TVS XL100 Manual
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TVS XL100 Manual

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CONTACT(S) FOR SUPPORT
Incase you need any Clarification please contact above Dealer
TVS Motor Company's Area Offices (flip over for addresses)
Disclaimer : TVS Motor Company or any of its officials / Authorized Main dealer / Authorized Dealer do not ask customers for bank
/ card / wallet details / authentication. In case you face any such claim, please report to the relevant local authorities immediately.
Or
Or
Toll Free Number : 1800-258-7111
Email : customercare@tvsmotor.com
I

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  • Page 1 Email : customercare@tvsmotor.com Disclaimer : TVS Motor Company or any of its officials / Authorized Main dealer / Authorized Dealer do not ask customers for bank / card / wallet details / authentication. In case you face any such claim, please report to the relevant local authorities immediately.
  • Page 2 CONTACT AT OUR AREA OFFICES TAMILNADU-1, 3 & 4 KARNATAKA-1, 2 & GOA MAHARASHTRA-3 & CHATTISGARH 1. TVS Motor Company Limited 4. TVS Motor Company Limited 7. TVS Motor Company Limited V Floor, Gee Gee Universal, No. 600, Anand Surya, 2nd Floor, No.
  • Page 3 MADHYA PRADESH-1 & 2 DELHI & HARYANA UTTAR PRADESH CENTRAL & EAST 9. TVS Motor Company Limited 11. TVS Motor Company Limited 14. TVS Motor Company Limited No. 211-212, 2nd Floor, D-3 & D-4, 2nd Floor, 1st Floor, Cyber Tower, TC-34/V-2,...
  • Page 4 ORISSA & JHARKHAND 17. TVS Motor Company Limited No. 303, 3rd Floor, Creative Plaza, Rasulgarh, Bhubaneshwar - 751 010. Phone : 0674-2580019 Email : AO.Bhubaneshwar@tvsmotor. NORTH EAST STATES 18. TVS Motor Company Limited 147 , Udayan, Ganesh Guri, Opp. Punjab National Bank, R G B.
  • Page 5 TVS XL100 with fuel and get going. This manual will help you get the best performance out of your new TVS XL100. 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.
  • Page 6 Prior permission of TVS Motor Company Limited is required for quoting, copying or reproducing any part of this owner’s manual.
  • Page 7 SAFETY INFORMATION Operating this vehicle safely is an important responsibility of the rider. To help you make decisions on safety, we have provided necessary operating procedure and other information in this manual. This information alerts you on potential hazards that could hurt you or others. Since it is not possible to warn you about all the hazards associated with operating or maintaining the vehicle, you must use your own judgement.

  • Page 8: Table Of Contents

    CONTENTS RUNNING-IN INFORMATION KNOW YOUR TVS XL100 RIDING YOUR TVS XL100 MAINTENANCE EXPRESS SERVICE EXPERT ON WHEELS PICKUP AND DROP WARRANTY AND SERVICES SERVICE INFORMATION TECHNICAL SPECIFICATIONS GENERAL INFORMATION VIII...

  • Page 9: Running-In Information

    Timely performance of the first free service will ensure optimum service life and performance from the engine. Replacing the engine cum transmission oil during first free service is most important for better life of engine. Always use TVS TRU4 PREMIUM oil (SAE 10W30 API-SL, JASO MA2) for better performance and life.

  • Page 10: Know Your Tvs Xl100

    KNOW YOUR TVS XL100 VEHICLE IDENTIFICATION NUMBER The frame and engine serial numbers are the only means of identifying your vehicle from others of the same model and type. They are also required to assist your Dealer for ordering parts or referring to special information.
  • Page 11 LOCATION OF PARTS - HANDLE BAR Horn switch 2. Turn signal lamp switch 3. Left hand brake lever 4. Head lamp switch 5. High / low beam switch 6. Speedometer Turn signal indicator lamp 8. Ignition switch 9. High beam indicator lamp 10.
  • Page 12 CONTROL KEY TVS XL100 comes with a pair of identical control Keep the ignition key in OFF position, when the keys. These keys are to operate ignition lock, steering vehicle is not in use to prevent battery drain.** lock, fuel tank cap, tool box lock and seat lock*.
  • Page 13 If the malfunction indicator lamp ‘ ‘ is glowing continually when the engine is started, immediately contact the nearest TVS Motor Company Authorised Main Dealer or Authorised Dealer. When the low fuel warning indicator lamp glows fill fuel immediately to avoid engine switch OFF / Damage to fuel pump which leads to replacement of pump without warranty.
  • Page 14 7. Electrical system indicator lamp** DAY TIME RUNNING LAMP (DRL) Electrical system indicator lamp (ESIL) blinks while TVS XL100 comes with a day time running LED lamp starting the vehicle using electric starter and goes which glows automatically once the engine is started OFF once the engine gets started.
  • Page 15 HANDLE BAR LEFT SIDE SBT technology helps to operate both front and rear brakes by distributing the force optimally between 1. Horn switch the two braking system. The brake lamp glows on Press the switch ‘ ’ to operate the horn. application of brake.
  • Page 16 5. Head lamp high / low beam switch HANDLE BAR RIGHT SIDE 1. Throttle grip With the head lamp in ‘ON’ condition, slide the beam Engine speed is controlled by the rotation of the control switch towards ‘ ’ to turn-on the head lamp throttle grip.
  • Page 17 3. i-Touch Start with Engine Kill switch** STEERING LOCK TVS XL100 is provided with integrated i-Touch Start TVS XL100 is provided with separate lock for locking with Engine Kill switch. the steering. The engine kill switch is used to switch off ‘...
  • Page 18 TVS Motor Company Authorised Main Dealer / Authorised Dealer. Do not clean the vehicle by laying down on floor, to avoid fuel entry into EVAP system.
  • Page 19 (1a) and press with adequate effort. Ensure both the legs of stand are touching the ground before placing the vehicle on stand. TVS XL100 also has a provision 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.
  • Page 20 HEAD LAMP FAIRING ASSEMBLY of the tool box properly, press the top side firmly TVS XL100 comfort vehicle comes with a stylish and and then lock it by rotating the key in clockwise elegant Head lamp Fairing assembly with LED DRL, direction.
  • Page 21 SEAT LOCK* TOOL KIT AND FIRST AID KIT To access the carrier*, the pillion seat assembly* To assist you in performing certain aspects of need to be removed. periodic maintenance and emergency repairs, a tool kit is supplied along with the vehicle and it is located To remove the pillion seat assembly, insert the control inside the tool box.
  • Page 22 It is always advisable to take your avoiding the direct water jet towards the unit. vehicle to TVS Motor Company Authorised Main Dealer 2. Use the USB charger only with standard approved / Authorised Dealer.

  • Page 23: Riding Your Tvs Xl100

    Enough fuel for the planned distance of electrical starter. If the ESIL lamp still glows take the running. vehicle to TVS Motor Company Authorised Main Dealer MIL lamp goes OFF after engine start. / Authorised Dealer. Proper working of electric start**.
  • Page 24 • The clutch engages automatically. components. Contact your TVS Motor Company Authorised Main Dealer / Authorised Dealer for • Keep your feet on the foot rest. From now on, usage.
  • Page 25 SOME USEFUL TIPS FUEL ECONOMY Smooth riding The maximum fuel economy is obtained between 30 to 45 km/h (indicated by a green zone on the • Avoid engine idling for long period. It is better to speedometer). There is a drop in fuel economy switch it ‘OFF’...
  • Page 26 Crankcase emission control system The engine of TVS XL100 is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and the fuel system.

  • Page 27: Maintenance

    Fi system, cylinder head, steering components, suspension, chain and wheel components etc., are key items and require very special and careful servicing. TVS Motor Company Limited strongly recommends that the jobs as per the maintenance schedule be performed by your TVS Motor Company Authorised Main Dealer / Authorised Dealer.
  • Page 28 PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier) In free service After free service Item Service Every Every Remarks 500 - 750 2500 - 3000 5000 - 6000 3000 km 6000 km Period from the date of sale 1 months 3 months 6 months Engine cum transmission oil...
  • Page 29 In free service After free service Item Service Every Every Remarks 500 - 750 2500 - 3000 5000 - 6000 3000 km 6000 km Period from the date of sale 1 months 3 months 6 months All fasteners I & TI I &...
  • Page 30 210 ml / leg* IOCL / HPCL / BPCL* ETL 1F* Bharat petroleum MP Grease no. 3 Grease – Servo Gem no. 3 Bechem Bechem premium 3 Chain lubricant – TVS Motor Company TRU SPRAY * Applicable for ‘XL100 comfort’ models only...
  • Page 31 SELF-MAINTENANCE PROCEDURES BATTERY TVS XL100 ‘i-Touch Start’ vehicles are fitted with a maintenance free battery and it is located inside the tool box below seat at front side of the seat. Remove the lid tool box, cover tool box and cover...
  • Page 32 In maintenance free (MF) type battery, it is not lncase of any abnormality or for removal of battery required to top-up the battery with distilled water. from the vehicle, contact TVS Motor Company Authorised Main Dealer / Authorised Dealer. •...
  • Page 33 2. Remove the lid tool box as explained in page electrical system are the main causes for fuse failure. No. 12. Two different fuses are provided in the XL100 they 3. Take out the fuse case. are: 4. Open the fuse case and pull out the blown fuse.
  • Page 34 6. Close the fuse case and re-fix it properly into its location. 7 . Turn ‘ON’ the ignition lock and check for proper functioning of the electrical systems. lncase the fuse fails again, consult the nearest TVS Motor Company Authorised Main Dealer / Authorised Dealer. 8. Re-fit the reflector unit.
  • Page 35 SPARK PLUG Inspect the spark plug gap with a wire gauge / feeler gauge. Readjust the spark plug gap to 0.6 ~ 0.7 mm 1. Pull out the suppressor cap from the spark plug. if required. 2. Clean the dust and mud around the spark plug After cleaning and adjusting the gap, reinstall the mounting to avoid falling inside the cylinder.
  • Page 36 Do not fill excess oil may cause oil leak. Always use ‘TVS the figure. TRU4 PREMIUM oil (SAE 10W30 API-SL, JASO MA2)’...
  • Page 37 Technology (SBT) adjust the brakes with additional care. If not it may result in brakes not working properly. Please contact TVS Motor Company Authorised Main Dealer or Authorised Dealer for any further assistance. 3. Slightly loosen the adjuster nut at top (2).
  • Page 38 5. After obtaining the necessary free play at the 8. Once again check and confirm the brake play at lever end, inspect for the clearance between the the lever end. bullet (3) and slot end (4) marked as ‘S’ as shown in figure.
  • Page 39 Left hand brake lever 3. If the measured free play is more or less than the specified limit, adjust the nut provided at the rear 1. Measure the free play of the left hand brake lever wheel end to obtain the correct play. at the lever end as shown in the figure.
  • Page 40 When the brake is applied, wear limit index mark (A) (serration tooth) with the help of the nearest TVS on both front and rear cam brake should be within the Motor Company Authorised Main Dealer / Authorised range of wear limit indicator (B) on panel assembly.
  • Page 41 TYRES Tyre pressure Check the tyre pressure atleast once in a week if not more frequently. Insufficient air pressure in the tyres not only hasten tyre wear, but also seriously affects the stability of the vehicle. Under inflated tyres make smooth cornering difficult and over inflated tyres decrease the tyre contact with the ground which can lead to skidding and loss of control.
  • Page 42 REAR SHOCK ABSORBERS TVS XL100 is provided with 5 step adjustable rear shock absorbers to meet different load condition. There are 5 notches for adjusting spring load. If the spring is adjusted to the minimum notch, then the shock absorber will be softer which is good for light loads.
  • Page 43 Get the drive chain checked, lubricated 5. Reverse the procedure for reassembling. Locate and adjusted at TVS Motor Company Authorised the lug on fork leg L to the slot in the brake panel Main Dealer / Authorised Dealer at specified intervals while reassembling.
  • Page 44 5. Tilt the vehicle to the left and take out the wheel assembly along with the brake panel assembly. Always make sure that whenever the wheel is removed, 6. Reverse the procedure for reassembly. axle nut is properly re-tightened to the specified torque. REAR WHEEL REMOVAL 1.
  • Page 45 Make sure that the 3. Fill the engine cum transmission oil [TVS TRU4 storage area is well ventilated and free from any PREMIUM oil (SAE 10W30 API-SL, JASO MA2)] source of flame or spark.

  • Page 46: Express Service

    EXPRESS SERVICE … Get your vehicle serviced in 1 hour at no additional cost. Contact your nearest Dealership for details. … Facility available at selected Dealerships only. Terms and conditions apply...

  • Page 47: Expert On Wheels

    EXPERT ON WHEELS Busy Life? Easy Servicing! Now, service your bike anywhere, anytime. Service the vehicle at your door step. Available for regular maintenance or breakdown service only. Offered at nominal convenience charges. … Contact your nearest Dealership for details. …...

  • Page 48: Pickup And Drop

    PICKUP AND DROP Busy Life? Easy Servicing! Now, service your bike anywhere, anytime. Service the vehicle at your door step. Available for regular maintenance or breakdown service only. Offered at nominal convenience charges … Contact your nearest Dealership for details. …...

  • Page 49: Warranty And Services

    While the Company has taken every care to maintain quality in the manufacture of the TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100, the above said warranty is subject to other terms of warranty: ...
  • Page 50 8. This is the only warranty given by the Company for the TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100. No employee, Dealer or other person is authorised to extend or enlarge this warranty.
  • Page 51 List of parts not covered under warranty ITEM WHAT TO CHECK FOR Normal Maintenance operations Engine tune-up, decarbonizing, fuel system cleaning, oil changes, head light focusing, fastener retightening, ignition timing, clutch and brakes as well as other normal adjustments. Wear & tear items Chain, sprockets, clutch and brake linings, fasteners, shims, washers, oil seals, gaskets, O’...
  • Page 52 Others Factors Vehicles on which any warranty service including scheduled paid service is not availed when it falls due (at TVS Motor Company Authorised Main Dealer / Authorised Dealer). Vehicles sold or transferred by original retail purchaser. Vehicles used for racing or any competition or used otherwise than for ordinary personal transportation.

  • Page 53: Service Information

    ..............start / TVS XL100 COMFORT i-TOUCH start / TVS XL100 HEAVY ..............DUTY / TVS XL100 COMFORT / TVS XL 100 vehicle during warranty ..............period. Of these, first three services are free services for which labour charges are free. In addition to these three free services, we Frame number..........
  • Page 54 Please note that carrying out the services for your vehicle at scheduled intervals at any of the TVS Motor Company Authorised Main Dealer / Authorised Dealer is necessary for availing of warranty. And please also remember that, after the services are over, periodic servicing of your vehicle at appropriate intervals, depending upon its extent of use, will keep your vehicle at its best level of performance.

  • Page 55: Technical Specifications

    TECHNICAL SPECIFICATIONS TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / DESCRIPTION TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100 TVS MOTOR COMPANY LIMITED P .B. No. 4, Harita, Hosur - 635 109, India.
  • Page 56 89 kg (TVS XL100 Heavy Duty i-Touch start) Kerb weight (with toolkit and 90% 88 kg ( TVS XL100 COMFORT i-TOUCH start / TVS XL 100 HEAVY DUTY / TVS XL 100) of fuel) 86 kg ( TVS XL 100 COMFORT)
  • Page 57 TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / DESCRIPTION TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100 BRAKES Front Hand operated, internally expanding shoe type 110 mm dia. Rear Hand operated, internally expanding shoe type 110 mm dia.
  • Page 58 TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / DESCRIPTION TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100 ELECTRICAL Tail / brake lamp bulb 12V, 5/21W x 1 Turn signal lamps bulb...
  • Page 59 TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / DESCRIPTION TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100 CAPACITIES Fuel BS VI / Unleaded Petrol 4 litres Fuel tank capacity …… TVS TRU4 PREMIUM oil...

  • Page 60: General Information

    GENERAL INFORMATION Dear Customer, It is mandatory under the Motor Vehicles Act to insure all motor vehicles. No motor vehicle can be used in a public place without a valid policy of insurance issued by an authorised insurer. Driving a motor vehicle without any such insurance is an offense under Motor Vehicles Act.

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