDual shock absorbers
Front BrakeDisc
Rear BrakeDrum
Fuel Tank Capacity12.5 liters
Engine TypeSingle cylinder, 4-stroke, air-cooled

Summary

A FEW WORDS ABOUT SAFETY

SERVICE INFORMATION

Manual intended for qualified technicians; risks of improper service.

FOR YOUR CUSTOMER’S SAFETY

Proper service ensures customer safety and vehicle reliability.

FOR YOUR SAFETY

Basic shop safety practices for technicians.

IMPORTANT SAFETY PRECAUTION

Clear understanding of practices, appropriate clothing, and safety equipment.

1. GENERAL INFORMATION

GENERAL SERVICE PRECAUTION

Replace gaskets, O-rings, etc. with new ones; tighten bolts in a criss-cross pattern.

FEATURE

Highlights key features of the motorcycle's engine, frame, brakes, etc.

GENERAL SAFETY

Safety precautions for carbon monoxide, gasoline, hot components, battery, and electricals.

SPECIFICATIONS

Detailed specifications for frame, engine, brakes, suspension, etc.

SERVICE LIMIT

Maintenance service limits for components like throttle grip, spark plug, etc.

ENGINE TORQUE VALUE

Torque values for maintenance, lubrication, and cylinder head.

SPECIAL TOOLS

List of special tools with their part numbers and applications.

2. BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION

Warning about hot exhaust system and general service notes.

TORQUE VALUES

Torque specifications for exhaust muffler components.

TROUBLESHOOTING

Common issues and probable causes related to the exhaust system.

SEAT

Steps to remove and install the seat.

FUEL TANK

Steps to remove and install the fuel tank.

FRONT FENDER

Steps to remove and install the front fender.

EXHAUST MUFFLER

Steps to remove and install the exhaust muffler.

REAR SHOCK ABSORBER

Steps for removing and installing the rear shock absorber.

3. MAINTENANCE

SPECIFICATIONS

Maintenance specifications for throttle grip, spark plug, valve clearance.

MAINTENANCE SCHEDULE

Detailed schedule of maintenance tasks at various service intervals.

VALVE CLEARANCE INSPECTION

Procedure for checking and adjusting valve clearance.

OIL CHANGE

Steps for draining and refilling engine oil, including torque values.

DRIVE CHAIN SLACK INSPECTION

How to inspect and adjust drive chain slack.

BRAKE SHOES

Replacing front and rear brake shoes based on wear indicators.

4. LUBRICATION SYSTEM

SPECIFICATIONS

Engine oil capacity and recommended oil specifications.

TROUBLESHOOTING

Common problems like low oil level, contamination, and low pressure.

OIL PUMP REMOVAL

Steps for removing the oil pump from the engine.

INSPECTION

Inspecting oil pump components and checking clearances.

LUBRICATION POINTS

Diagram showing lubrication points for control cables and bearings.

5. FUEL SYSTEM

SPECIFICATIONS

Fuel system specifications including tank capacity and carburetor details.

TROUBLESHOOTING

Diagnosing engine start issues, lean/rich mixture, and poor performance.

AIR CLEANER HOUSING

Steps to remove the air cleaner housing.

CARBURETOR

Steps to remove and disassemble the carburetor.

FLOAT

Removing and inspecting the float and float pin.

6. ENGINE REMOVAL/INSTALLATION

SPECIFICATIONS

Engine oil capacity specifications.

TORQUE VALUES

Torque values for engine mounting bolts and plates.

ENGINE REMOVAL

Steps to disconnect wires, cables, and remove nuts.

ENGINE INSTALLATION

Steps for installing the engine, including mounting bolts and torque.

7. CYLINDER HEAD/VALVES

SPECIFICATIONS

Specifications for cylinder compression, valve clearance, and rocker arm.

TROUBLESHOOTING

Diagnosing compression issues and excessive noise.

CYLINDER COMPRESSION

Procedure for measuring cylinder compression and interpreting results.

CYLINDER HEAD COVER

Steps to remove and install the cylinder head cover.

CAMSHAFT HOLDER DISASSEMBLY

Removing camshaft set plate, camshaft, and rocker arm shaft bolts.

VALVE SEAT REFACING

Refacing valve seats using cutters to correct wear.

8. CYLINDER/PISTON

SPECIFICATIONS

Specifications for cylinder I.D., taper, warpage, and piston clearances.

TROUBLESHOOTING

Diagnosing compression issues, smoke, noise, and overheating.

CYLINDER INSPECTION

Inspecting cylinder wall for scoring and wear.

PISTON/PISTON RING INSPECTION

Inspecting piston and rings for cracks, wear, and clearances.

PISTON RING INSTALLATION

Cleaning and installing piston rings onto the piston.

9. CLUTCH/GEARSHIFT LINKAGE/KICK STARTER

SPECIFICATIONS

Specifications for clutch and kick starter components.

TROUBLESHOOTING

Common problems related to clutch lever, engagement, slips, and shifting.

CLUTCH DISASSEMBLY

Removing oil filter rotor cover, GPD holder, and clutch components.

CLUTCH FRICTION DISC

Checking friction discs for scoring and measuring thickness.

MAINSHAFT

Measuring mainshaft O.D. and applying oil to components.

10. ALTERNATOR/STARTER CLUTCH

SPECIFICATIONS

Specifications for gear reduction and starter driven gear.

TROUBLESHOOTING

Diagnosing engine not starting due to faulty starter clutch or motor.

LEFT CRANKCASE COVER REMOVAL

Removing side cover, alternator connector, and crankcase cover bolts.

STATOR/IGNITION PULSE GENERATOR REMOVAL

Removing stator socket bolts and ignition pulse generator.

STARTER DRIVEN GEAR/STARTER CLUTCH INSPECTION

Checking roller contact surface and needle bearing for wear.

11. CRANKCASE/TRANSMISSION/CRANKSHAFT

SPECIFICATIONS

Specifications for shift fork, shift drum, and transmission components.

TROUBLESHOOTING

Diagnosing transmission jump out of gear and hard shifting.

CRANKCASE SEPARATION

Steps to separate crankcase halves, remove bolts and plugs.

TRANSMISSION REMOVAL

Separating crankcase halves, removing crankshaft, and shift forks.

MAINSHAFT/COUNTERSHAFT

Measuring shaft O.D. and calculating bush clearances.

CRANKSHAFT REMOVAL

Removing crankshaft from the right crankcase.

12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING

SPECIFICATIONS

Specifications for minimum tyre tread depth, cold tyre pressure, etc.

TORQUE VALUES

Torque values for front axle nut, fork cap, bridge bolts, etc.

TROUBLESHOOTING

Diagnosing front wheel wobbling, soft suspension, and brake issues.

HANDLEBAR REMOVAL

Removing rear view mirrors and disconnecting clutch switch connectors.

FRONT WHEEL REMOVAL

Lifting wheel, removing axle nut, and front brake panel.

INSPECTION

Checking wheel axle, bearing, and rim runout.

FRONT BRAKE

Inspecting brake drum and lining thickness.

FORK REMOVAL

Removing front wheel, fender, and fork bridge bolts.

STEERING STEM REMOVAL

Disconnecting cables, removing headlamp, wheel, and fender.

STEERING STEM ADJUSTMENT

Adjusting steering bearing nut for free rotation and specified torque.

13. REAR WHEEL/BRAKE/SUSPENSION

SPECIFICATIONS

Specifications for rear wheel, brake, and suspension components.

TROUBLESHOOTING

Diagnosing rear wheel wobbles, soft suspension, and brake issues.

REAR WHEEL REMOVAL

Removing brake rod, cotter pin, nuts, and rear wheel.

WHEEL BEARING

Checking wheel bearing play and replacing if noisy.

BRAKE DRUM INSPECTION

Measuring brake drum I.D.

REAR SHOCK ABSORBER REMOVAL

Removing seat, covers, carrier, muffler, and mounting bolts.

SWING ARM REMOVAL

Lifting wheel, removing pivot nut, chain covers, and exhaust muffler.

14. BATTERY/CHARGING SYSTEM

SPECIFICATIONS

Specifications for battery capacity, fuse, and alternator.

TROUBLESHOOTING

Diagnosing battery overcharging and abnormal charging voltage.

CHARGING OF BATTERY

Preparation of electrolyte and temperature correction factors.

REGULATED VOLTAGE INSPECTION

Checking regulated voltage at different engine speeds.

CURRENT LEAKAGE TEST

Procedure for testing current leakage in the system.

15. IGNITION SYSTEM

SPECIFICATIONS

Specifications for spark plug, peak voltage, ignition timing, and coil.

TROUBLESHOOTING

Diagnosing ignition coil and pulse generator issues.

IGNITION SYSTEM INSPECTION

Checking spark plug, primary peak voltage, and connections.

IGNITION TIMING

Checking ignition timing at idle and advance.

16. ELECTRIC STARTER

SPECIFICATIONS

Specification for starter motor brush length.

TROUBLESHOOTING

Flowchart for diagnosing starter motor not turning issues.

STARTER MOTOR REMOVAL

Disconnecting cables and removing mounting bolts.

COMMUTATOR INSPECTION

Inspecting commutator bars for discoloration and wear.

17. LAMPS/METERS/SWITCHES

SPECIFICATIONS

Specifications for headlamp, position lamp, tail lamp, etc.

TROUBLESHOOTING

Diagnosing lighting issues like no lights when ON.

BULB REPLACEMENT

Steps for removing and installing the headlamp bulb.

POSITION LAMP

Steps for removing and installing the position lamp.

TURN SIGNAL LAMPS

Steps for removing and replacing turn signal bulbs.

COMBINATION METER REMOVAL

Removing visor, headlamp, and meter assembly.

NEUTRAL SWITCH

Removing and installing the neutral switch.

STOP LAMP SWITCH

Checking operation of the stop lamp switch.

HANDLEBAR SWITCH

Checking continuity of handlebar switch connectors.

19. TROUBLESHOOTING

Engine will not start or is Hard to start

Troubleshooting steps for engine starting issues.

Engine lacks power

Diagnosing causes for lack of engine power.

Poor performance at idle and low speeds

Troubleshooting poor performance at low speeds.

Poor performance at high speeds

Diagnosing poor performance at high speeds.

Poor holding

Troubleshooting issues related to steering and handling.

Related product manuals