TVS TVS XL 100, Manual

Page 1: ... 100 From information on how best to ride it to its maintenance you will find all the relevant information in the following pages Follow them carefully to make the most of your vehicle We re delighted to inform you that as part of our company policy you are entitled to benefits for the maintenance of your vehicle Free services and other warranty repairs can be availed from the TVS Motor Company Au...

Page 2: ...Company Limited may however incorporate modifications or improvements on its vehicles at any time without notice and therefore in such events it is possible that the relevant part of the owner s manual does not apply to your vehicle Prior permission of TVS Motor Company Limited is required for quoting copying or reproducing any part of this owner s manual Accessories shown in the picture may not b...

Page 3: ...le to warn you about all hazards associated with operating or maintaining the vehicle you must use your own judgement You will find important safety information in following form in this manual These words carry the following connotations Warning Disregarding this message might result in injury to the rider Caution This message indicates special procedures or precautions to be followed to avoid da...

Page 4: ...Running in information 01 Know your TVS XL 100 02 Riding your TVS XL 100 15 Maintenance 19 Scheduled service record sheet 36 Technical specifications 38 CONTENTS CONTENTS IV ...

Page 5: ...special care and restrain exercised during the running in period It is especially important that you avoid operating the engine in high speed RPM which could expose the engine parts to excessive stress Maximum recommended speed during the running in is Maximum 40 kmph speed upto 1000 km vary the engine speed for better mating of parts The first service at 500 750 km is most important During runnin...

Page 6: ...quired to assist your Dealer for operating parts or referring to special information Please fill the above boxes now for future reference Frame number Engine number Control key number 2 The frame serial number is stamped on the right side of the steering head tube The engine serial number is stamped on the top surface of right side crankcase near engine breather tube ...

Page 7: ...itch 8 Speedometer 9 Turn signal indicator lamp 10 Ignition switch 11 High beam indicator lamp 12 Rear view mirror R 13 Front brake lever 14 Throttle grip 15 Electric starter switch 16 Electric system indicator lamp 17 Smart phone charger KNOW YOUR TVS XL 100 Optional accessory will be charged extra Applicable for i Touch Start models only 3 2 1 4 8 9 6 5 7 12 13 14 15 16 17 10 11 ...

Page 8: ...rical circuits are ON and the engine can be started now Key cannot be removed in this position KNOW YOUR TVS XL 100 Tail lamp day time running DRL brake lamp and head lamp glows only after starting the vehicle If the vehicle is not started for more than 30 minutes afterswitchingonthe ignitionkeythe vehicle maynotstartwiththe self start TurnOFF the ignition key and turn it ON again to start the veh...

Page 9: ...amp Electrical system indicator lamp ESIL blinks while starting the vehicle using electric starter and goes OFF once the engine gets started If this indicator glows continuously even after starting the vehicle it indicates that there is some problem with the vehicle s electrical system and the vehicle may not get start Contact TVS Motor Company Authorised Distributor or Dealer Authorised Service C...

Page 10: ...ull the choke lever towards left to apply choke During cold start apply the choke and start the vehicle without opening of throttle Once the engine is started and running in stable RPM release the choke and ride the vehicle KNOW YOUR TVS XL 100 KNOW YOUR TVS XL 100 Caution Always use choke for starting the cold engine Never open the throttle fully when the choke is applied It may lead to flooding ...

Page 11: ... when the switch is positioned at and engine is running KNOW YOUR TVS XL 100 KNOW YOUR TVS XL 100 6 Head lamp high low beam switch With the head lamp in ON condition slide the beam control switch towards to turn on the head lamp high beam Slide the switch towards to turn on the head lamp low beam Warning Always use the appropriate turn signal lamps when you intend to change lanes or take turns Be ...

Page 12: ... it to decrease the engine speed 2 Front brake lever The front brake is applied by squeezing the front brake lever gently towards the throttle grip The brake lamp glows on application of the front brake 2 1 3 The ESI lamp blinks during start of the vehicle using electric start Refer page 05 for more details Note The vehicle cannot be started using electric starter with low discharged battery Conta...

Page 13: ...W YOUR TVS XL 100 Warning Never attempt to move the vehicle when the steering is locked you may lose balance FUEL TANK CAP To open fuel tank cap insert the key into the lock and turn it in clockwise direction Now rotate the fuel tank cap in anti clockwise direction and take out Key cannot be taken out of the cap in this condition Fill the required amount of petrol as per the tank capacity and refi...

Page 14: ...ion when the fuel is above the reserve level in the tank RES Switch over the fuel cock lever to this position when the fuel stops flowing in ON position OFF Fuel flow cuts off from the tank to carburettor ON OFF RES While riding the vehicle with fuel cock lever in ON position and if the fuel in the tank reaches reserve level you may experience engine sluggishness and jerky feeling Take the vehicle...

Page 15: ...vision for fixing a side stand side stand is optional Side stand can be operated with your foot by pushing it away from the vehicle till it stops Please remember that the vehicle can t be started even by using kickstarter with the drained battery fitted in it Disconnect the battery positive terminal and tape properly to start the vehicle Contact TVS Motor Company Authorised Distributor or Dealer A...

Page 16: ...ened Follow the procedure given below to open the lid 1 Insert the control key into the lock of lid tool box and rotate it in anti clockwise direction Gently take out the lid from the tool box 2 While reassembling locate the lid at the bottom of the tool box properly press the top side firmly and then lock it by rotating the key in clockwise direction Take out the key once the lid is locked 12 Cov...

Page 17: ... the seat locate the seat in its position and push it towards the front and then press down KNOW YOUR TVS XL 100 TOOL KIT To assist you in performing certain aspects of periodic maintenance and emergency repairs a tool kit is supplied along with the vehicle and it is located inside the tool box To access the tool kit open the tool box lid as explained in the page no 12 The tool kit consists of the...

Page 18: ...unit by closing the flap properly and by avoiding the direct water jet towards the unit 2 Use the USB chager only with standard approved USB charging cable recommended for your smart phone 3 Do make sure the flap is not damaged while opening inserting the USB cable DON TS 1 Do not leave the USB charging flap open partially closed 2 Do not attempt to use charge any other device other than smart pho...

Page 19: ...any one of the brake and just Press the electric starter switch to start the engine electrically otherwise kickstart When the engine is cold q Actuate and hold the choke by pressing it towards left side q Start the engine using electrical starter kick starter with no opening very less opening of throttle q Once the engine is started and running stable release the choke lever and ride the vehicle w...

Page 20: ...Apply both brakes simultaneously l Turn OFF the ignition and fuel cock l Park the vehicle on a firm flat surface l Lock the steering and take out the control key FUEL RECOMMENDATION Use unleaded petrol only The petrol should be 85 to 95 octane by research method Use recommended fuel additives for longer life of engine components and lower maintenance Petrol mixed with ethanol will have impact on e...

Page 21: ...ow running in information l Apply brakes only when necessary l Always ride within the optimum speed range for better fuel economy l Avoid overloading FUEL ECONOMY The maximum fuel economy is obtained between 30 to 45 km h indicated by a green zone on the speedometer There is a drop in fuel economy both at lower speeds and even more at higher speeds Frequent braking long periods of idling and overl...

Page 22: ...les are tested in the factory for optimum fuel efficiency and CO levels Do not disturb the Carburettor settings as this may lead to higher fuel consumption and also higher CO levels If the vehicle needs any adjustments please consult nearest TVS Motor Company Authorised Distributor or Dealer Authorised Service Centers While adequate care is exercised at the factory to ensure that the emissions are...

Page 23: ...careful servicing TVS Motor Company Limited strongly recommends that the jobs as per the maintenance schedule be performed by your TVS Motor Company Authorised Distributor or Dealer Authorised Service Centers Periodic inspections may reveal one or more parts that may need replacement Whenever replacing parts on TVS XL 100 it is recommended that you use only the TVS Motor Company Genuine parts MAIN...

Page 24: ...er first service Tappet clearance I A I A I A Fuel cock sediment bowl C C C C Hose fuel I I I I Replace every three years Plate clutch assy clutch shoe Inspect and if required replace every 12000 km Drum clutch clutch housing Inspect and if required replace every 12000 km 1 All control cables I A L I A L I A L I A L Throttle grip L L Lubricate using grease Choke operation I I I I Steering smooth o...

Page 25: ... S I S I S 2 Idling CO I S Refer page no 18 for emission control Center side stand pivot L L L L Lubricate using TRU4 oil Kick starter pedal pivot L L L L Lubricate using TRU4 oil Control levers L L L L Lubricate using grease Swing arm bearings C L using grease every two years R Replace I Inspect T Top up C Clean A Adjust L Lubricate TI Tighten S Set 1 Inspect for proper operation and adjust play ...

Page 26: ...or Company TVS TRU4 PREMIUM oil SAE 10W30 API SL JASO MA2 Front fork oil 100 ml leg IOC Castrol 20W40 oil Grease Bharath petroleum MP Grease no 3 IOC Servo Gem no 3 Bechem Bechem premium grade 3 Chain lubricant TVS Motor Company TRU SPRAY Fuel additives As recommended IFTEX MAINTENANCE 22 MAINTENANCE ...

Page 27: ...screws A from both the sides of tool box 3 Similarly remove the bottom mounting screws B from both side of tool box and take out the tool box 4 Remove the mounting bolts C form the cover tool box and gently take out the cover Since the battery fitted in your vehicle is of maintenance free type MF it is not required to top up the battery with distilled water But to ensure the performance and long l...

Page 28: ...als Always connect the positive terminal first red wire and then negative black wire to avoid sparking The inversion of the battery wires can damage the battery and the recharging system If the battery is removed from the vehicle please ensure to tape the terminals of the wiring harness to avoid the terminals make contact with each other which will prevent the vehicle from starting 24 l Do not add...

Page 29: ...and replace the fuse Main fuse 1 Turn OFF the Ignition 2 Remove the lid tool box as explained in page no 12 3 Take out the fuse case 4 Open the fuse case and pull out the blown fuse 5 Replace the blown fuse with a new extra fuse is provided in the wiring harness itself in a pouch 6 Close the fuse case and re fix it properly into its location 7 Turn ON the ignition lock and check for proper functio...

Page 30: ... fuse case and re fix it properly into its location MAINTENANCE Good Fuse Blown Fuse Do not use vehicle by shorting the wires without fuse This may result in overheating of electrical items wiring and may result in fire Do not use fuse of higher amperage than specified for the safety of electrical system Caution 26 7 Turn ON the ignition lock and check for proper functioning of the electrical syst...

Page 31: ... km Cover the spark plug hole with cloth when the plug is removed to prevent dust water entry It is advisable to tight the new spark plug by hand till the end and then loose and again re tight the spark plug by 1 8 of rotation after sealing by using only the hand tool Inspect the spark plug electrodes A and B for any corrosion If found any replace the spark plug with a new Inspect the spark plug g...

Page 32: ...th less engine cum transmission oil engine components will be severely damaged Check the oil level as per the schedule to avoid costly damage Do not fill excess oil may cause oil leak Always use TVS TRU4 PREMIUM oil SAE 10W30 API SL JASO MA2 only 5 The oil level should be between minimum and maximum level marks of the gauge as shown in the figure 6 If the oil level is less than the minimum level a...

Page 33: ...front wheel end to obtain the correct play 4 Turn the adjuster nut in clockwise direction for reducing the free play or turn it in anticlockwise direction for increasing the free play Rear brake 1 Measure the free play of the rear brake lever at the lever end as shown in the figure 2 The free play of the brake lever before the engagement of the brake should be between 15 20 mm MAINTENANCE A B 29 W...

Page 34: ... wear limit indicator shows beyond the wear limit even after indexing the lever Brake shoe wear limit indicator When the brake is applied wear limit index mark A on front and rear brake cams should be within the range of wear limit indicator B on the front and rear brake panel Incase the index mark is going beyond the wear limit index the lever to next slot with the help of Dealer to extended shoe...

Page 35: ...t 1 75 kg cm 25 PSI 1 75 kg cm 25 PSI Rear 2 46 kg cm 35 PSI 2 81 kg cm 40 PSI Tyre tread condition Operating the vehicle with excessively worn tyres will decrease riding stability and can lead to loss of control It is recommended to replace the tyre when the tyre wears off to the tyre wear indicator A level indicated by TWI on the tyre Warning The tyre inflation pressure in cold condition and the...

Page 36: ...ter which is good for light loads If the spring is adjusted to maximum notch then it will be stiffer which is good for heavy loads Adjust the spring preload by shifting the adjuster to the required notch according to the different load condition Caution Keep both left and right shock absorbers spring adjusters in the same position The more you compress the shock absorber spring the suspension beco...

Page 37: ...rvice Centers at specified intervals if required more frequently depending upon usage FRONT WHEEL REMOVAL 1 Remove the hexagonal nut along with washer from either LH or RH side of front axle 2 Pull out the axle from the wheel along with the hexagonal nut and a washer 3 Place a support wooden block below the engine to prevent the vehicle from falling MAINTENANCE 33 4 Lift the front fork up dislocat...

Page 38: ... STORAGE PROCEDURES For storage of your vehicle for longer periods of over a month and above we recommend to carry out the following steps 1 Clean the vehicle thoroughly Park the vehicle on center stand 2 Empty the fuel tank Turn the fuel cock lever to OFF position 3 Warm up the engine and drain engine cum transmission oil Store the oil if new in a dust free container 4 Run the engine with fuel co...

Page 39: ...the vehicle 2 Remount the battery after bench charging if required 3 Fill the engine cum transmission oil TVS TRU4 PREMIUM oil SAE 10W30 API SL JASO MA2 and check the level using gauge oil level 4 Lubricate the parts as instructed in the periodic maintenance schedule 5 Fill up fresh petrol in the fuel tank 6 Check and inflate the tyres to the specified tyre pressure 7 Check and correct the points ...

Page 40: ...amp and sign 1 1st service between a 500 750 km or b 1 month 2 2nd service between a 2500 3000 km or b 3 months 3 3rd service between a 5000 6000 km or b 6 months 5 4th service between a 8500 9000 km or b 9 months 5 5th service between a 11500 12000 km or b 12 months 6 6th service between a 14500 15000 km or b 15 months 7 7th service between a 17500 18000 km or b 18 months 36 SCHEDULED SERVICE REC...

Page 41: ...etween a 20500 21000 km or b 21 months 9 9th service between a 23500 24000 km or b 24 months 10 10th service between a 26500 27000 km or b 27 months 11 11th service between a 29500 30000 km or b 30 months 12 12th service between a 32500 33000 km or b 33 months 13 13th service between a 35500 36000 km or b 36 months SCHEDULED SERVICE RECORD SHEET 37 SCHEDULED SERVICE RECORD ...

Page 42: ... i Touch start Engine idling rpm 1550 100 rpm under warm condition Starting system Kick starter Electric start Emission norms BS IV TRANSMISSION Clutch Centrifugal shoe type wet clutch Primary transmission Single speed gear box Secondary transmission Chain and sprockets Final reduction 12 66 1 XL100 XL 100 Comfort STD 13 87 1 XL100 Heavy Duty CHASSIS Overall length 1895 mm Overall width 670 mm Ove...

Page 43: ... BRAKES Front Hand operated internally expanding shoe type 80 mm dia drum Rear Hand operated internally e x p a n d i n g s h o e t y p e 110 mm dia drum ELECTRICAL Type AC generator Ignition system Electronic Ignition pulsar type IDI cum IG Coil Control unit ISG Spark plug B O S C H U R 5 K C CHAMPION RG8MC Spark plug gap 0 6 0 7 mm Battery type 12V 3 Ah MF battery Body earthing Negative terminal...

Page 44: ...rve 1 3 liters approx Engine cum transmission TVS TRU4 PREMIUM oil oil grade SAE 10W30 API SL JASO MA2 Engine cum transmission 900 ml oil capacity Front fork oil grade 20W40 oil Front fork oil capacity 100 ml per leg Note Specifications are subjected to change without notice The fuel tank is not a measuring instrument and the capacity of fuel tank may slightly vary from the indicated capacity Appl...