HERO MAESTRO User manual

PREFACE
This booklet is your guide to the basic operation and maintenance of your new
Hero MotoCorp MAESTRO scooter. Please take time to read it carefully. As with any
fine machine, proper care and maintenance is essential for trouble-free operation and
optimum performance.
Let us make this world a safer, healthier and more environment friendly place.
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 all applicable legislation including
environment legislation and strengthen the green supply chain.
Your Authorised Hero MotoCorp dealer will be glad to provide further information or
assistance and is equipped to handle your future service needs.
Thank you for selecting a Hero MotoCorp MAESTRO scooter. We wish you many
miles of continued riding pleasure in the years ahead.
Your Scooter is conforming to latest (Bharat Stage-III norms) regulation for emission,
safety & noise levels. We are also using non asbestos brake shoes and engine gaskets
which are environment friendly in nature.

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. Hero MotoCorp Limited. 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 Hero MotoCorp Limited.
NOTE
ACCESSORIES SHOWN MAY NOT BE THE PART OF STANDARD FITMENT.
IT IS OUR ENDEAVOR TO CONSTANTLY IMPROVE OUR PRODUCTS. THIS
COULD LEAD TO CHANGE IN PRODUCT SPECIFICATIONS WITHOUT
NOTICE. Hero MotoCorp MAESTRO COMPLIES WITH THE LATEST
EMISSION NORMS.

Pg. No.
CONTENTS
• BRAKES 17
ESSENTIAL INDIVIDUAL COMPONENTS 27
TIPS FOR HEALTHY ENVIRONMENT 10
• ODOMETER/TRIPMETER/FUEL GAUGE 15
• SERVICE DUE INDICATOR 16
• CENTER COMPARTMENT 33
BODY PARTS REMOVAL 33
• CENTER COMPARTMENT 31
FEATURES 29
MAJOR COMPONENTS 17
• FUEL 20
• BODY COVER 34
• PROTECTIVE APPAREL 5
• RIGHT HANDLEBAR CONTROLS 28
• STEERING LOCK 30
SCOOTER SAFETY 4
PARTS FUNCTION 14
• ACCESSORIES AND MODIFICATIONS 9
• IMPORTANT SAFETY INFORMATION 4
• IGNITION SWITCH 27
• LOAD LIMITS AND GUIDELINES 7
SCOOTER IDENTIFICATION 1
PRODUCT SPECIFICATION 2
SCOOTER VIEWS 11
• LCD PANEL 15
• INSTRUMENTS AND INDICATOR 14
• TYRES 22
• LEFT HANDLEBAR CONTROLS 28
• SEAT LOCK 30
• LUGGAGE HOOK 32
• FRONT INNER BOX 32
• FRONT CENTER COVER 35
• HEADLAMP CASE 38
• REAR VIEW MIRROR 37
• HEADLAMP FOCUS 38
• FRONT COVER 36
Pg. No.
HERO GENUINE PARTS
ROAD SIGNS 73
WARRANTY DETAILS
• REMOVAL FROM STORAGE 72
OPERATIONS 39
• PRE-RIDE INSPECTION 39
• RIDING 42
• RUNNING IN 41
• PARKING 47
• STARTING THE ENGINE 40
FIRST AID KIT 49
• MAINTENANCE SAFETY 50
• DRAIN TUBE 57
• STEERING LOCK 48
• BATTERY 63
• AIR CLEANER 55
• IDLE SPEED 61
• POLISHING 70
• SECONDARY AIR SUPPLY SYSTEM 56
• BULB REPLACEMENT 66
• STORAGE 71
TOOL KIT 48
• ENGINE OIL 57
• FUSE REPLACEMENT 65
STORAGE GUIDE 71
• ANTI-THEFT TIPS 48
MAINTENANCE 49
CLEANING 69
• SPARK PLUG 60
• BRAKE SHOE WEAR 62
• IMPORTANCE OF MAINTENANCE 49
• SAFETY PRECAUTIONS 51
• MAINTENANCE SCHEDULE 52
• WASHING 69

SCOOTER IDENTIFICATION
1
Model Code.:
Model Engine
Maestro (Dlx. Combined Braking System)
Maestro (Std. Without Combined
Braking System)
VIN
AB
AA
AA
AA
MBLXXXXABYZXYYYYY
MBL
Manufacturer
Code
XXXXAB
Vehicle
Description
Y
Year of
Mfg.
Z
Assembly
Plant
X
Month of
Mfg.
YYYYY
Serial
Number
XXXXAA
Engine
Description
Y
Year of
Mfg.
Z
Assembly
Plant
X
Month of
Mfg.
YYYYY
Serial
Number
XXXXAAYZXYYYYY
XXXXAAY
ZXYYYYY
Engine No.
Vehicle Identification Number (VIN)
Location: Stamped on the lower side of
the left crank case.
Location: Stamped on the lower right side
of the frame, visible from the frame no.
cover at the lower right cover.
VIN and Engine No. may be required:
1. During registration of the Scooter.
2. For dealing with Legal & Insurance
Department.
MBLXXXXABYZXYYYYY
VIN

110 kg
1780 mm
710 mm
1165 mm
1240 mm
770 mm
155 mm
Overall Length
Overall Width
Overall Height
Wheelbase
Saddle Height
Ground Clearance
6.0 kW (8.2 Ps) @ 7500 r/min
50.0 x 55.5 mm
9.5:1
109 cc
NGK CPR 7 EA 9
0.8-0.9 mm
IN : 0.16 mm EX : 0.16 mm
1700 ± 100 r/min
0.80 litre
0.70 litre at draining
0.12 litre
0.10 litre at draining
5. 3 litres (minimum)
SPECIFICATIONS
DIMENSIONS
WEIGHT
Kerb Weight
CAPACITIES
Engine Oil
Transmission oil
Fuel Tank
ENGINE
Power
Bore and Stroke
Compression Ratio
Displacement
Spark Plug
Spark Plug Gap
Valve Clearance (Cold)
Idle Speed
2

CHASIS AND SUSPENSION
Chassis Type High rigidity underbone type
Front Suspension Bottom link with spring loaded
hydraulic damper
Rear Suspension Unit swing with spring loaded
hydraulic damper O
Caster 27
Tyre size, front 90 / 100 x 10 - 53 J
Tyre size, rear 90 / 100 x 10 - 53 J
Tube with Puncture Endurance
Front / Rear Brake Drum Type Internal expanding shoe type (130 mm)
Combined Braking System (optional)
POWER TRANSMISSION
Primary Reduction Variomatic drive (2.5 : 1 - 0.85 : 1)
Alternator 110 W
Head Lamp (High / Low) 12V 35W / 35W Halogen Bulb, MFR*
Battery 12V - 3Ah **MF Battery
ELECTRICAL
Turn Signal Lamp 12V 10W (Amber bulb) x 4 nos. MFR*
Meter Illumination L.E.D
High Beam indicator L.E.D
Position Lamp 12V 5W
FUSE
Final Reduction 50 / 20 x 49 / 13 (9.423)
Main Fuse 10 A
Turn Signal indicator (RH +LH) L.E.D
Clutch System Dry, Automatic Centrifugal Clutch
Starting System Kick / Electric Start
Tail/Stop Lamp 12V 5W / 21W (Amber bulb) with clear lens-MFR*
3* MFR stands for Multifocal Reflector Type
** MF stands for Maintenance Free

Make Yourself Easily Visible
Some drivers do not see scooters because
they are not looking for them. To make
yourself more visible, wear bright
reflective clothing, position yourself so
SCOOTER SAFETY
There is much that you can do to protect
yourself when you ride. You will find
many helpful recommendations through
out this manual. Following are a few that
we consider most important.
Your scooter can provide many years of
ser vic e and ple a su r e if you tak e
responsibility for your own safety and
understand the challenges you can meet on
the road.
IMPORTANT SAFETY
INFORMATION
Always Wear a Helmet
It is a proven fact, Helmet significantly
reduces the number and severity of head
injuries. So always wear a helmet and
make sure your pillion rider does the same.
We also recommend that you wear eye
protection, sturdy boots, gloves and other
protective gear (page 5).
Keep Your Scooter in Safe Condition
that others can see you, signal before
turning or changing lanes, and use horn
which will help others to notice you.
Ride Within Your Limits
Pushing the limits is another major cause
of scooter accidents. Never ride beyond
your personal abilities or faster than
conditions demand. Remember that
alcohol, drugs, fatigue and negligence can
significantly reduce your ability to make
good judgements and ride safely.
For safe riding, its important to inspect
your scooter before every ride and
perform all recommended maintenance.
Never exceed load limits, and use
accessories that have been recommended
by Hero MotoCorp for this vehicle. See
(page 7-9) for more details.
4

For your safety, we strongly recommend
that you always wear an approved helmet
(ISI marked), eye protection, boots,
gloves, long pants and a 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 injury when you ride.
Following are suggestions to help you
choose proper riding gear.
PROTECTIVE APPAREL
Your Helmet is your most important piece
of riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and
securely. A bright coloured helmet can
make you more noticeable in traffic, as
can reflective strips.
Helmets and Eye Protection
Additional riding Gear
An open-face helmet offers some
protection, but a full-face helmet offers
more. Always were face shield or goggles
to protect your eyes and help your vision.
Leather gloves to keep your hands
warm and help prevent blisters, cuts,
burns, and bruises.
In addition to a helmet and eye protection,
we also recommend:
A two wheeler riding suit or jacket for
comfort as well as protection. Bright
coloured reflective clothing can help
make you more noticeable in traffic. Be
sure to avoid loose clothes that could
get caught on any part of your scooter.
Sturdy boots with non-slip soles to help
protect your feet and ankles.
5
WARNING
Be sure you and your passenger
always wear a helmet, eye protection
and other protective apparel when
you ride.
Not wearing a helmet increases the
chance of serious injury or death in a
crash.

6
Always wear a HELMET
Wear Bright or Reflective
clothing
Wear a Face Shield or Goggles
Wear Gloves
Shoes should be close fitting, low heels
and offer ankle protection
PROTECTIVE APPAREL

However exceeding the weight limit
or carrying an unbalanced load can
seriously affect your scooter's handling,
bra kin g an d stab i li t y. Non Hero
MotoCorp accessories, modifications,
and poor maintenance can reduce your
safety margin.
Your scooter has been designed to carry
you, one pillion and limited amount of
cargo. When you add cargo or carry a
passenger, you may feel some difference
during acceleration and braking. But so
long as you keep your scooter well
maintained, with good tyres and brakes,
you can safely carry loads within the
limits and guidelines.
LOAD LIMITS AND
GUIDELINES
The following pages give more specific
information on loading, accessories and
modifications.
WARNING
Follow all load limits and other
loading guidelines in this manual.
Overloading or improper loading can
cause a crash and you can be seriously
injured.
7
Maximum weight capacity: 130 kg
Load limits
Following are the load limits for your
scooter:
Includes the weight of the rider, pillion, all
cargo and all accessories.
How much weight you put on your
scooter, and how you load it, are important
to your safety. Anytime you ride with a
pillion or cargo you should be aware of the
following information.
Loading