Cotton is a globally important crop that serves as a major source of fibre and edible oil while supporting millions of livelihoods. With increasing demand for sustainable materials, improving cotton productivity in an eco-friendly way has become essential. One promising approach is the integration of legume intercropping with efficient weed management to reduce the potential yield loss of up to 86 % caused by weed competition. A two-year field experiment during 2021 and 2022 at Agronomy Research Farm, Chaudhary Charan Singh (CCS) Haryana Agricultural University, Hisar, Haryana, India, assessed the impact of various management practices on cotton yield, economic returns and soil health. Using a split-plot design, the study contrasted monoculture cotton with a cotton + green gram (1 : 2) intercropping system under 11 weed management treatments. Results revealed that sole cotton recorded greater plant height (177.05 cm) and dry matter accumulation (427.40 g plant-1). However, intercropping with green grams significantly improved soil fertility, with higher available nitrogen (N) (126.7 kg ha-1) and phosphorus (P) (17.6 kg ha-1) observed at harvest. Among the weed management treatments, the weed-free treatment recorded the highest seed cotton yield (26.64 q ha-1), followed by two hoeings at 25–30 and 40–45 days after sowing (24.20 q ha-1). Notably, the integrated application of pendimethalin (1000 g ha-1, PRE) followed by single hoeing at the 35–40 days proved highly effective, increasing seed cotton yield by approximately 40 % compared with herbicide use alone. Cotton-legume intercropping enhances soil fertility and profitability. Combining chemical and cultural weed management practices ensures better weed control, improved productivity and sustainable soil health.