TVS KING KARGO Manual
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TVS KING KARGO Manual

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(Liquid cooled 4 Stroke Petrol)
Owner's manual / TVS King Kargo / Petrol / English / Rev.0 / August 2021

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Summary of Contents for TVS KING KARGO

  • Page 1 (Liquid cooled 4 Stroke Petrol) Owner’s manual / TVS King Kargo / Petrol / English / Rev.0 / August 2021...
  • Page 2 CUSTOMER DATA NAME : ..............Address : ....................................................................................PIN Code :..........Mobile No : ..........Tel. No : ..........Alt. Mobile No : ..........Booklet No : ..........Date of sale : ..........Vehicle Chassis No : ..........Engine No : ..........
  • Page 3 .We hope it will fulfill your dreams and ambitions. This booklet is your guide to maintain and operate your TVS King Kargo. So please read and follow the manual carefully to enjoy years of pleasurable riding and increased earnings. As with any good machine, proper care and maintenance is essential for trouble free operation and optimum performance of your vehicle.
  • Page 4 All information illustrations, photographs and specifications contained in this owner's manual are based on the latest product information available at the time of this publication. TVS Motor 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.
  • Page 5 In case of critical problems during the course of product usage, servicing or any technical assistance you may contact us at TVS Motor Company Limited. P .B. No.4, Harita, Hosur - 635 109 Tamil Nadu, India. Tel: +91(4344) 276780. Website: www.tvsmotor.com/ib/home...
  • Page 6 Safety of yours and others are very important while operating this vehicle . To help you make informed decision about safety, we have provided operating procedure and other information on labels in this manual. This information alerts you on potential hazards that could hurt you , others and goods.

  • Page 7: Table Of Contents

    Page.No. Description Useful Information Vehicle Identification Number Know Your Vehicle Features in Your Vehicle Safe Riding Tips Operating Your Vehicle Periodic Maintenance Schedule CONTENTS Recommended Lubricants Self-Maintenance Procedures Service Record Sheet Technical Specifications...

  • Page 8: Useful Information

    Running-in information. The first 2000 km is a crucial part of TVS King Kargo. Proper running-in operation during this period helps in ensuring a longer life and smooth performance of your vehicle. During running-in period do not exceed following speed limits .

  • Page 9: Vehicle Identification Number

    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 Distributor or Dealers for ordering parts or referring to special information Know your 0L4LJ4 900522...
  • Page 10 Know your vehicle VEHICLE - LH (LT - Load Tray) VEHICLE LH 1. Soft top assembly 2. Load tray Integrated Foot Step 3. Spare wheel with cover 4. Petrol Tank 5. Driver back rest 6. Driver seat 7. Hand starter lever 8.
  • Page 11 Know your vehicle VEHICLE LH VEHICLE - LH (PF - Plat Form)** 1. Soft top assembly 2. Load tray Integrated Foot Step 3. Spare wheel with cover 4. Petrol Tank 5. Driver back rest 6. Driver seat 7. Hand starter lever 8.
  • Page 12 Know your vehicle VEHICLE LH VEHICLE - LH (DAC - Drive Away Chassis) 1. Soft top assembly 2. Spare wheel with cover 3. Petrol Tank 4. Driver back rest 5. Driver seat 6. Hand starter lever 7. Mirror assembly LH VEHICLE - RH VEHICLE - RH (DAC - Drive Away Chassis) 8.
  • Page 13 Know your vehicle FRONT VIEW FRONT VIEW 1. Wiper blade 2. Turn signal lamp 3. Head lamp 4. Position lamp 5. Front brake fluid hose 6. Logo grill 7. Number plate bracket front 8. Wind shield glass 9. Rear view mirror REAR VIEW REAR VIEW 10.
  • Page 14 Know your vehicle CONTROL PANEL CONTROL PANEL 1. Glove box LH 2. Clutch operating lever 3. Speaker grill LH 4. Music switch cluster 5. Mobile charger unit 6. Cluster assembly tell tale lamp 7. Fuel level gauge 8. Speaker grill RH 9.
  • Page 15 Know your vehicle DRIVER CABIN - RH DRIVER CABIN - RH 1. Handle bar 2. Wiper motor 3. Dash board 4. Hand brake control lever 5. Master cylinder assembly 6. Brake pedal 7. Driver seat CONTROL SWITCHES - LH CONTROL SWITCHES - LH CONTROL SWITCHES - RH 8.
  • Page 16 Know your vehicle LOAD Body Load Body 1. Load body side door latch lever Rear RH 2. Integrated load body foot step 3. 3 Side openable doors 4. Load body mounting - 6 nos. 5. Load body door stopper 6. Rope hook 7.

  • Page 17: Features In Your Vehicle

    Here you can familiarize yourself with operation of features provided in your vehicle. 1. Control Key operations 2. Safety Features 3. Operating Features Accessories provided with the vehicle 1. Tool Kit 2. Owner’s Manual 3 . Chassis Mounted Bumper 4. Idol Stand Kit FEATURES IN 5.
  • Page 18 Turn the key anti-clock direction Ignition switch TVS King Kargo comes with a set of two control keys. 2. Steering lock. This key is used to operate ignition switch, steering lock, glove To protect your vehicle from theft, steering lock is provided in box and fuel lid.
  • Page 19 Features in your vehicle Closed Direction Open Direction 4. Service door 3. Fuel tank cap with locking system To open the Service door a latch lever is provided on the Fuel tank cap is provided on the LH side of the vehicle. service door.
  • Page 20 Features in your vehicle 5. Glove boxs 6. Switch assembly LH It is provided on the left hand side and right hand side of the It is positioned on Handlebar LH dash board. We can store up to 2.9 liters (Aprox) in each a) Head Lamp Switch glow box.
  • Page 21 Features in your vehicle TVS King Kargo comes with DC headlamp. In this switch 7. Switch assembly RH position, ‘ ’head lamp also will glow along with It is located on the handlebar RH speedometer lamps, tail lamps, number plate lamp and position lamp irrespective of Engine ON / Off condition.
  • Page 22 10. Mobile charger being restarted. To restart the engine, again short Press Your TVS King Kargo comes with smart USB type mobile the switch. charger on idol stand as shown in the below fig.
  • Page 23 Features in your vehicle Parking brake lever Speedometer and Odometer a. Speedometer b. Odometer 12. Speedometer & Odometer 11.Parking brake lever. It is provided below the dash board. Use the parking a. Speedometer brake while parking the vehicle especially on gradient to Indicates the vehicle on- road speed in kilometer per hour.
  • Page 24 Features in your vehicle 13.Tell tale lamps 13. Tell tale lamps a. Turn signal indicator lamps b. High temperature warning lamp c. Neutral indicator lamp d. High beam indicator lamp e. Engine oil pressure indicator f. Malfunction indicator lamp ( not applicable ) g.
  • Page 25 Features in your vehicle 15.Tube complete throttle Engine rpm is controlled by the position of the throttle grip. Rotate it in anti-clockwise to increase the engine rpm. Rotate it clockwise or release it to decrease the engine speed. Clutch lever & Tube complete throttle. 14.
  • Page 26 Features in your vehicle 17.Petrol Choke Box spanner Use the petrol choke lever when vehicle is starting in petrol mode , pull the lever up -wards to operate the choke Extension rod Screw driver CAUTION Remember to release the choke in petrol mode after 14X17 starting.
  • Page 27 Load Body 21. Load body 20. Utility box Utility box is fitted in RH side of the vehicle. It is Your TVS Kin g Kargo GK LT ariant comes with load provided with locking system. you can store up to deck.
  • Page 28 Factory fitted USB drive allows you to enjoy 4. USB port your favorite music. Set of Speakers not only gives you a 5. Aux Port pleasant journey but also entertains your passenger. Stay tuned to FM channels with TVS KARGO FM stereo system.
  • Page 29 Features in your vehicle Music player : Automotive qualified music player capable of playing from common flash drives in MP3 format and FM radio. Power wattage : 10 +10 Watts Stereo Amplifier - Class AB Dimensions of Music Player : 76mm x 120mm x 31.5mm Weight of Music Player : 196 grams Operating Temperature...
  • Page 30 Features in your vehicle Aux Port : 3.5 mm Stereo. USB Socket : 1 no. of USB socket for interface with common flash drives. Speakers : 2 nos. of 15+15 Watts speakers with water & dust protection. FM Radio : PLL based auto tuning capability in frequency range of 88-108 MHZ. Volume Controls : 8 steps digital "UP - DOWN"...
  • Page 31 Features in your vehicle The various switch cluster operations of SYMBOLS BUTTONS OPERATIONS music system are listed as follows: ON / OFF To switch ON & OFF the system Volume Up To increase volume Volume Down To decrease volume Play / Pause In Bluetooth mode and MP3 mode: To Play or Pause the tracks Not function in FM mode...
  • Page 32 Features in your vehicle Switching operations ( ON/OFF ( ) Switch Power on switch has 4 position toggle mode operations (refer drawn flow chart). After switching on ignition key, press once ‘ ‘, music system starts automatically on FIRST PRESS Bluetooth mode.
  • Page 33 During switch 'ON' the system starts with default 50% volume. Select TVS MOTOR and pair the device. CAUTION After pairing, you can play the songs from smart phone. Always maintain pleasant sound level in public places in Press (+) button to increase the volume and Press (-) button to order to have healthy atmosphere with co riders.
  • Page 34 Features in your vehicle In FM Mode: Wrong forcible insertion may result in damaging the socket or drive or both. To tune to next channel press button ‘ ‘ once. To tune to previous channel press button ‘ ‘ once. This system has 70 mm length USB adopter cable which is part of factory fitment.
  • Page 35 Aux Port : Any attention grabbing activity like listening to good music TVS KARGO music system is fitted of 3.5 mm stereo aux port. while driving a high powered machine like “TVS KARGO” need to be done with adequate precautions for one's own If you want to listen music from your music player or smart safety and other road user's safety.

  • Page 36: Safe Riding Tips

    Importance Your safety and safety of others is very important. Operating this vehicle safely is a big responsibility . For safe driving SAFE RIDING TIPS Always make a pre ride inspection before you start the vehicle. We suggest that you practice driving your vehicle in a non traffic situation until you are thoroughly familiar with your vehicle operations and its control.

  • Page 37: Operating Your Vehicle

    OPERATING YOUR VEHICLE - The vehicle will start moving forward. As the vehicle Starting the vehicle picks up speed shift to the next higher gear. Select - Insert the ignition key in the ignition switch and turn it the required gears in similar manner. clockwise to ON position.
  • Page 38 Fuel saving tips WARNING ● Carry out the periodic maintenance services regularly at Do not press the clutch while braking at high speeds. TVS authorised distributor or dealers / authorized service Always apply the parking brake while parking on center. gradient.
  • Page 39 It is recommended to top up distilled water only at Battery Specification Authorised proprietary Service Centres. For maintenance of electrical system, it is recommended TVS Petrol vehicle comes with lead acid type 12V, ● to approach our Distributor or Dealer / Authorized 32Ah battery.

  • Page 40: Contents

    Periodic Maintenance Schedule 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000 Parameters S.No Activity 40-45 95-100 145-150 200-205 250-255 305-310 355-360 410-415 460-465 515-520 565-570 620-625 670-675 725-730 775-780 830-835...
  • Page 41 Periodic Maintenance Schedule 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000 Parameters S.No Activity 40-45 95-100 145-150 200-205 250-255 305-310 355-360 410-415 460-465 515-520 565-570 620-625 670-675 725-730 775-780 830-835...
  • Page 42 Periodic Maintenance Schedule 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000 Parameters S.No Activity 40-45 95-100 145-150 200-205 250-255 305-310 355-360 410-415 460-465 515-520 565-570 620-625 670-675 725-730 775-780 830-835...
  • Page 43 Periodic Maintenance Schedule 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000 Parameters S.No Activity 40-45 95-100 145-150 200-205 250-255 305-310 355-360 410-415 460-465 515-520 565-570 620-625 670-675 725-730 775-780 830-835...

  • Page 44: Recommended Lubricants

    BECHEM PREMIUM III BECHEM Coolant Antifreeze -37º , 50:50 Castrol Radicool SFO Premix 1400ml CAUTION Use only TVS Motor Recommended genuine lubricant & coolant. * Applicable only for Asia & Asean Country’s Applicable only for Africa, Middle east & Latam Country’s...

  • Page 45: Self-Maintenance Procedures

    ● Allow 5 to 10 min for the oil to settle down. Attending major maintenance work and repairs yourself can affect the performance of your vehicle. Approach TVS authorised Dealer or service center in the case of any ● Remove the dip stick from its location. major problem.
  • Page 46 Self maintenance procedure Differential Oil level checking and topping up Differential oil level can be checked with the help of oil level checking bolt provided on cover differential. ● Park the vehicle on the level ground. ● Allow 5 to 10 min. for the oil to settle down. ●...
  • Page 47 Self maintenance procedure Engine Oil Replacement Engine Oil Replacement ● Refit drain plug along with plain washer and tighten it. ● Run the Engine for a few minutes to warm up the oil ● Remove the dip stick and pour the correct quantity of ●...
  • Page 48 Self maintenance procedure ● Loosen and take out the filler bolt and fill correct quantity of recommended oil by using special tool. ● Tighten filler bolt. Check oil level ● Replace differential oil at every 10000Km Tool name Tool size Differential Oil Replacement Ring spanner, Tubular spanner 17mm...
  • Page 49 Self maintenance procedure SPARK PLUG LOW Engine Oil Pressure Indicator ● It is located on cluster assembly tell tale lamp as shown Cleaning the spark plug in the figure. ● Pull out the suppressor cap from the spark plug. ● This indicator must glow in Ignition switch ON and ●...
  • Page 50 Self maintenance procedure Changing tyres and wheels Tool name 16 mm plug spanner 1. Spare wheel removal Spark plug Gap 0.6 - 0.7mm ● Spare wheel is fitted to the Left Side chassis of the vehicle below the load deck. Spark plug Type Bosch UR 6 DE ●...
  • Page 51 Self maintenance procedure Spare wheel removal Assembly ● While assembling the spare wheel tighten the wheel nuts diagonally. NOTE Mount the spare wheel on the bracket properly and tighten ● Lower the vehicle slowly to the ground then tighten the the nuts thoroughly, close the spare wheel with cover.
  • Page 52 Self maintenance procedure Tyre Assembly Rotation of tyre is recommended for uniform tread wear on all the wheel positions to achieve optimum tyre life. So it is advised that rotation of tyres be carried out after every 5000 kms. CAUTION Front Rear The best tyres should always be fixed at the rear wheels...
  • Page 53 Self maintenance procedure BRAKES WARNING In the case of changing brake fluid it is recommended to approach our Distributor or Dealer / Authorized Service centers. Avoid dust entry to the fluid reservoir while topping up. Bellows should be kept in good condition and replace. Rubber bellows for propeller shaft Brake fluid level checking &...
  • Page 54 Self maintenance procedure ELECTRICAL Head lamp bulb removal To replace bulb ● Remove the headlamp bulb holder ( A ) from reflector housing which is located under the dash board. ● Gently pull out the Rubber Boot (B) from reflector housing. ●...
  • Page 55 Self maintenance procedure Front turn signal bulb replacement ● Loosen and remove screws ( 1 nos. ) ( A ) holding the lens. ● Remove lens. Push the bulb in and twist in anti clockwise direction to remove bulb. ● Replace bulb and assemble back in reverse order of removal.
  • Page 56 Self maintenance procedure Clutch cable adjustment Throttle cable adjustments Clutch cable adjustment Throttle cable adjustment Clutch free play is measured at the clutch lever end. Throttle cable free play can be measured by holding the ● Loosen lock nut ( A ). adjuster and pulling the cable gently out.
  • Page 57 Self maintenance procedure Clutch cable inner replacement Removal ● Loosen the stopper nut at rear ● Remove cable from release lever ( A ) ● Take out the cable from stopper ● Disconnect cable from lever end ● Pull out cable inner from lever end Clutch cable assembly at pulley end Assembly ●...
  • Page 58 Self maintenance procedure Gear cable inner replacement Removal ● Loosen lock nut (A) and adjuster nut (B) at engine end ● Remove cover handle bar ( C ) by loosening two screws ● Remove the lock clip ( D ) ●...
  • Page 59 Self maintenance procedure ● Connect adjuster to stopper gear cable at engine end. ● Connect the pulley to shaft gear shifter and tighten nut. ● Connect pulley to handle bar end and insert sleeve in to handle bar ● Lock the pulley with clip ●...
  • Page 60 In case vehicle is operating very dusty environment, it is recommended to clean the air filter frequently for better life of engine WARNING Approach nearby TVS Authorised Distributor or Dealer / Service Center incase the high engine temperature Engine High Temperature Warning Lamp warning lamp glows contentiously.
  • Page 61 Top up only TVSM recommended Premixed Coolant. WARNING Do not over fill the reservoir. Approach nearby TVS Authorised Distributor or Dealer / Do-not mix the different brand coolant. Service Center incase the Charging and Low Battery Voltage Indicator lamp glows contentiously.

  • Page 62: Service Record Sheet

    Service Record Sheet S.No Description Odometer reading Job card number / date Servicing dealers stamp & sign 1st Service 2nd Service 3rd Service 4th Service 5th Service 6th Service 7th Service 8th Service 9th Service 10th Service 11th Service 12th Service 13th Service 14th Service 15th Service...

  • Page 63: Technical Specifications

    Technical Specifications Models Chassis & Dimensions TVS King GK LT / GK PF / - (Petrol With Load tray / Platform Frame - Semi Monocoque chassis - Pressed longitudinal & cross members GK DAC /Drive Away Chassis) Overall Length - 3010 mm...
  • Page 64 Technical Specifications Brakes Capacity Front & Rear - Drum & Foot Operated, Hydraulic, Fuel tank - 15 ± 0.5 litre Internally Expanding Shoe with Auto Engine oil grade - TRU4 DURAMATE oil (20W40 API-SL, Adjuster type JASO Ma2)* Parking - Hand brake (mechanical) - TRU4 DURALIFE oil (20W50 API-SL, Brake fluid grade - DOT 3 / DOT 4...

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