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TVS XL Series Manual
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TVS XL Series Manual

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FOREWORD
Dear Customer,
Congratulations! Over one crore Indians are part of the TVS XL family and now, it gives us great pleasure to welcome you
to it. We hope you have a great journey ahead just as millions of satisfied TVS customers have.
With stringent quality checks, great attention and care has been taken to ensure that your TVS XL 100 is in a perfect
operating condition as it leaves our factory. With a powerful engine and great new features, all you have to do is to fill up
your new TVS XL 100 with fuel and get going.
This manual will help you get the best performance out of your new TVS XL 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 Authorised Distributor or
Dealer / Authorised Service Centers nearest to you. The staff at the Authorised Distributor or Dealer / Authorised Service
Centers have been trained by us to take great care of your after sales/service requirements.
We wish you a long and fruitful journey ahead with your TVS XL 100, for years and years to come.
Warm regards,
TVS MOTOR COMPANY LIMITED
-I-

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Summary of Contents for TVS XL Series

  • Page 1 TVS XL 100 with fuel and get going. This manual will help you get the best performance out of your new TVS XL 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.
  • Page 2 Prior permission of TVS Motor Company Limited is required for quoting, copying or reproducing any part of this owner’s manual.
  • Page 3 SAFETY INFORMATION Operating this vehicle safely is an important responsibility of the rider. To help you make decisions about safety, we have provided 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 hazards associated with operating or maintaining the vehicle, you must use your own judgement.

  • Page 4: Table Of Contents

    CONTENTS Running-in information Know your TVS XL 100 Riding your TVS XL 100 Maintenance Scheduled service record sheet Technical specifications -IV-...

  • Page 5: Running-In Information

    Timely performance of the first free service will ensure optimum service life and performance from the engine. Caution Replacing the engine cum transmission oil during first 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 6: Know Your Tvs Xl 100

    KNOW YOUR TVS XL 100 VEHICLE IDENTIFICATION NUMBER Serial numbers of both frame and engine are required for vehicle identification. They are also required to assist your Dealer for operating parts or referring to special information. The frame serial number is stamped on the right side of The engine serial number is stamped on the top surface the steering head tube.
  • Page 7 KNOW YOUR TVS XL 100 LOCATION OF PARTS - HANDLE BAR Choke lever Horn switch Turn signal lamp switch Rear brake lever Rear view mirror L Headlamp switch High / low beam switch Speedometer Turn signal indicator lamp Ignition switch...
  • Page 8 KNOW YOUR TVS XL 100 CONTROL KEY 2. ‘ON’ position TVS XL 100 comes with a pair of identical control In this position, all the electrical circuits are ‘ON’ keys. These keys are to operate ignition switch, and the engine can be started now. Key cannot be steering lock, fuel tank cap, tool box lock and seat removed in this position.
  • Page 9 3. Turn signal indicator lamp problem with the vehicle’s electrical system and Flashes when the ‘left’ or ‘right’ side turn signal the vehicle may not get start. Contact TVS Motor lamp is activated. Company Authorised Distributor or Dealer / Authorised Service Centers immediately.
  • Page 10 KNOW YOUR TVS XL 100 DAY TIME RUNNING LAMP (DRL) HANDLE BAR LEFT SIDE TVS XL 100 comes with a day time running LED 1. Choke lever lamp which glows automatically once the engine is Pull the choke lever towards left to apply choke.
  • Page 11 KNOW YOUR TVS XL 100 2. Horn switch 6. Head lamp high / low beam switch With the head lamp in ‘ON’ condition, slide the Press the switch ‘ ’ to operate the horn. beam control switch towards ‘ ’ to turn-on the 3.
  • Page 12 Caution brake lamp glows on application of the front brake. The vehicle cannot be started using electric starter with low / discharged battery. Contact TVS Motor Company Authorised Distributor or Dealer / Authorised Service Centers for rectification**. ** Applicable for ‘i-Touch Start’ models only...
  • Page 13 STEERING LOCK FUEL TANK* CAP To open fuel tank cap, insert the key into the lock TVS XL 100 is provided with separate lock for and turn it in clockwise direction. Now, rotate the locking the steering. fuel tank cap in anti-clockwise direction and take To lock the steering, turn the handle bar fully out.
  • Page 14 KNOW YOUR TVS XL 100 Warning Avoid spilling of fuel on the hot engine. Never refill fuel near open flame. Do not smoke while refueling. Do not use cell phones while refueling. Note Whenever refueling the vehicle, fill upto the bottom of the neck portion of the fuel tank.
  • Page 15 Ensure both the legs of stand are touching the ground before placing the vehicle on stand. Warning TVS XL 100 also has a provision for fixing a side Hold the rear brake as a safety precaution while stand (side stand is optional). Side stand can be...
  • Page 16 KNOW YOUR TVS XL 100 TOOL BOX Tool box is located below the seat assembly at the front end. To access the tool kit, first aid kit, fuse and battery** the lid tool box need to be opened. Follow the procedure given below to open the lid: 1.
  • Page 17 KNOW YOUR TVS XL 100 SEAT LOCK* TOOL 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 To remove the pillion seat assembly, insert the located inside the tool box.
  • Page 18 It is always advisable to take your the direct water jet towards the unit. vehicle to TVS Motor Company Authorised 2. Use the USB chager only with standard approved Distributor or Dealer / Authorised Service Centers.

  • Page 19: Riding Your Tvs Xl 100

    - Enough fuel for the planned distance of starting the vehicle using electrical starter. If the running. ESI lamp still glows take the vehicle to TVS Motor Company Authorised Distributor or Dealer / - Correct tyre pressure and adequate tread Authorised Service Centers.
  • Page 20 The clutch engages automatically. maintenance. Petrol mixed with ethanol will have Keep your feet on the foot rest. From now on, impact on engine components. Contact your TVS your road speed is controlled only by throttle. Motor Company Authorised Distributor or Dealer / Always keep to the left of the road.
  • Page 21 Note Make your self familiar with the traffic signs and regulations. The on-road mileage of TVS XL 100 is dependent For safe riding, it is advised to use a good on several factors like road condition, quality of quality helmet while driving.
  • Page 22 Anticipate the barriers ahead and decelerate at the earliest. EMISSION CONTROL All the TVS vehicles 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.

  • Page 23: Maintenance

    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.
  • Page 24 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier) Item Service Service Remarks Every Every 500-750 2500-3000 5000-6000 3000 km 6000 km Period from date of sale 1 month 3 months 6 months Engine cum transmission oil I & T I &...
  • Page 25 MAINTENANCE Item Service Service Remarks Every Every 500-750 2500-3000 5000-6000 3000 km 6000 km Period from date of sale 1 month 3 months 6 months Drive chain* C, L & A C, L & A C, L & A C, L & A –...
  • Page 26 MAINTENANCE RECOMMENDED LUBRICANTS Application Manufacturer Brand Engine cum transmission oil 900 ml TVS Motor 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.
  • Page 27 MAINTENANCE SELF-MAINTENANCE PROCEDURES BATTERY TVS XL 100 ‘i-Touch Start’ vehicles are fitted with a maintenance free battery and it is located inside the tool box below seat’s front side. Remove the lid tool box, cover tool box and cover battery to access the battery by following the procedure given below: 1.
  • Page 28 Distributor or Dealer / Authorised Service lncase of any abnormality or for removal of battery Centers. from the vehicle, contact TVS Motor Company While connecting the terminals, observe the Authorised Distributor or Dealer / Authorised correct polarity. Connect the red wire to the ‘+’...
  • Page 29 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 Distributor or Dealer / Authorised Service Centers. ** Applicable for ‘i-Touch Start’ models only...
  • Page 30 Lighting fuse functioning of the electrical systems. lncase 1. Turn ‘OFF’ the Ignition. the fuse fails again, consult the nearest TVS 2. Remove the screws from the headlamp Motor Company Authorised Distributor or housing assembly on both sides and gently Dealer / Authorised Service Centers.
  • Page 31 MAINTENANCE Inspect the spark plug electrodes (A) and (B) for any SPARK PLUG corrosion. If found any, replace the spark plug with 1. Pull out the suppressor cap from the spark plug. a new. 2. Clean the dust and mud around the spark plug Inspect the spark plug gap with a wire gauge / mounting to avoid falling inside the cylinder.
  • Page 32 Check the oil level as per the schedule to avoid costly damage. Maximum Do not fill excess oil may cause oil leak. Always use ‘TVS TRU4 PREMIUM oil‘ (SAE 10W30 API-SL, JASO MA2) only. Minimum -28-...
  • Page 33 MAINTENANCE BRAKES Front brake 1. Measure the free play of the front 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.
  • Page 34 MAINTENANCE Brake shoe wear limit indicator 3. If the measured free play is more or less than When the brake is applied, wear limit index mark the specified limit, adjust the nut provided at (A) on front and rear brake cams should be within the rear wheel end to obtain the correct play.
  • Page 35 MAINTENANCE 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 36 MAINTENANCE REAR SHOCK ABSORBERS TVS XL 100 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 37 Get the drive chain checked, lubricated and adjusted at TVS Motor Company 4. Lift the front fork up, dislocate the brake panel along with the brake cable. Remove the hub Authorised Distributor or Dealer / Authorised drive and slide the wheel out.
  • Page 38 MAINTENANCE Caution REAR WHEEL REMOVAL 1. Remove the rear brake adjuster nut (1) and Once the split pins are removed, replace them with disconnect the brake cable from the brake new ones. panel assembly. 2. Remove the split pin (2) and the nut (3). STORAGE PROCEDURES Disconnect the torque link.
  • Page 39 This will ensure better tyre life. 3. Fill the engine cum transmission oil [TVS TRU4 8. Cover up the vehicle completely with a clean PREMIUM oil (SAE 10W30 API-SL, JASO tarpaulin or any other suitable cover.

  • Page 40: Scheduled Service Record Sheet

    SCHEDULED SERVICE RECORD SHEET SCHEDULED SERVICE RECORD Sl.No. Description (kms or month whichever of the Odometer Job card no. / Date Servicing Dealer’s two occurs early from the date of purchase) reading stamp and sign. 1st service between (a) 500 - 750 km or (b) 1 month 2nd service between (a) 2500 - 3000 km or (b) 3 months 3rd service...
  • Page 41 SCHEDULED SERVICE RECORD SHEET Sl.No. Description (kms or month whichever of the Odometer Job card no. / Date Servicing Dealer’s two occurs early from the date of purchase) reading stamp and sign. 8th service between (a) 20500 - 21000 km or (b) 21 months 9th service between (a) 23500 - 24000 km or (b) 24 months 10th service...

  • Page 42: Technical Specifications

    TECHNICAL SPECIFICATION MANUFACTURER : TVS MOTOR COMPANY LIMITED P.B. No. 4, Harita, Hosur - 635 109, India. ENGINE TRANSMISSION Type : Single cylinder, 4 stroke, air Clutch : Centrifugal shoe type wet clutch cooled spark ignition engine Primary transmission : Single speed gear box...
  • Page 43 TECHNICAL SPECIFICATION CHASSIS BRAKES Maximum laden weight : 210 kg Front : Hand operated, internally (XL 100, XL 100 Comfort STD) expanding shoe type 80 mm : 214 kg dia. drum (XL 100 Heavy Duty) : 216 kg Rear : Hand operated, internally (XL 100 i-Touch start) e x p a n d i n g s h o e t y p e : 217 kg...
  • Page 44 Fuel : Unleaded petrol Fuel tank capacity : 4.0 liters (including reserve) Reserve : 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...

This manual is also suitable for:

Xl 100