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

I
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.

…
Facility available at selected Dealerships only. Terms and conditions apply

II
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.
…
Facility available at selected Dealerships only. Terms and conditions apply

III
CONTENTS

EXPRESS SERVICE I
EXPERT ON WHEELS II
PICKUP AND DROP III
CONTENTS IV
CONTACT(S) FOR SUPPORT 1
FOREWORD 5
NOTICE 6
SAFETY INFORMATION 7
RUNNING-IN INFORMATION 8
KNOW YOUR TVS XL100 9
RIDING YOUR TVS XL100 22
MAINTENANCE 26
WARRANTY AND SERVICES 48
SERVICE INFORMATION 52
TECHNICAL SPECIFICATIONS 55
GENERAL INFORMATION 60

IV
CONTACT(S) FOR SUPPORT

Incase you need any Clarification please contact

TVS Motor Company Authorised Main Dealer / Authorised Dealer
Or
TVS Motor Company’s Area Offices (flip over for addresses)
Or

Toll Free Number : 1800-258-7111

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.

1
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. 502B, 6th Floor, B Wing,
No. 2, MC Nichols Road, 15th Cross, 6th Phase, JP Nagar, Shriram Shyam Towers,
Chetpet, Chennai - 600 031. Opp. BMTC Bus Stop, Near LIC Square, Sardar,
Phone : 044-28361651/28361654 Bangalore - 560 078. Nagpur - 440 001.
Email : AO.Chennai@tvsmotor.com Phone : 080-26653433 Phone : 0712-2569932
AO.Madurai@tvsmotor.com Email : AO.Bangalore@tvsmotor.com Email : Service.Nagpur@tvsmotor.com
AO.Raipur@tvsmotor.com
TAMILNADU-2 ANDHRAPRADESH & TELANGANA
2. TVS Motor Company Limited 5. TVS Motor Company Limited GUJARAT
No. 10, 2nd floor, Rukumani Towers, First Floor, 8. TVS Motor Company Limited
Shree Shanmugapriya Towers, No. 3-11-30, Plot No. 11, 1208-1213, Shivalik Satyamev,
Kannuswamy Street, Paigha Colony, Behind Anand Theater, Below Bopal Over Bridge,
Behind Hotel Annapoorna, Secunderabad - 500 003. Ambli-SP Ring Road Junction, Bopal,
R S Puram, Coimbatore - 641 002. Phone : 040-27840590/27844419 Ahmedabad- 380 058.
Phone : 0422-4350060/2541035 Email : AO.Hyderabad@tvsmotor.com Phone : 079-65443748
Email : AO.Coimbatore@tvsmotor.com AO.Vijayawada@tvsmotor.com Email : AO.Ahmedabad@tvsmotor.com

KERALA MAHARASHTRA-1 & 2

3. TVS Motor Company Limited 6. TVS Motor Company Limited
Ambady Towers, Second Floor, No. 401, 4th Floor, The Chambers,
Door No. 27/631, A6, Plot No. 4/12/3, Near Ganapati Chowk,
Edappally-Pookkattupady Road, Viman Nagar, Pune - 411 014.
Edappally PO., Cochin - 682 024. Phone : 020-26632112/26632110
Phone : 0484-2544578/2556938 Email : Service.pune@tvsmotor.com
Email : AO.Cochin@tvsmotor.com

2
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,
Chinar Incube Business Centre, Sector - 10, Noida, Vibhuti Khand, Gomti Nagar,
Chinar Fortune City, Uttar Pradesh - 201 301. Lucknow - 226 010.
Near Brindhavan Dhaba, Phone : 011-29834640/29834773 Phone : 0522-4918300/4918301
Hosangabad Road, Email : AO.Delhi@tvsmotor.com Email : AO.Lucknow@tvsmotor.com
Bhopal - 462 026.
Phone : 0755-2499406/2499306 PUNJAB & CHANDIGARH WEST BENGAL
Email : AO.Bhopal@tvsmotor.com 12. TVS Motor Company Limited 15. TVS Motor Company Limited
AO.Indore@tvsmotor.com 4th Floor, Royal Business Park, Ground Floor & First Floor,
Chandigarh Ambala Highway, 133 A. S. P. Mukherjee Road,
RAJASTHAN-1 & 2 Zirkapur - 140 603. Opp. Tollygunge Police Station,
10. TVS Motor Company Limited Phone : 01762-464777/465777 Kolkatta - 700 026.
Plot No. 17-18, Email : AO.Chandigarh@tvsmotor.com Phone : 033-24617096/24617092
2nd Floor of National Motors Building, Email : AO.Kolkatta@tvsmotor.com
Jhotwara Industrial Area, UTTAR PRADESH WEST
Jaipur - 302 012. 13. TVS Motor Company Limited BIHAR
Phone : 0141-5150901/5150902 D-3 & D-4, 2nd Floor, 16. TVS Motor Company Limited
Email : AO.Jaipur@tvsmotor.com Sector - 10, Noida, N-Plaza, Jamal Road,
AO.Udaipur@tvsmotor.com Uttar Pradesh - 201 301. P.S. Kotwali,
Phone : 011-29834640/29834773 Patna - 800 001.
Email : AO.Delhi@tvsmotor.com Phone : 0612-2200068/2200069
Email : AO.BNJ@tvsmotor.com

3
ORISSA & JHARKHAND
17. TVS Motor Company Limited
No. 303, 3rd Floor,
Creative Plaza, Rasulgarh,
Bhubaneshwar - 751 010.
Phone : 0674-2580019
Email : AO.Bhubaneshwar@tvsmotor.com

NORTH EAST STATES

18. TVS Motor Company Limited
147, Udayan, Ganesh Guri,
Near Hotel D Courtyard,
R G B. Road, Guwahati - 781 005.
Phone : 0361-2202030/2202031
Email : AO.Guwahati@tvsmotor.com

4
 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 XL100 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 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.
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 Main
Dealers / Authorised Dealers nearest to you. The staff at the Authorised Main Dealers / Authorised Dealers 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 XL100, for years and years to come.
Warm regards,

TVS MOTOR COMPANY LIMITED

5
 NOTICE

This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold
or transferred to a new owner.
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.
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 be a part of standard equipment.

Pictures shown in the manual are of TVS XL100 i-Touch Start until otherwise specified.

Since your vehicle is fitted with side stand cut-off system ensure to retract the side stand before starting the vehicle.

TVS XL100 comes with the BSVI complaint futuristic fuel injection technology which delivers best-in-class
performance. Ensure to maintain the vehicle in its top-notch condition by getting it serviced periodically at TVS
Motor Company Authorised Main Dealer / Authorised Dealer. Always drive the vehicle with enough amount of fuel
(Low Fuel indicator shall not come ON).

Revision 6, As on 24 Nov 2022

6
 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.
You will find important safety information in following form in this manual. These words carry the following connotations:

Disregarding this message might result in injury to the rider or deadly accidents.

This message indicates special procedures or precautions to be followed to avoid damage to the vehicle.

This message provides further clarification for clear understanding of any particular information.

7
 RUNNING-IN INFORMATION

The first 1000 km is a crucial part of your vehicle. Proper running-in operation during this period helps in ensuring a
maximum life and smooth performance of your vehicle.
The reliability and performance of your vehicle depends on the 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 free service at 500 ~ 750 km is most important. During running-in period all the engine components and
other parts will have set in. All adjustments to be restored, all fasteners to be tightened. Engine cum transmission oil
to be replaced. 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.
Since your vehicle is fitted with the Evaporative Emission Control System, the vehicle should not be laid on the floor
during water wash. Else it may lead to difficulty in starting and improper running of the motorcycle.

8
 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.

The frame serial number is stamped on the right side The engine serial number is stamped on the top
of the steering head tube. surface of right side crankcase near engine breather
tube.

9
LOCATION OF PARTS - HANDLE BAR
1. Horn switch
2. Turn signal lamp switch
4 5 6 7 8 9 10 3. Left hand brake lever
4. Head lamp switch
5. High / low beam switch
6. Speedometer
7. Turn signal indicator lamp
3 11 8. Ignition switch
9. High beam indicator lamp
10. Malfunction indicator lamp
11. Right hand brake lever
12. Throttle grip
12 13. i-Touch Start with Engine Kill
2 switch**
13 14. Electric system indicator lamp**
1
14 15. Low fuel warning indicator lamp

15

** Applicable for ‘i-Touch Start’ models only

10
CONTROL KEY
TVS XL100 comes with a pair of identical control
keys. These keys are to operate ignition lock, steering Keep the ignition key in OFF position, when the
lock, fuel tank cap, tool box lock and seat lock*. vehicle is not in use to prevent battery drain.**
IGNITION LOCK If the vehicle is not started for prolonged time after
The ignition lock enables and disables the electrical switching ON the ignition key the vehicle may not
circuit. The two positions of the lock are described start with the self start immediately. Turn OFF the
below: ignition key and turn it ON again to start the vehicle
1. ‘OFF’ position using self start.**
All the electrical circuits are deactivated. The key can
be removed from the lock.
2. ‘ON’ position
All the electrical circuits are activated. Engine can be When you switch ON the ignition key, the pump
started. Control key cannot be taken out from the priming noise may be heard which is normal. Avoid
lock. frequent switch OFF & ON of the ignition key to avoid
unnecessary run of fuel pump.
Tail lamp, day time running lamp (DRL), brake lamp and
head lamp of the vehicle glows only after starting the
vehicle.

* Seat lock is not applicable for Comfort models

** Applicable for ‘i-Touch Start’ models only

11
SPEEDOMETER ASSEMBLY 2. Odometer
1. Low fuel warning indicator lamp# Displays the total distance covered by the vehicle
‘Low Fuel Warning Indicator lamp (LFI)’ is a safety in kilometers. The last digit denotes one tenth of a
indicator to caution you to fill the petrol as soon as kilometer.
possible. Minimum 1.25 liter of petrol will be available 3. Speedometer
in the tank when this indication comes ‘ON’. Indicates vehicle speed in kilometers per hour.
4. Turn signal indicator lamp
4 5 Flashes when the ‘left’ or ‘right’ side turn signal lamp
is activated.
3 5. High beam indicator lamp
6 Glows when the head lamp high beam is activated.
2 6. Malfunction indicator lamp (MIL)
MIL is turned ON when the ECU detects a fault in
the system.
1 7 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.
During every key ON, the MIL glows and turns OFF once
‘LFI’ is not a mileage calculating medium and it should not be
# the engine starts. This is a part of self check, which is
used for measurement of fuel consumption. normal.

12
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. and continue to glow till the engine is turned ‘OFF’ or
If this indicator glows continuously even after starting head lamp is switched ‘ON’.
the vehicle, it indicates that there is some problem
with the vehicle’s electrical system. Contact TVS
Motor Company Authorised Main Dealer / Authorised
Dealer immediately.

If the ESIL lamp glows continuously once the ignition is

turned ON , then there may be a issue with the vehicle’s
electrical system and the vehicle may not get started.
Contact TVS Motor Company Authorised Main Dealer /
Authorised Dealer incase if this error occurs.
Please make a note that the failure of bulbs will not be
shown by the electrical system indicator lamp (ESIL) and
MIL lamp.

** Applicable for ‘i-Touch Start’ models only

13
HANDLE BAR LEFT SIDE SBT technology helps to operate both front and rear
1. Horn switch brakes by distributing the force optimally between
Press the switch ‘ ’ to operate the horn. the two braking system. The brake lamp glows on
application of brake.
2. Turn signal lamp switch
Slide the turn signal lamp switch to left ‘ ’ or right
side ‘ ’ to operate respective turn signal lamps (LH/
In the vehicles fitted with SBT brake system, it is
RH). Slide the knob to the center position to turn
essential to maintain the brake system in good condition
‘OFF’ the lamps. to ensure its effectiveness. Adjust the SBT at periodic
3. Left hand brake lever (SBT brake lever) intervals without fail for the proper working of system.
Synchronized Braking Technology (SBT) can be
Always use the appropriate turn signal lamps when you
operated by pressing the left hand brake lever gently
intend to change lanes or take turns. Be sure to switch
towards the handle grip.
‘OFF’ the turn signal lamps after negotiating the turns
or lanes.

3 4 5 4. Head lamp switch

Head lamp switch has two positions, they are:
OFF : Head lamp and speedometer back illumination
are turned ‘OFF’ when the switch is positioned
at ‘ ’ even though the engine is running.
ON : Head lamp and speedometer back illumination
2 glows when the switch is positioned at ‘ ’
and engine is running.

14
5. Head lamp high / low beam switch HANDLE BAR RIGHT SIDE
With the head lamp in ‘ON’ condition, slide the beam 1. Throttle grip
control switch towards ‘ ’ to turn-on the head lamp Engine speed is controlled by the rotation of the
high beam. Slide the switch towards ‘ ’ to turn-on throttle grip. Twist it towards you to increase the
the head lamp low beam. engine speed and away from you or release it to
decrease the engine speed.
2. Right hand brake lever
The front brake is applied by squeezing the right hand
Use appropriate head lamp beam ‘high / low’ as per the brake lever gently towards the throttle grip. The brake
traffic and road conditions for your safety and to avoid lamp glows on application brake.
inconvenience to other riders.
2

In ‘i-Touch Start’ models, if the vehicle is left in idling

for more than 20 seconds (approx.) with the head lamp
ON condition, the intensity of the head lamp will reduce
automatically to avoid draining of battery.

3 1

Brakes are items of personal safety and should always

be maintained in proper condition.

15
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 ‘ ‘ the To lock the steering, turn the handle bar all the way to
engine but to keep other DC system active. The the left, insert the control key into the lock and rotate
ignition circuit is disabled, preventing the engine it in clockwise direction and take out. For unlocking
from being started. To restart the engine, return the insert the key in the lock and turn it in anti-clockwise
switch to the ‘ ‘ position. direction and take out.
To start the engine electrically, ensure the side stand
is retracted, keep the switch in ‘ ‘ position, apply
any one the brake and press the switch to ‘ ‘
position and release.
The ESIL lamp blinks while starting the vehicle
electrically. Refer page No. 013 for more details.

The vehicle cannot be started using electric starter

with low / discharged battery or retracted side stand.
Incase of low / discharged battery, contact TVS Motor
Company Authorised Main Dealer / Authorised Dealer
for rectification.** Never attempt to move the vehicle when the steering is
** Applicable for ‘i-Touch Start’ models only locked, you may lose balance.

16
FUEL TANK# CAP
To open the fuel tank cap, insert the key into the lock
Avoid spilling of fuel on the hot engine. Never refill fuel
and turn it in clockwise direction. Now, rotate the fuel
near open flame. Do not smoke while refueling. Do not
tank cap in anti-clockwise direction and take out. Key use cell phones while refueling.
cannot be taken out of the cap in this condition.
Fill the required amount of petrol (as per the tank
capacity) and refit the fuel tank cap in the reverse
order of removal. Whenever refueling the vehicle, fill maximum upto the
bottom of the neck portion of the fuel tank. Filling above
the neck may result in seepage of fuel from the fuel tank
cap.

EVAPORATIVE EMISSION CONTROL SYSTEM

This vehicle is fitted with Evaporative Emission
Control System (EVAP). If there is any abnormal jerk,
startability issue are felt in the vehicle or noise due
to sudden escape of gas during opening of fuel tank
cap, immediately report to the 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.
#
Fuel tank is not a measuring instrument and capacity of the
fuel tank may slightly vary from the indicated capacity.

17
KICKSTARTER LEVER STANDS
The kickstarter lever is located on the right side of the To place the vehicle on center stand (1), hold the
engine. The engine can be started by kicking the lever handle bar left grip with the left hand and load carrier
with the ignition key in ‘ON’ position and engine kill / pillion handle with the right hand.
switch ‘ ‘ position**, while applying the rear brake Place your foot firmly on the center stand extension
as a safety precaution. (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.

1a
1
Hold the rear brake as a safety precaution while starting
the vehicle to avoid rear wheel rotation and loss of
control.

** Applicable for ‘i-Touch Start’ models only #

Optional accessories will be charged extra

18
 TOOL BOX
Always retract the side stand to its full up position before Tool box is located below the seat assembly at the
starting the vehicle. Else, the vehicle will get ‘Switched front end. To access the tool kit, first aid kit, fuse and
OFF’. In key ‘ON’ & side stand deployed condition, battery the lid tool box need to be opened. Follow the
continuous beep sound will be released from the vehicle procedure given below to open the lid:
to alert the rider to retract the side stand before starting 1. Insert the control key into the lock of lid tool box
the vehicle. 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
Never sit on the vehicle when it is supported by side
of the tool box properly, press the top side firmly
stand. Always park the vehicle on a flat, firm surface.
and then lock it by rotating the key in clockwise
HEAD LAMP FAIRING ASSEMBLY direction. Take out the key once the lid is locked.
TVS XL100 comfort vehicle comes with a stylish and
elegant Head lamp Fairing assembly with LED DRL,
ride brighter with the TVS XL100 Comfort.
Cover tool box

Lid tool box

19
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
To remove the pillion seat assembly, insert the control kit is supplied along with the vehicle and it is located
key into the seat lock which is located at the left side inside the tool box.
rear end of the vehicle and rotate it in clockwise To access the tool kit and first aid kit, open the tool
direction. Once the lock is released, gently take out box lid as explained in the page No. 19.
the seat from its mounting. The tool kit consists of the following :
To assemble back the seat back, locate the seat in 1. Grip driver x1
the frame in its position and push it towards the 2. Bit (+) (–) x1
front and then press down. Finally ensure the proper
3. 17 x 19 open end spanner x 1
locking of the seat.
4. Tool bag x1

* Not applicable for Comfort models

20
 Do’s
1. Ensure that no water enters into the USB
It is recommended to use the tool kit in case of any charging unit by closing the flap properly and by
emergency only. It is always advisable to take your
avoiding the direct water jet towards the unit.
vehicle to TVS Motor Company Authorised Main Dealer
/ Authorised Dealer. 2. Use the USB charger only with standard approved
USB charging cable recommended for your smart
phone.
SMART PHONE CHARGER# 3. Do make sure the flap is not damaged while
A smart phone charger has been provided in your opening / inserting the USB cable.
vehicle for charging your smart phone even when Don’ts
you are travelling and it is located in the cowl of 1. Do not leave the USB charging flap open / partially
speedometer. Follow the guidelines given below to closed.
use the charger properly.
2. Do not attempt to use / charge any other device,
other than smart phone phones. Only one smart
phone should be charged at a given time.
3. Do not try to force the USB connector in, check
whether it is inserted in the appropriate direction,
to prevent the damage to the charger.
4. Do not charge your smart phone when engine is
off.

#
Applicable for selected models only

21
 RIDING YOUR TVS XL100

Before riding your vehicle, make yourself throughly

familiar with all the controls of the vehicle and their
functions. In ‘i-Touch Start’ vehicles, incase if the ESIL lamp glows
Inspection before riding after switching ‘ON’ the ignition and while pressing the
electric starter switch, turn ‘OFF’ the ignition and once
• Check the following items before riding
again repeat the procedure of starting the vehicle using
- 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**.
Press the electric starter switch without applying the
- Correct tyre pressure and adequate tread throttle. The engine will not start if the throttle is opened
depth / no cracks or cuts. full.
- Proper working of all lamps and horn.
- Smooth movement of steering.
- Smooth operation of throttle.
- Correct free play of brakes. Do not keep the engine in idling rpm for long and do
- Free rotation of wheels. not open excessive throttle when engine is idling,
else it leads to overheating and damage to internal
Starting the engine
components.
Ensure the availability of adequate fuel in the fuel
tank (low fuel indication shall not come ON). Insert
the control key into the ignition lock and turn it to the
‘ON’ position. Retract the side stand. Turn the engine
cut off switch** to the ‘ ‘ position. Apply any one
of the brake and press the electric starter switch** to
start electrically or kick start.
** Applicable for ‘i-Touch Start’ models only

22
Riding Higher ethanol content in petrol can
• After starting the engine, sit comfortably on the • degrade plastic and rubber components of
seat and open the throttle gradually. Do not open fuel system and vehicle parts
throttle suddenly to full. • cause corrosion damage to metal parts like
• The clutch engages automatically. fuel tank, etc
• Keep your feet on the foot rest. From now on, • result in startability & drivability issues
your road speed is controlled only by throttle. • decrease fuel economy
• Always keep to the left of the road. This will allow Ethanol absorbs water very easily, resulting fuel
other fast moving vehicles to overtake you safely separation. Extra care shall be taken to prevent
and easily. moisture entry into fuel tank while filling ethanol
• To overtake other vehicles, look ahead of you and blended petrol and water washing of vehicle. Painted
into the rear view mirror to ensure that there are parts (viz. panels, covers) shall not come in contact
no vehicles close by. Then open the throttle and with ethanol blended fuels.
overtake from the right. Manufacturer is not responsible for any warranty
Stopping and parking issues that results from using ethanol blend in excess
• Close the throttle completely. Apply both brakes of 10% by volume.
simultaneously. In case of any abnormalities observed due to use of
• Turn OFF the ignition. ethanol blended fuels, customers are advised to use
• Park the vehicle on a firm, flat surface. a different fuel station/brand for standard E10 fuel or
contact authorised service centres.
• Lock the steering and take out the control key.
FUEL RECOMMENDATION
Use only BS VI petrol with minimum RON 91.
Never mix oil in petrol in the fuel tank. Always fill fuel
BS VI petrol containing upto 10% of ethanol by
from the reputed and reliable fuel stations.
volume can be used.

23
SOME USEFUL TIPS FUEL ECONOMY
Smooth riding The maximum fuel economy is obtained between
• Avoid engine idling for long period. It is better to 30 to 45 km/h (indicated by a green zone on the
switch it ‘OFF’ and start again. speedometer). There is a drop in fuel economy
• It is harmful to increase the engine speed with both at lower speeds and even more at higher
brakes applied as the engine gets unduly strained. speeds. Frequent braking, long periods of idling and
overloading will result in much lower fuel economy.
• Make your self familiar with the traffic signs and
Tips to improve fuel economy
regulations.
• Minimise braking and idling.
• For safe riding, it is advised to use a good
quality helmet while driving. • Avoid sudden acceleration, applying brakes and
throttle simultaneously and overloading.
• Avoid use of mobile phones while riding as it
could lead to fatal accident. • Inspect the tyre pressure regularly and inflate it
to the recommended pressure (refer page No.
Improve service life of your vehicle
42).
• Adhere to the recommended maintenance
• Ride in optimum road speed ie. 30 to 45 km/h.
schedule and follow running-in information.
• Perform maintenance as per the schedule.
• Never drive the vehicle with low fuel as it
damages the fuel pump. • Use recommended oils and fuel only.
• Apply brakes only when necessary. • Always maintain your vehicle in good state by
getting it periodically serviced.
• Always ride within the optimum speed range for
better fuel economy. • Reduce petrol evaporation by parking your vehicle
in shade.
• Avoid overloading.
• Reduce speed on bumps and rough roads.
• Avoid adjusting idling or any other fuel injection
system related components. • Anticipate the barriers ahead and decelerate at
the earliest.

24
EMISSION CONTROL
All the TVS vehicles are tested in the factory for
If there is any abnormal jerk, startability issue are felt in
optimum fuel efficiency and CO levels. If any the vehicle or noise due to sudden escape of gas during
abnormality, please consult nearest TVS Motor opening of fuel tank cap, immediately report to the TVS
Company Authorised Main Dealer or Authorised Motor Company Authorised Main Dealer / Authorised
Dealer. Dealer.
While adequate care is exercised at the factory to
ensure that the emissions are within the limits, it
is essential for the owner to always maintain their
vehicles in good condition by getting it periodically Your vehicle is tested and certified for emission which
serviced and checked by TVS Motor Company meets BS VI emission norms and is valid for initial 12
Authorised Main Dealer or Authorised Dealer so months from the date of purchase. Get your vehicle
that the emission and fuel consumption level are certified by the Government authorised emission
maintained as per norms. testing station after initial 12 months of usage. And
Crankcase emission control system ensure to get the vehicle certified on expiry of the
certificate obtained.
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.
Evaporative Emission Control System
TVS XL100 is equipped with an evaporative emission
control system which consists of a canister and
associated piping. This system prevents the escape
of fuel vapors from the fuel tank.

25
 MAINTENANCE

MAINTENANCE SCHEDULE
The maintenance schedule indicates the intervals between periodic services. At the end of each interval, be sure
to inspect, check, replace, adjust, lubricate and service as instructed. If the maintenance is not done periodically, it
will result in rapid wear and severe damage to the vehicle. If the vehicle is used under high stress conditions such
as continuous full throttle operation or if used / operated in dusty climate, certain jobs should be performed more
often to ensure reliability of the vehicle. 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.
Periodic inspections may reveal one or more parts that may need replacement. Whenever replacing parts on
TVS XL100, it is recommended that you use only the TVS Motor Company Genuine parts.

Proper running-in and maintenance are mandatory for making certain that your vehicle is reliable and gives optimum
performance at all times. Be sure that the periodic maintenance is performed thoroughly in accordance with the instructions
given in this owner’s manual.
In more dusty areas, the air filter element may required early replacement than the mentioned kilometers to avoid costly
damages to the engine.

26
PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier)
Item In free service After free service
Service 1st 2nd 3rd Every Every
Remarks
km 500 - 750 2500 - 3000 5000 - 6000 3000 km 6000 km
Period from the date of sale 1 months 3 months 6 months 3 months 6 months
Engine cum transmission oil R I &T R I &T R
Oil filter (strainer) C – C – C
Centrifugal filter – – C – C
Inspect, Clean and adjust if required,
Spark plug I – – – –
Replace every 12000 km
Air cleaner element I – – – – Replace every 9000 km
SAI filter element I – – – – Replace every 12000 km
Fuel filter assembly and pencil Inspect and check every 24000 km
– – – – –
filter in fuel pump Replace every 24000 km
Inspect for any noise / starting trouble
Tappet clearance I – I&A – I&A
and adjust if required
Hose fuel – – – – – Replace every three years or 30000 km
EVAP hoses – – – – – Replace every three years or 30000 km
All control cables and lever1 I&A I, A & L I&A I&A – Lubricate every 6000 km after free services
Throttle grip – – L – L Lubricate using grease if necessary
Steering smooth operation /
I&A I&A I&A I&A – C & L with fresh grease every 12000 km
play
Front fork oil – – – – – Replace every 12000 km

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. Lubricate ends using grease. Contd...

27
Item In free service After free service
Service 1st 2nd 3rd Every Every
Remarks
km 500 - 750 2500 - 3000 5000 - 6000 3000 km 6000 km
Period from the date of sale 1 months 3 months 6 months 3 months 6 months
Front and rear suspension I I I I – Inspect for proper functioning
Speedometer hub drive / cable – – L – L Lubricate using grease if necessary
Brake cams / SBT system parts – – C&L – C&L Lubricate using grease
All fasteners I & TI I & TI I & TI I & TI –
Drive chain2 C, L & A C, L & A C, L & A C, L & A –
All bulbs, horn and switches I I I I – Inspect for proper functioning
Head lamp beam I I I I – Adjust if necessary
Battery voltage I I I I – Recharge if necessary
Brake effectiveness / play I&A I&A I&A I&A –
Wheel freeness I I I I –
Wheel spokes I & TI – I & TI – I & TI
Tyre pressure in cold condition I&S I&S I&S I&S –
Center / side stand pivot / Kick
L L L L – Lubricate using TRU4 oil
starter pedal pivot
Check and resolve the errors using diagnos-
Malfunction indicator lamp I I I I – tic tool if the lamp is ON even after starting
the engine
Engine idling speed – – – – – Inspect incase of any abnormality
R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set

2
Clean the drive chain and apply TRU SPRAY / TRU4 oil as frequently as every 750 kms and adjust when necessary for better chain life and
smooth vehicle running.

28
RECOMMENDED LUBRICANTS
APPLICATION QTY MANUFACTURER BRAND
TVS TRU4 PREMIUM oil
Engine cum transmission oil 900 ml TVS Motor Company
(SAE 10W30 API-SL, JASO MA2)
100 ml / leg IOC / Castrol 20W40 oil
Front fork oil
210 ml / leg* IOCL / HPCL / BPCL* ETL 1F*
Bharat petroleum MP Grease no. 3
Grease – IOC Servo Gem no. 3
Bechem Bechem premium 3
Chain cleaner – TVS Motor Company TRU SPRAY chain cleaner
Chain lubricant – TVS Motor Company TRU SPRAY

* Applicable for ‘XL100 comfort’ models only

29
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 C C
battery to access the battery by following the
procedure given below:
1. Remove the lid tool box as explained in page No.
19.
2. Remove the top mounting screws (A) from both
the sides of tool box. 3. S imilarly, 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.
To ensure the performance and long life of the battery
A follow the steps given below:
• Check and ensure the battery voltage as per the
B maintenance schedule given in page No. 27.
• If the voltage measured is less than 12.4 Volts,
charge the battery using recommended battery
charger at TVS Motor Company Authorised Main
Dealer / Authorised Dealer.

30
• 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
• While connecting the terminals, observe the Authorised Main Dealer / Authorised Dealer.
correct polarity. Connect the red wire to the ‘+’
terminal and black wire to the ‘-’ terminal of the
battery.
• Apply petroleum jelly at terminals to prevent it Never check the battery charge by shorting the terminals.
from corrosion. Always connect the positive terminal first (red wire) and
then negative (black wire) to avoid sparking.
• Do not add any additional electrical accessories
which may affect the battery life and also results The inversion of the battery wires can damage the
in startability issue. 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 / ground which
will prevent the vehicle from starting.

31
Recommendations to maintain battery health c. Alternatively, battery connecting wires
during prolonged parking conditions (positive and negative wires) can be
While your vehicle is parked for prolonged duration, disconnected and fasteners can be secured
battery continues to discharge and if left unattended with battery terminals.*
can get completely discharged. It is recommended to 2. During Storage
ride the vehicle for minimum 60 km every week to a. Store it at room temperature or lower.
keep the battery in healthy condition This could be at b. Store the vehicle in the shade and protected
a stretch in one ride or several rides during the week. from rain and cover the vehicle to prevent
The vehicle speed will vary during the ride but an rodents from entering and damaging the
average speed of minimum 30 kmph will be helpful wires.
to ensure proper battery charging. Use kick-starting, 3. After Storage
if available, to conserve battery charge during such a. Connect the wires and fuse, if discon-
period. This is only a recommendation to maintain nected earlier, with ignition switch in
battery charge and regular service schedules must OFF position*
be followed to maintain your vehicle in good running
b. Start the vehicle by kick starting.
condition.
The following is recommendations to users regarding (Above recommendations do not consider storage
battery maintenance before, during and after long effects on other systems such as induction and fuel
storage of battery: systems and wheels)
1. Before Storage
a. Store the battery only after fully charging it
b. Battery fuse to be disconnected and stored
safely. This will reduce the sleep mode current
and hence enhance storage life of battery.* * To be done by skilled personnel

32
Periodic Maintenance of Batteries:
• Keep top of battery clean
Never operate the vehicle with discharged battery as it
• Check cables, clamps, and case for obvious may damage electrical components.
damage or loose connections
Do not push start the vehicle, use a good battery to start
• Clean terminals and connectors as necessary the vehicle.
Recharge battery if voltage is below 12.4V.
Valve Regulate Lead Acid (VRLA) / Lead Acid batteries
are prone to water damage. Any water entry, through
vents or otherwise; will result in irreparable damage
to the battery or the vehicle.

Battery develop explosive gases. Keep it away from

heat sources. If charging is required the battery must be
charged in well ventilated area.
Unusable battery must be disposed in environment
friendly manner. Do not discard it with household
thrash. Handover the battery to the battery dealers or to
a recycle center that accept used battery.

33
FUSE REPLACEMENT
Non-working of electrical systems may be due to
safety fuse failure. Short circuit or overload in the
electrical system are the main causes for fuse failure.
Two different fuses are provided in the XL100 they
are:
ES Model KS Model
12V, 15A x 1 (blade type) 12V, 15A x 1 (blade type)
12V, 10A x 1 (blade type) 12V, 7.5A x 1 (blade type)
12V, 10A x 1 (glass fuse) 12V, 7.5A x 1 (glass fuse)
5. R eplace the blown fuse with a new (extra fuse is
The main fuse is located inside the tool box below provided in the wiring harness itself in a pouch).
battery and the lighting fuse is located inside the 6. Close the fuse case and re-fix it properly into its
head lamp. location.
Follow the procedure given below to inspect and 7. Turn ‘ON’ the ignition lock and check for proper
replace the fuse: functioning of the electrical systems. lncase the
Main fuse fuse fails again, consult the nearest TVS Motor
1. Turn ‘OFF’ the Ignition. Company Authorised Main Dealer / Authorised
2. Remove the lid tool box as explained in page Dealer.
No. 19.
3. Take out the fuse case.
4. Open the fuse case and pull out the blown fuse.

34
 3. T ake out the fuse case from the housing head
lamp.
4. Open the fuse case and pull out the blown fuse.
5. Replace the blown fuse with a new (extra fuse is
provided near the fuse case itself ).
6. Close the fuse case and re-fix it properly into its
location.
7. Turn ‘ON’ the ignition lock and check for proper
Lighting fuse functioning of the electrical systems. lncase the
fuse fails again, consult the nearest TVS Motor
1. Turn ‘OFF’ the Ignition.
Company Authorised Main Dealer / Authorised
2. Remove the screws from the head lamp housing Dealer.
assembly on both sides and gently take out the
8. Re-fit the reflector unit.
reflector unit.

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.

35
SPARK PLUG Inspect the spark plug gap with a wire gauge / feeler
1. Pull out the suppressor cap from the spark plug. gauge. Readjust the spark plug gap to 0.5 ~ 0.7 mm
2. Clean the dust and mud around the spark plug if required.
mounting to avoid falling inside the cylinder. After cleaning and adjusting the gap, reinstall the
3. Remove the spark plug. spark plug and tighten by hand to avoid cross
threading. Finally tighten using spark plug spanner.
Inspect the spark plug for heavy carbon deposits,
Do not over tight or cross thread the spark plug.
a spark plug with heavy carbon deposits will not
produce strong sparks. Hence, remove the carbon
deposits from the spark plug with a small wire brush
or using spark plug cleaning tool.
Always use only recommended make and type of spark
Inspect the spark plug electrodes (A) and (B) for any
plug. Replace the spark plug every 12000 km.
corrosion. If found any, replace the spark plug with
a new. Don’t remove the spark plug when the engine is hot.
Cover the spark plug hole with a cloth when the plug is
removed to prevent entry of dust / water.
It is advisable to tighten the new spark plug by hand till
the end, using plug spanner tighten by 1/4 turn. Then
loosen the plug by 1/8 turn and re-tighten using plug
spanner.

7
A
0.5 ~ 0.7 mm

7
B

36
ENGINE CUM TRANSMISSION OIL LEVEL 6. I f the oil level is less than the minimum level, add
Check the engine cum transmission oil level ‘TVS TRU4 PREMIUM oil (SAE 10W30 API-SL,
periodically. JASO MA2)’ upto the maximum level mark.
1. Place the vehicle on center stand on a flat surface. 7. Wipe out the oil traces with a clean cloth to
Wipe-off the surroundings of the gauge oil level. prevent dust accumulation and assemble back
2. Remove the gauge oil level and wipe it clean. the gauge oil level.
3. Fix the gauge oil level back to its mounting hole.
Do not thread in.
4. Take out the gauge oil level and check the level of
If the vehicle is driven with less engine cum transmission
the oil. oil, engine components will be severely damaged. Check
5. The oil level should be between minimum and the oil level as per the schedule to avoid costly damage.
maximum level marks of the gauge as shown in
the figure. Do not fill excess oil may cause oil leak. Always use ‘TVS
TRU4 PREMIUM oil (SAE 10W30 API-SL, JASO MA2)’
only.

Maximum

Minimum

37
BRAKES
Right hand brake lever
1. Measure the free play of the right hand 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 2
10 ~ 15 mm.
S

I
1
10 ~ 15 mm

Since the vehicle is fitted with Synchronized Braking

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).
4. Turn the adjuster nut at bottom side (1) in the slot
marked as ‘I’ in clockwise direction for reducing
the free play or in anti-clock wise direction for
increasing the free play

38
5. A fter obtaining the necessary free play at the 8. O
nce 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.
6. If any clearance is found then turn the adjuster
nut (2) at slot marked as ‘S’ in clockwise direction
until there is no clearance between the bullet (3)
and slot end (4). Clearance
7. After adjusting the adjuster nut (2), If any 2 S
clearance is observed in between the bullet (5)
and slot end (6) marked as ‘I’ as shown, then I

turn the adjuster nut (2) in anti-clockwise until the 1

clearance is closed.
5 6

Clearance

2 S

1 I

3 4

39
Left hand brake lever 3. I f the measured free play is more or less than the
1. Measure the free play of the left hand brake lever specified limit, adjust the nut provided at the rear
at the lever end as shown in the figure. wheel end to obtain the correct play.
2. The free play of the brake lever before the 4. Turn the adjuster nut in clockwise direction for
engagement of the brake should be between reducing the free play or turn it in anticlockwise
15 ~ 20 mm. direction for increasing the free play.

15 ~ 20 mm

Please remember that the rear brake lever free play

adjustment to be done only after adjusting the front
brake lever play.

40
Brake shoe wear indicator However, if cam lever adjustment goes beyond
When the brake is applied, wear limit index mark (A) certain range then index the cam lever to next slot
on both front and rear cam brake should be within the (serration tooth) with the help of the nearest TVS
range of wear limit indicator (B) on panel assembly. Motor Company Authorised Main Dealer / Authorised
Incase the index mark (A) is going beyond the wear Dealer to utilize remaining shoe life until wear limit
limit (B), replace the brake shoes as a complete set, index mark (A) exceeds beyond the range of wear
with the help of the nearest TVS Motor Company limit indicator (B).
Authorised Main Dealer / Authorised Dealer.

B
A
B
A

Replace the brake shoes as a set, if wear limit index mark

(A) exceeds beyond the range of wear limit indicator (B)
even after indexing the lever.

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

I
TW
the stability of the vehicle.
Under inflated tyres make smooth cornering difficult A
and over inflated tyres decrease the tyre contact with
the ground which can lead to skidding and loss of
control. Be sure that the tyre pressure is within the
specified limits at all times.
Solo Dual
Front 1.75 kg/cm² (25 PSI) 1.75 kg/cm² (25 PSI) The tyre inflation pressure in cold condition and the
Rear 2.46 kg/cm² (35 PSI) 2.81 kg/cm² (40 PSI) tyre tread condition are extremely important for the
performance and safety of the rider. Check the tyres
frequently for inflation pressure as well as the wear
Tyre tread condition pattern on it.
Operating the vehicle with excessively worn tyres Use of a tyre other than the standard may cause
will decrease riding stability and can lead to loss of instability.
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).

42
Tyre Maintenance Tips
Inflation Pressure Check - Condition

R T

Within Within
1 km 5 km

If vehicle is in hold condition for long time

• Need movement of vehicle to avoid particular spot of tyre not to touch the ground for more than week time.
• Inflation pressure should check on cold condition maximum travel time should not exceed more than 1 km.
• Weekly basis inflation pressure check helps to improve 10% of tread life & fuel efficiency.

43
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. If the spring is adjusted to maximum notch,
then it will be stiffer which is good for heavy loads.
Adjust the spring pre-load by shifting the adjuster
to the required notch according to the different
load condition. The more you compress the shock
absorber spring, the suspension becomes more stiff.

Keep both left and right shock absorbers spring adjusters

in the same position.

HARD SOFT

44
DRIVE CHAIN FRONT WHEEL REMOVAL
Proper lubrication and adjustment of drive chain gives 1. Remove the hexagonal nut along with washer
long service life of chain. Poor maintenance of chain from any one side of the front wheel axle.
causes premature wear or damage to the drive chain 2. Pull out the axle from the wheel along with the
and sprockets. hexagonal nut and a washer.
The drive chain must be checked, lubricated and 3. Place a support (wooden block) below the engine
adjusted at specified intervals mentioned in the to prevent the vehicle from falling.
maintenance schedule. 4. Lift the front fork up, dislocate the brake panel
If the vehicle is used under severe conditions and more along with the brake cable. Remove the hub drive
dusty area, the drive chain must be attended more and slide the wheel out.
frequently. 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.
if required more frequently depending upon usage.

45
 5. T ilt 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,
axle nut is properly re-tightened to the specified torque. 6. Reverse the procedure for reassembly.

REAR WHEEL REMOVAL

1. Remove the rear brake adjuster nut (1) and Once the split pins are removed, replace them with new
disconnect the brake cable from the brake panel ones.
assembly.
2. Remove the split pin (2) and the nut (3). STORAGE PROCEDURES
Disconnect the torque link. For storage of your vehicle for longer periods of over
3. Remove the axle nut (4). a month and above, we recommend to carry out the
4. Pull out the axle (5) and take out the spacer from following steps:
the rear wheel assembly. 1. Clean the vehicle thoroughly. Park the vehicle on
center stand.
4 2. Empty the fuel tank.
3. Warm up the engine and drain engine cum
transmission oil. Store the oil, if new, in a dust
free container.
4. Remove the spark plug and feed in several drops
of engine cum transmission oil through spark plug
hole. Crank the engine few times and reinstall the
5 spark plug.
5. Remove the battery, store it away from direct
1 3 2 sunlight and freezing temperatures.

46
6. P
lace a suitable support at the bottom of the TAKING THE VEHICLE OUT OF STORAGE FOR
frame so that both the tyres are off the ground. REGULAR USE
This will ensure better tyre life. 1. Take the vehicle out of the garage and clean it
7.
Cover up the vehicle completely with a clean thoroughly.
tarpaulin or any other suitable cover. Store the 2. Remount the battery after bench charging if
vehicle inside a garage or similar area to avoid required.
damage due to dust and rain. 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. and check the level using gauge oil level.
4. Lubricate the parts as instructed in the periodic
maintenance schedule.
The exhaust system becomes hot after a run. Park the
vehicle in a place where pedestrians or children are not 5. Fill up fresh petrol in the fuel tank.
likely to touch the vehicle. 6. Check and inflate the tyres to the specified tyre
pressure.
7. Turn the ignition switch to ‘ON’ position. Retract
Do not park the vehicle on a slope or soft ground or else the side stand if the vehicle is parked on side
it may fall down. stand. Start the engine and run in idle for a few
minutes and ride out.

Avoid using alkaline solution like detergent soaps for

washing. This may damage head lamp and other lamp
assemblies.

47
 WARRANTY AND SERVICES
TVS Motor Company Limited (‘the Company’) give this warranty with respect to the TVS XL100 HEAVY DUTY
i-TOUCH start / TVS XL100 COMFORT i-TOUCH start / TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100
manufactured by the Company.
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: 
During 3 Years from the date of purchase or during the first 36,000 km of run for the vehicle in the hands of original
retail purchaser, whichever is earlier, the parts of the vehicle covered under warranty which prove to the satisfaction of the
Company to have a manufacturing defect will be repaired or replaced free of cost.
The Company’s obligation under this warranty is limited to repairing or replacing, free of cost, those parts of the vehicle
which upon examination by the Company may prove to the Company’s satisfaction to have a manufacturing defect, and in
such cases the Company’s decision either to repair or replace the affected parts will be final. In the event of replacement of
parts, the Company also reserves the right to use parts of the same brand as the affected parts or any other brand which is
used by the Company in the course of manufacture. All parts replaced under this warranty will become the property of the
Company and must be returned to the company.
Limitations of Warranty:
This warranty shall not apply to following condition:
1. Any natural wear and tear, including without limitation, aging.
2. Warranty claims on proprietary items such as tyres, tubes and batteries etc,. should be preferred by the user directly
on the respective manufacturer, as per their warranty terms and the Company shall not be liable in any manner in
respect to the same.
• Battery warranty for “MF type (Maintenance Free)” is applicable for a period of 21 months from the date of
charging or 18 months from the date of sale or 20,000 kms, whichever is earlier.
• Battery warranty for “Lead Acid type” is applicable for a period of 15 months from date of charging or 12 months
from date of sale or 10000 kms whichever is earlier.
3. Parts repaired or replaced under this warranty are warranted only throughout the remainder of the original warranty
period.

48
 4. The Company is not liable for any delay in servicing due to reasons beyond the control of the Company or any of its
Authorised Main Dealers / Authorised Dealers.
5. In any event, the Company is not liable for indirect, remote, incidental or consequential damages. 
6. The Company may make any modification or improvement to vehicles in future production at any time without prior
notice and without any obligation to install the same on vehicles previously dispatched for sale.
7. Any claim under this warranty will lie only when the customer:  
• takes his vehicle to an Authorised Main Dealer / Authorised Dealer of the Company and reports the problem he /
she felt in the vehicle to enable the Authorised Main Dealer / Authorised Dealer to inspect the same and assess
the cause for the reported problems. 
• produces to such Authorised Main Dealer / Authorised Dealer the Service Handbook for the concerned vehicle
for verification of relevant details.
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.

Modifications to this vehicle not approved by the TVS Motor Company may cause loss of performance and render it unsafe
for use and disqualifies for warranty coverage also.

Following Toll Free numbers can be contacted for battery related queries if any.
Incase of EXIDE battery, call :- 1800 103 5454 Incase of AMCO battery, call :- 1800 425 0096
Incase of TATA GREEN battery, call :- 1800 419 8888 Incase of AMARON battery, call :- 1800 425 5858
Following Toll Free numbers can be contacted for Tyre related queries if any.
Incase of TVS Srichakra, call :- 04522443300 Incase of JK tyre, call :- 18002581100
Incase of Maxxis tyre, call :- 1800 532 2888

49
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 and Tear Items Chain, sprockets, clutch and brake linings, fasteners, shims, washers, oil seals,
gaskets, O’ rings and spokes etc.
Electrical Bulbs , fuse, DRL, brake switch
Service Maintenance Parts Oil filters, spark plug, air filter, SAI filter, oil and brake fluid
Rubber, Rexine and Plastic Items All hoses , pipes and plastic aesthetics
Proprietary Items Battery, tyres and tubes (the warranty terms are subject to our agreement with
proprietary OEM)
(Battery warranty for “MF type (Maintenance Free)” is applicable for a period
of 21 months from the date of charging or 18 months from the date of sale or
20,000 kms, whichever is earlier).
(Battery warranty for “Lead Acid type” is applicable for a period of 15 months
from date of charging or 12 months from date of sale or 10000 kms whichever
is earlier).
Parts of the vehicle getting affected due to atmospheric effect / environmental
factors (rusting, paint peel off etc.). However, depending on the vehicle usage
condition, warranty would be accepted up to 2 years from the date of purchase.
Others Factors Parts of the vehicle which have been tampered with, altered, repaired or
replaced by persons not authorised by the Company and which in the sole
judgement of the Company affect the performance of the vehicle.

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List of parts not covered under warranty

ITEM WHAT TO CHECK FOR

Parts which are used in conjunction with parts not made or recommended by
the Company.
Parts suffering damage or resultant damage by accident, misuse, negligent
treatment, use of bad quality lubricants or impure fuel or by omission to follow
the guidance and instructions contained in this owner’s manual.
Vehicles on which engine number or chassis number is deleted, defaced or
altered.
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.
Vehicles attached with side cars etc. 
Vehicles which have been taken out of India.
Vehicles affected by natural calamities like flood, earthquake, tsunami, storm
etc,.
If the vehicle has been used for commercial purpose like taxi or used for rental
or hiring or any other purpose other than regular personal transportation.

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 SERVICE INFORMATION

SERVICE INFORMATION
There are thirteen services for TVS XL100 HEAVY DUTY i-TOUCH 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 have a
scheme of ten pay services. For keeping maintenance track of your vehicle, a free and pay service record sheets
are attached with this Service Handbook. Please have the record sheets filled by the Dealer who is carrying out the
maintenance service.
For availing any of the thirteen warranty services, please take your vehicle and your Service Handbook to any of our
Authorised Main Dealer or any of our Authorised Dealer. After effecting the service the Authorised Main Dealer or the
Authorised Dealer will affix their stamp on the last column of the free or pay service record sheet for your record and
reference. An OTP would be sent to customer’s registered mobile number. The same to be shared with the servicing
Dealer on or before vehicle delivery.
Periodic maintenance always helps good performance of an automobile and our services are planned to keep your
TVS XL100 vehicle performing good. 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.
In case you need any clarification or assistance, please feel free to write to us mentioning the frame number, engine
number and the date of purchase of your vehicle also the name and place of the Authorised Main Dealer / Authorised
Dealer from whom you bought the vehicle and getting it serviced.
Service Department
TVS MOTOR COMPANY LIMITED
P.O. Box No. 4, Harita, Hosur - 635 109,
TAMILNADU, INDIA.
Toll free no:- 1800-258-7111

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PLANNED SERVICE SCHEDULE (kms or month whichever of the two occurs early)
Sl. No. SERVICE TYPE Kms MONTHS
1 1st service 500 ~750 1 month
2 2nd service Free 2500 ~ 3000 3 months
3 3rd service 5000 ~ 6000 6 months
4 4th service 8500 ~ 9000 9 months
5 5th service 11500 ~ 12000 12 months
6 6th service 14500 ~ 15000 15 months
7 7th service Pay 17500 ~ 18000 18 months
8 8th service 20500 ~ 21000 21 months
9 9th service 23500 ~ 24000 24 months
10 10th service 26500 ~ 27000 27 months

Free services enables the customer to avail the service at free of labour charges. Charges for the pay service should be borne
by the customer. Cost of engine oil, periodic maintenance parts, filter, all types of greases, petroleum jelly, distilled water,
chain cleaner, lubricants, coolants, cleaning cloths for both free and paid services are chargeable to the customer.

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 Sl. No. SERVICE TYPE Kms MONTHS
11 11th service 29500 ~ 30000 30 months
12 12th service Pay 32500 ~ 33000 33 months
13 13th service 35500 ~ 36000 36 months

Please remember that, after the above schedule, periodic servicing of your vehicle at appropriate intervals, depending upon its extent of use,
will keep your vehicle at its best level of performance.

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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.
MANUFACTURER
TVS MOTOR COMPANY LIMITED
P.B. No1, Bythahalli, Kadakola post, Mysore - 571 311, India.
ENGINE
Type Single cylinder, 4 stroke, fuel injection, air cooled, spark ignition engine
Cylinder bore 51 mm
Stroke 48.8 mm
Piston displacement 99.7 cc
Compression ratio 10.3 : 1
Air filter Paper filter element
Lubrication system Forced lubrication
Maximum power in kW 3.2 kW (4.3 bhp) @ 6000 rpm
Maximum torque in Nm 6.5 Nm @ 3500 rpm
58 km/h
Engine idling rpm 1550 ± 100 rpm (under warm condition)
Starting system Kick starter / Electric starter*
Emission norms BS VI
** Applicable for ‘i-Touch Start’ models only

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 TVS XL100 HEAVY DUTY i-TOUCH start / TVS XL100 COMFORT i-TOUCH start /
DESCRIPTION TVS XL100 HEAVY DUTY / TVS XL100 COMFORT / TVS XL 100
TRANSMISSION
Clutch Centrifugal shoe type wet clutch
Primary transmission Single speed gear box
Secondary transmission Chain and sprockets
Final reduction 13.87 : 1
CHASSIS
Overall length 1895 mm
Overall width 670 mm
Overall height 1077 mm
Ground clearance (unladen) 145 mm
Wheel base 1228 mm
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)
Pay load 130 kg
219 kg (TVS XL100 Heavy Duty i-Touch start)
Maximum laden weight 218 kg ( TVS XL100 COMFORT i-TOUCH start / TVS XL 100 HEAVY DUTY / TVS XL 100)
216 kg (TVS XL 100 COMFORT)
Frame Welded tubular step through construction
Front suspension Telescopic spring type
Rear suspension Swing arm fitted with hydraulic shock absorbers with variable rated spring

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 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.
TYRE
Tyre size (Front) 2.50-16 - 6 PR 41L
Tyre size (Rear) 2.50-16 - 6 PR 41L
Tyre pressure (Front)** 1.75 kg/cm² (25 PSI)
Tyre pressure (Rear - Solo)** 2.46 kg/cm² (35 PSI)
Tyre pressure (Rear - Dual)** 2.81 kg/cm² (40 PSI)
ELECTRICAL
Type AC generator
Ignition system Electronic fuel injection with IDI : EMS ECU
Spark plug BOSCH UR5KC / CHAMPION RG8MC
Spark plug gap 0.6 ± 0.1 mm
12V, 3Ah MF battery (ES model)
Battery type
12V, 2.5Ah Lead Acid battery (KS model)
Body earthing Negative terminal
Head lamp 12V, 35/35W x 1
DRL 12V, LED
** In cold condition

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 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 12V, 10W x 4
Speedometer lamp bulb 12V, 3.4W x 1
Turn signal indicator lamp bulb 12V, 2W x 1
High beam indicator lamp 12V, 2W x 1
Low fuel indicator 12V, 2W x 1
ESIL lamp* 12V, 2W x 1
Malfunction indicator lamp 12V, 2W x 1
Horn 12V, DC x 1
12V, 15A x 1 (blade type) (ES model) 12V, 15A x 1 (blade type) (KS model)
Fuse 12V, 10A x 1 (blade type) (ES model) 12V, 7.5A x 1 (blade type) (KS model)
12V, 10A x 1 (glass fuse) (ES model) 12V, 7.5A x 1 (glass fuse) (KS model)

Using the bulb other than the specified rating can result in overloading of the electrical system or premature failure of the
bulb.
LEDs should not be directly connected with the batteries.

* Applicable for ‘i-Touch Start’ models only

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 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
BS VI petrol with minimum RON 91
Fuel
(Containing upto 10% of ethnol by volume)
Fuel tank capacity…… 4 litres
TVS TRU4 PREMIUM oil
Engine cum transmission oil grade
(SAE 10W30 API-SL, JASO MA2)
Engine cum transmission oil capacity 900 ml
Front fork oil grade 20W40 oil / ETL 1F*
Front fork oil capacity 100 ml per leg / 210 ml per leg*

Specifications are subject to change without notice.

……
The fuel tank is not a measuring instrument and the capacity of the fuel tank may vary from the indicated
capacity
* Applicable for ‘XL100 comfort’ models only

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 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.
To assist our Customers on their insurance requirements such as the prompt issue and renewal of policies as well
as expeditious settlement of claims if any, our preferred insurers are:

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