HERO MotoCorp XPULSE 200T User manual

PREFACE No : IB28A
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 and strengthen the green supply chain. We are also using non asbestos brake
shoes and engine gaskets which are environment friendly in nature.
Authorised Distributor or dealer(s) of the Distributor (‘‘Dealer’’) will be glad to provide you
further information or assistance and to handle your future service needs.
Thank you for selecting a Hero MotoCorp XPULSE 200T. We wish you many miles of
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 Hero
MotoCorp XPULSE 200T. Please take time to read it carefully. As with any fine machine,
proper care and maintenance are essential for trouble-free operation and optimum
performance.

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 Ltd 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 Ltd.
NOTE

Pg. No. Pg. No.
CONTENTS
ACCESSORIES & MODIFICATIONS 9
VEHICLE IDENTIFICATION 1
VEHICLE VIEWS 2
VEHICLE SPECIFICATION 7
ANTI-THEFT TIPS 9
•Ignition switch 14
PARKING/TOOL KIT 37
ABS INDICATOR 28
SAFE RIDING TIPS 12
STARTING THE ENGINE 34
FUEL TANK 29
•Important Safety Information 10
•Protective Apparel 11
SIDE STAND INDICATOR/SWITCH 28
VEHICLE SAFETY 10
FUEL VALVE 30
PART FUNCTION 14
RIDING/BRAKING 35
SAFETY PRECAUTION 39
HANDLEBAR SWITCHES CONTROL 26
MAINTENANCE 38
SEAT LOCK 31
•Instruments and Indicators 15
TIPS FOR HEALTHY ENVIRONMENT 13
•LCD panel 17
USB CHARGER 31
PRE-RIDE INSPECTION 32
FEATURES 20
CLEANING AND WASHING THE VEHICLE 38
MAINTENANCE SCHEDULE 40
ENGINE OIL 43
SPARK PLUG INSPECTION 43
BRAKES 56
MAIN/SIDE STAND LUBRICATION 61
CARBURETOR 48
OIL FILTER SCREEN & CENTRIFUGAL FILTER
VALVE CLEARANCE ADJUSTMENT 49
CLEANING 45
DRIVE CHAIN SLACKNESS 52
DRIVE CHAIN SLIDER INSPECTION 55
SUSPENSION 58
CATALYTIC CONVERTER 69
BYSTARTER OPERATION 52
CLUTCH LEVER FREE PLAY 50
AIR CLEANER 47
THROTTLE OPERATION 51
WHEEL 59
TUBELESS TYRES 62
POLISHING OF VEHICLE 70
BASIC TROUBLESHOOTING 71
AIR SUCTION VALVE (ASV) 69
EVAPORATIVE EMISSION CONTROL SYSTEM 70
STOP LAMP SWITCH 68
NAVIGATION SIGNS 73
BATTERY 65
HEADLAMP FOCUS ADJUSTMENT 68
FUSE REPLACEMENT 67
NUT, BOLTS & FASTENERS 65
JOB APPLICABLE TO PERIODIC SERVICES
SERVICE ADVICE SHEET
DELIVERY CERTIFICATE
HERO GENUINE PARTS
SERVICE RECORD SHEET
OWNERSHIP RECORD AND DATA

VIN: MBLLDU01#########
Model: XPULSE 200T
VIN Engine
Variants
LDU01 MC20AE
Electric start/Front disc with ABS/Rear disc/Cast wheel
MBL LDU01 # # # #####
Manufacturer
code Vehicle
Description Model Year Plant
Code Month of
Manufacturing Production
Serial Number
#
Check
Digit
Engine No.: MC20AE########
MC20AE # # # #####
Engine
Description Year of
Manufacturing Assembly Plant Month of Manufacturing Serial Number
VIN and Engine No. may be required:
•During registration of the vehicle.
•For dealing with legal & insurance departments.
1
VEHICLE IDENTIFICATION
Engine No.
Location: Stamped on the lower side of the
left crankcase.
Vehicle Identification Number (VIN)
Location: Stamped on the right side of the
steering head tube.
MBLLDU01#########
MC20AE#
#######

FRONT VIEW
(1) Front fender
(3) Right position lamp
(2) Front right turn signal lamp
(4) Headlamp (Low Beam) (8) Leg guard
(5) Left position lamp
(6) Front left turn signal lamp
(7) Headlamp (High Beam)
8
1
*Accessories and features shown may not be part of standard fitment.
2
VEHICLE VIEWS
2
3
6
7
5
4

REAR VIEW
(2) Left rear turn signal lamp
(1) Rear fender
(3) Tail/stop lamp
(4) Licence plate lamp
(5) Right rear turn signal lamp
(6) Rear reflex reflector
(7) Rear brake fluid reservoir
2
3
*Accessories and features shown may not be part of standard fitment.
4
5
3
6
7
1

M
S
TOP VIEW
4
*Accessories and features shown may not be part of standard fitment.
14
3
4
5
6
7
8910 11 12 13 16
17
15
18
21
2
1
20
(9) Side stand indicator
(3) Bystarter knob
(6) Clutch lever
(7) Pass lamp switch
(1) High beam indicator
(2) Ignition switch with key
(4) Horn switch
(5) Turn signal switch
(8) LCD panel of Meter console. Refer
instruments and indicators (page 15)
for fuel gauge, speedometer and other
features of console
(13) Mode (M) and Set (S) buttons
(18) Throttle grip
(10) Left turn signal indicator
(20) ABS indicator
(12) Right turn signal indicator
(14) Front brake master cylinder/Reservoir
(16) Rear view mirrors
(19) Electric starter switch
(15) Engine stop switch
(17) Front brake lever
(21) Fuel tank cap
(11) Neutral indicator
19

(2) Fuel valve
(4) Starter motor
(5) Gear shift pedal
(1) Side reflex reflector
(3) Bash plate
(6) Rider foot rest
(10) Saree guard
(8) Side stand
(7) Main stand
(11) Rear grip
(9) Pillion foot rest
(12) Seat lock
(15) Side stand switch
(14) Battery compartment (inside)
(13) Left side cover
(16) Air suction valve (inside)
LEFT SIDE VIEW
*Accessories and features shown may not be part of standard fitment.
4510
111316 15
5
68
13
14
27 9
12

(1) Rear master cylinder
(4) Oil level dipstick
(6) Front disc
(8) Seat
(7) Carburetor
(2) Brake pedal
(5) Front caliper assembly
(3) Kick starter pedal
(9) Tool kit compartment (inside)
(10) Fuse box (inside)
(11) USB charger compartment (inside)
(14) Exhaust muffler
(15) Rear disc
(13) Rear caliper assembly
(12) Air cleaner assembly (inside)
RIGHT SIDE VIEW
2
11
*Accessories and features shown may not be part of standard fitment.
6
3
7
5 6
8
14
15
10
1 4
13
9
12

7
SPECIFICATIONSITEM
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Saddle height
Ground clearance
Kerb weight
2118 mm
806 mm
1089 mm
1393 mm
799 mm
178 mm
150 kg
Weight
VEHICLE SPECIFICATION
Engine oil
Fuel tank capacity
Fuel reserve capacity
Front fork oil at disassembly
Hydraulic brake fluid
Maximum power
Maximum torque
Bore and stroke
Compression ratio
Displacement
Spark plug
Spark plug gap
Valve clearance
Idle speed
Front suspension
1200 ml at disassembly and 1070 ml at draining
13.0 litres
2.0 litres (Usable)
340 cc (Per leg)
DoT-4/DoT-3
13.5 kW @ 8000 rpm
17.1 N-m @ 6500 rpm
66.5x57.5 mm
10:01
199.6 cc
NGK-CPR 8 EA9, BOSCH UR5DC
0.8-0.9 mm
0.07 mm +0.01/-0.02
0.09 mm +0.01/-0.02
1400±100 rpm
Telescopic front forks (dia 37 mm)
with anti friction bush
Capacities
Engine
Intake (cold)
Exhaust (cold)
Chassis and suspension
Rear suspension
Caster angle Rectangular swingarm with mono shock
25.5°
Trail length 80.5 mm
Payload 130 kg

8
SPECIFICATIONSITEM
Primary reduction
Final reduction
Transmission
st
Gear ratio, 1
rd
3th
4th
5
Battery
Alternator
Headlamp
Tail/Stop lamp
Turn signal lamp
Meter illumination
Neutral indicator
Turn signal indicator (RH/LH)
Position lamp
Hi beam indicator
ABS indicator
Service reminder indicator
Licence plate lamp
Side stand indicator
Fuse
3.350 (67/20)
2.846 (37/13)
5 Speed constant mesh
3.0769 (40/13)
1.7895 (34/19)
1.500 (30/20)
1.100 (22/20)
0.9583 (23/24)
12V-4 Ah, (ETZ-5) *MF Battery
110 W @ 5000 rpm
12V-5.6W/9.3W (LED)
12V-0.2/2.1W (LED)
12V-10Wx4 nos. **MFR (Amber bulb-clear lens)
LED
LED
12V-0.9W (LED)
LEDx2 nos.
LED
LCD display
12V-5W
LED
20A, 15A, 10A, 10A
Transmission
Electricals
Tyre pressure
2 2
1.75 kgf/cm (25 psi)/1.75 kgf/cm (25 psi)
Front (Rider only/Rider & Pillion)
Rear (Rider only/Rider & Pillion)
Brakes Dia. 276 mm
Dia. 220 mm
Front (Disc type)
Rear (Disc type)
nd
2
*MF stands for Maintenance Free
**MFR stands for Multi-Focal Reflector type
VEHICLE SPECIFICATION
LED
Tyre size 100/80 x 17-52 P (Tubeless tyre)
Front
Rear 130/70 x R17-62 P (Radial tubeless tyre)
2 2
1.96 kgf/cm (28 psi)/2.1kgf/cm (30 psi)

9
MotoCorp accessories can make your vehicle
unsafe. Before you consider making any
modifications or adding an accessory, be sure
to read the following information.
ACCESSORIES & MODIFICATIONS
Modifying your vehicle or using non-Hero
operation. Such changes could seriously
impair your vehicle's handling, stability and
braking, making it unsafe to ride. Removing or
modifying your lamps, mufflers, emission
control system or other equipment can also
make your vehicle illegal.
•Park your vehicle in a locked garage
whenever possible.
•Always lock the steering and never leave the
key in the ignition switch. This sounds
simple but people do forgets.
•Be sure the registration information for your
vehicle is accurate and correct.
•Use an additional anti-theft device of good
quality.
ANTI-THEFT TIPS
•Never park your vehicle in an isolated area.
Park as far as possible in a designated area.
•Enter your name, address and phone
number in this Owner's Manual and keep it
in your vehicle at all times. Many times
stolen vehicles are identified by information
in the Owner's Manuals that are still with
them.
_______________________________________________________
_______________________________________________________
NAME: _____________________________________________
ADDRESS: _______________________________________
PHONE NO : _____________________________________
_______________________________________________________
We strongly advise you not to remove any
original equipment or modify your vehicle in
any way that would change its design or
•Do not pull a trailer or sidecar with your
vehicle. This vehicle was not designed for
these attachments, and their use can
seriously impair your vehicle's handling.
Modifications
•Be sure electrical equipment does not
exceed the 's electrical system vehicle
capacity (page 8). A blown fuse can cause a
loss of lights.
Accessories
•Make sure that the accessory does not
obscure any lamps, reduce ground
clearance, limit suspension travel or steering
travel, affect your riding position or interfere
with operating any controls.
•Improper accessories or modifications can
cause a crash in which you can be seriously
hurt or killed.
•Follow all instructions in this owner's manual
regarding accessories and modifications.
WARNING
!!

Your vehicle can provide many years of
service and pleasure if you take responsibility
for your own safety and understand the
challenges you can meet on the road.
VEHICLE SAFETY
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.
Before riding your vehicle
Make sure that you are physically fit, mentally
focused and free of alcohol and drugs. Check
that you and your pillion are both wearing an
approved vehicle helmet and protective
apparel. Instruct your pillion on holding onto
the grab rail or your waist, leaning with you in
turns, and keeping their feet on the footrest,
even when the vehicle is stopped.
Take time to learn & practice your
vehicle
Even if you have ridden other vehicles,
practice riding in a safe area to become
familiar with how this vehicle works and
handles, and to become accustomed to the
vehicle's size and weight.
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.
Make yourself easily visible
Riding under the influence of alcohol or drugs
is dangerous. Alcohol can reduce your ability
to respond to changing conditions and reduce
the reaction time. Do not drink and ride.
Keep your vehicle in safe condition
Always pay due attention to other vehicles
around you, and do not assume that other
drivers see you. Be prepared to stop quickly or
perform an evasive maneuver.
Ride within your limits
Pushing the limits is another major cause of
vehicle accidents. Never ride beyond your
personal abilities or faster than conditions
demand. Remember that fatigue and
negligence can significantly reduce your ability
to make good judgements and ride safely.
Do not drink and ride
Some drivers do not see vehicles because they
are not looking for them. To make yourself
more visible, wear bright reflective clothing,
position yourself so that others can see you,
signal before turning or changing lanes, and
use horn which will help others to notice you.
Ride defensively
For safe riding, its important to inspect your
vehicle before every ride and perform all
recommended maintenance. Never exceed
load limits (page 7), and only use accessories
that have been approved by Hero MotoCorp
for this vehicle.
10

11
Additional riding gear
•Sturdy boots with non-slip soles to help
protect your feet and ankles.
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.
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.
•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 vehicle.
In addition to a helmet and eye protection, we
also recommend:
•Leather gloves to keep your hands warm
and help prevent blisters, cuts, burns, and
bruises.
Helmets and eye protection
PROTECTIVE APPAREL
For your safety, we strongly recommend that
you always wear a helmet which should
conform as per your country standards, in
addition to 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.
If you decide to continue riding, first evaluate
the condition of your vehicle. If the engine is
still running, turn it off. Inspect for fluid leaks,
check the tightness of critical nuts and bolts,
and check the handlebar, brake levers, brakes,
and wheels. Ride slowly and cautiously. Your
vehicle may have suffered damage that is not
immediately apparent. Have your vehicle
thoroughly checked at a qualified service
facility as soon as possible.
Personal safety is your first priority. If you or
anyone else has been injured, take time to
assess the severity of the injuries and whether
it is safe to continue riding. Call for emergency
assistance if needed. Also follow applicable
laws and regulations if another person or
vehicle is involved in the crash.
If you are involved in a crash
Following are suggestions to help you choose
proper riding gear.
•Be sure you and your pillion 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.
WARNING
!!

SAFE RIDING TIPS
12
• Always conduct simple pre-ride inspection
(page 32).
•While riding, sit in a comfortable position with your
legs close to fuel tank.
Do's:
•Before riding make sure that engine stop switch is
in “ON” ( ) position.
•Keep checking speedometer. In case of ABS
malfunction, speed display may go to zero.
•Always wear a helmet with chinstrap securely
fastened and insist on a helmet for your pillion rider.
Helmet should conform as per safety standards
applicable in your country.
•For stopping vehicle, use both brakes simultaneously,
keeping throttle in the close position.
•Ride defensively and at a steady speed (between
40-50 km/hr).
•To make yourself more visible, wear bright
reflective clothing that fits well.
•Give way to others on the road and signal before
you make a turn.
•Take care of loose/hanging clothes while
solo/pillion riding.
•vehicleGet your serviced regularly by the
Authorised Distributor/Dealer.
•During night time vehicle, dip headlamps of your for
oncoming traffic, or when following another
vehicle.
•Keep checking the ABS indicator. At any point if
indicator remains on, then ABS is not working
(page 28).
•It is suggested to go through the do’s & dont’s of
ABS (page 36) and practice your ABS vehicle
initially in low-traffic condition unless you are
thoroughly familiar with your vehicle and its
controls.
•Do not panic by mechanical noises or slight pedal
pulses while applying the brake in vehicle. These
conditions are normal and indicates that ABS is
working.
•Never touch any part of the hot exhaust system like
muffler.
•Avoid sudden acceleration, braking and turning of
your vehicle.
•Never use cell phone while riding the vehicle.
Don'ts
•Never shift gears without disengaging the clutch
and closing the throttle.
•Never ride under the influence of alcohol or drugs.
•Concentrate on the road and avoid talking to the
pillion rider or others on the road.
•Do not litter the road.
•Never take your hands off the steering handle while
riding.
•Do not attempt to apply the front brake lever
intermittently for ABS vehicle.
•Do not apply the hard braking in wet or rainy
conditions.
•Do not switch off the engine stop switch while
riding the vehicle (page 28).
•Do not attach large or heavy items to the
handlebars, front forks, or fenders.
•Navigation system assists you to reach your
destination, don't be distracted while driving. Drive
safely and always obey traffic rules.
•Do not cross the continuous white/yellow line in
the center of the road, while overtaking.

•Genuine spares: Always insist on Hero MotoCorp genuine parts as spurious or
incompatible spares and accessories can upset or deteriorate your vehicle’s running
condition.
•Fuel saving & reduce pollution: Switch "OFF" the engine while waiting at traffic signal
points to save fuel and reduce pollution, if the waiting period is long.
•Regular servicing: Get your vehicle serviced at an Authorised Distributor/Dealer, as per
the service schedule, for an optimum performance and keep the emission level under check.
•Genuine engine oil: Hero 4T Plus SAE 10W 30 SL grade (JASO MA2) engine oil
recommended by Hero MotoCorp and make sure you change it every 6000 km. (with top
up every 3000 kilometres) to keep the engine fit and environment healthy.
•Noise pollution: Noise beyond a certain decibel is pollution. Whether it is from horns or
defective mufflers, excessive noise will cause headaches and discomfort.
The following tips shall ensure a healthy vehicle, healthy environment, and a healthy you.
•Healthy engine: The engine is the lifeline of every vehicle. To keep it healthy, it should be
tuned regularly, which will also help reduce pollution and improve vehicle performance &
fuel efficiency.
TIPS FOR HEALTHY ENVIRONMENT
13

14
The LCD panel illuminates & initial display of
multi function digital segments are displayed.
The tachometer segment and the fuel gauge
segment will swing to the maximum scale once
and back to its normal position. The engine can
be started. Turn signal lamp, horn, tail/stop
lamp, fuel gauge, & pass lamp, position lamp
neutral indicator will be functional.
Key cannot be removed.
Engine cannot be started and no electrical
system will be functional. Key can be removed.
Steering can be locked. Key can be removed.
“OFF” ( )
Position/Lock Open
“LOCK” Position
“ON” ( )
Position
“LOCK”
“ON” ( )
“OFF” ( )
5. “ON” ( ) position
4. Steering lock position
1. Ignition switch
2. Ignition key
3. “OFF” ( ) position
Key position Function Key removal
IGNITION SWITCH
PARTS FUNCTION
4
3
1
5 2

Sl. No. Description Function
1
6Anti-lock braking system (ABS)
indicator
Tachometer Shows engine revolution per minute. The tachometer
digital segments will swing to maximum scale on the meter
console once the ignition switch is turned “ON” .
High beam indicator Light glows when headlamp is in high beam.
4
Neutral indicator Light glows when vehicle is in neutral.
Turn signal indicator (R) Flashes when right turn signal switch is operated.
7
The indicators are in the speedometer panel
above the headlamp. The functions are as
below.
INSTRUMENTS AND INDICATORS
15
This indicator normally comes on for approx 1.8 seconds
when the ignition switch is turned “ON” ( ) & then keeps
blinking until the vehicle attains speed of 5 km/h. If there
is a problem with the anti-lock brake system, ABS
indicator turns “ON” (page 28).
5
3Turn signal indicator (L) Flashes when left turn signal switch is operated.
x 000
I
FFF
E
EE
km/h
RPM
Gear
ODO
ODOODO
km
0 00
III
222
333
4
44
5556667
778
88999IO
IOIO IIIIII
241.6 km
to go
Serv
6
4 75
9
132
1413
15
16
8
12
Side stand indicator Light glows when the vehicle is parked on the side stand. 2
Mode button Switches display between odometer, tripmeter-1 & 2,
clock, eco mode & bluetooth connectivity.
8
101111a

Sl. No. Description Function
12
15
14
13
16
Odometer Shows accumulated distance travelled (page 18).
Speedometer
Indicates hours & minutes .(page 17)
Digital clock
Indicates .riding speed
Fuel gauge
Service reminder
indicator Displays when the next service is due (page 20).
11
10 Next service distance Indicates how many kilometers are left before the
next service is due. It appears for few seconds when the
ignition switch is turned “ON” ( ) (page 20).
Gear indicator Displays the selected gear while riding (page 21).
16
Indicates approximate fuel available in the form of
digital segments. The digital segments (11a) will swing to
maximum scale on the meter console once the ignition
switch is turned “ON” ( ). If all the segments (11a) are
displayed it means fuel quantity in the fuel tank is 13
litres. If only one segment is displayed and blinks, this
indicates the fuel quantity is low and the fuel tank should
be refilled as soon as possible.
9Set button To adjust clock, date & tripmeter.
When long pressed resets tripmeter to zero.