TVS XL Series User manual

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
FOREWORD
FOREWORD
-I-

NOTICE
-II-
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 part of the standard equipment.
Pictures shown in this manual are ‘TVS XL 100 i-Touch Start’ unless specified
Part Number :- P7210020 Revision 1, Dec 2018
Note

SAFETY INFORMATION
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.
You will find important safety information in following form in this manual. These words carry the following
connotations:
Warning
Disregarding this message might result in injury to the rider.
Caution
This message indicates special procedures or precautions to be followed to avoid damage to the vehicle.
Note
This message provides further clarification for clearer understanding of any particular information.
-III-

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

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.
RUNNING-IN INFORMATION
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 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.
-1-

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.
Please fill the above boxes now for future reference
Frame number
Engine number
Control key number
-2-
The frame serial number is stamped on the right side of
the steering head tube.
The engine serial number is stamped on the top surface
of right side crankcase near engine breather tube.

KNOW YOUR TVS XL 100
LOCATION OF PARTS - HANDLE BAR
-3-
1. Choke lever
2. Horn switch
3. Turn signal lamp switch
4. Rear brake lever
#
5. Rear view mirror L
6. Headlamp switch
7. High / low beam switch
8. Speedometer
9. Turn signal indicator lamp
10. Ignition switch
11. High beam indicator lamp
#
12. Rear view mirror R
13. Front brake lever
14. Throttle grip
15. Electric starter switch**
16. Electric system indicator lamp**
17. Smart phone charger**
KNOW YOUR TVS XL 100
# Optional accessory will be charged extra
** Applicable for ‘i-Touch Start’ models only
3
2
1
4
8 9
6
5712
13
14
15
16
17
10 11

-4-
KNOW YOUR TVS XL 100
CONTROL KEY
TVS XL 100 comes with a pair of identical control
keys. These keys are to operate ignition switch,
steering lock, fuel tank cap, tool box lock and seat
lock*.
IGNITION SWITCH
The ignition switch has two positions:
1. ‘OFF’ position
All the electrical circuits are turned ‘OFF‘ in this
position. Engine will not start. Key can be taken
out.
2. ‘ON’ position
In this position, all the electrical circuits are ‘ON’
and the engine can be started now. Key cannot be
removed in this position.
KNOW YOUR TVS XL 100
Tail lamp, day time running (DRL), brake lamp and
head lamp glows only after starting the vehicle.
If the vehicle is not started for more than
30 minutes after switching on the ignition key the
vehicle may not start with the self start. Turn OFF
the ignition key and turn it ON again to start the
vehicle using self start.**
Keep the ignition key in off position, when the
vehicle is not in use, to prevent battery drain.**
Note
Note
* Seat lock is not applicable for Comfort models
** Applicable for ‘i-Touch Start’ models only

SPEEDOMETER ASSEMBLY
1. Odometer
Registers and displays the total distance covered
by the vehicle in kilometers. The last digit denotes
one tenth of a kilometer.
2. Speedometer
Indicates vehicle speed in kilometers per hour.
3. Turn signal indicator lamp
Flashes when the ‘left’ or ‘right’ side turn signal
lamp is activated.
-5-
4. High beam indicator lamp
Glows when the head lamp high beam is activated.
5. Electrical system indicator lamp**
Electrical system indicator lamp (ESIL) blinks while
starting the vehicle using electric starter and goes
OFF once the engine gets started.
If this indicator glows continuously even after
starting the vehicle, it indicates that there is some
problem with the vehicle’s electrical system and
the vehicle may not get start. Contact TVS Motor
Company Authorised Distributor or Dealer /
Authorised Service Centers immediately.
KNOW YOUR TVS XL 100
KNOW YOUR TVS XL 100
2
1
5
3 4
Please make a note that the failure of bulbs will not
be shown by the electrical system indicator lamp
(ESIL)**.
Note
** Applicable for ‘i-Touch Start’ models only

-6-
DAY TIME RUNNING LAMP (DRL)
TVS XL 100 comes with a day time running LED
lamp which glows automatically once the engine is
started and continue to glow till the engine is
turned ‘OFF’ or head lamp is switched ‘ON’.
HANDLE BAR LEFT SIDE
1. Choke lever
Pull the choke lever towards left to apply choke.
During cold start, apply the choke and start the
vehicle without opening of throttle. Once the
engine is started and running in stable RPM,
release the choke and ride the vehicle.
KNOW YOUR TVS XL 100
KNOW YOUR TVS XL 100
Caution
Always use choke for starting the cold engine.
Never open the throttle fully when the choke is
applied. It may lead to flooding of engine and
difficulty in starting.
1
4
56
32

-7-
2. Horn switch
Press the switch ‘ ’ to operate the horn.
3. Turn signal lamp switch
Slide the turn signal lamp switch to left ‘ ’ or
right side ‘ ’ to operate respective turn signal
lamps (LH/RH). Slide the knob to the center
position to turn ‘OFF’ the lamps.
4. Rear brake lever
The rear brake is applied by squeezing the rear
brake lever gently towards the handle grip. The
brake lamp glows on application of the rear brake.
5. Head lamp switch
Head lamp switch has two positions, they are:
OFF : Head lamp and speedometer lamp are
turned ‘OFF’ when the switch is positioned
at ‘ ’ even though the engine is running.
ON : Head lamp and speedometer lamp glows
when the switch is positioned at ‘ ’ and
engine is running.
KNOW YOUR TVS XL 100
KNOW YOUR TVS XL 100
6. Head lamp high / low beam switch
With the head lamp in ‘ON’ condition, slide the
beam control switch towards ‘ ’ to turn-on the
head lamp high beam. Slide the switch towards
‘ ’ to turn-on the head lamp low beam.
Warning
Always use the appropriate turn signal lamps when
you intend to change lanes or take turns. Be sure to
switch ‘OFF’ the turn signal lamps after negotiating
the turns or lanes.
Use appropriate head lamp beam ‘high / low’ as per
the traffic and road conditions for your safety and to
avoid inconvenience to other riders.
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.
Note

-8-
3. Electric starter switch**
Apply any one the brake. Press and release the
starter switch ‘ ‘to start the engine electrically.
KNOW YOUR TVS XL 100
KNOW YOUR TVS XL 100
HANDLE BAR RIGHT SIDE
1. Throttle grip
Engine speed is controlled by the rotation of the
throttle grip. Twist it towards you to increase the
engine speed and away from you or release it to
decrease the engine speed.
2. Front brake lever
The front brake is applied by squeezing the front
brake lever gently towards the throttle grip. The
brake lamp glows on application of the front brake.
2
1
3
The ESI lamp blinks during start of the vehicle using
electric start. Refer page 05 for more details**.
Note
The vehicle cannot be started using electric starter
with low / discharged battery. Contact TVS Motor
Company Authorised Distributor or Dealer /
Authorised Service Centers for rectification**.
Caution
** Applicable for ‘i-Touch Start’ models only

-9-
STEERING LOCK
TVS XL 100 is provided with separate lock for
locking the steering.
To lock the steering, turn the handle bar fully
towards left, insert the control key into the lock and
rotate it in clockwise direction and take out the key.
For unlocking insert the key in the lock and turn it in
anti-clockwise direction and take out the key.
KNOW YOUR TVS XL 100
KNOW YOUR TVS XL 100
Warning
Never attempt to move the vehicle when the
steering is locked, you may lose balance.
FUEL TANK* CAP
To open fuel tank cap, insert the key into the lock
and turn it in clockwise direction. Now, rotate the
fuel tank cap in anti-clockwise direction and take
out. Key cannot be taken out of the cap in this
condition.
Fill the required amount of petrol (as per the tank
capacity) and refit the fuel tank cap in the reverse
order of removal.
* Fuel tank is not a measuring instrument and capacity of the fuel
tank may slightly vary from the indicated capacity.

-10-
KNOW YOUR TVS XL 100
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.
Whenever refueling the vehicle, fill upto the
bottom of the neck portion of the fuel tank. Filling
above the neck may result in improper breathing of
fuel tank and seepage of fuel.
Note
FUEL COCK
Fuel cock has the following three positions:
ON: Fuel flows in this position when the fuel is
above the reserve level in the tank.
RES: Switch over the fuel cock lever to this
position when the fuel stops flowing in
‘ON’ position.
OFF: Fuel flow cuts off from the tank to
carburettor.
ON
OFF
RES
While riding the vehicle with fuel cock lever in ‘ON’
position and if the fuel in the tank reaches reserve
level, you may experience engine sluggishness
and jerky feeling. Take the vehicle to the left side of
the road while taking care of traffic and change the
fuel cock lever position to ‘RES’.
Leaving the fuel cock in ‘ON’ or ‘RESERVE’
position may cause the fuel tank to completely
drain out, incase any malfunctioning of carburettor
float system.
Caution

-11-
KNOW YOUR TVS XL 100
KICKSTARTER LEVER
Warning
Hold the rear brake as a safety precaution while
starting the vehicle to avoid rear wheel rotation and
loss of control.
STANDS
To place the vehicle on center stand (1), hold the
handle bar left grip with the left hand and load
carrier with the right hand.
Place your foot firmly on the center stand
extension (1a) and press with adequate effort.
Ensure both the legs of stand are touching the
ground before placing the vehicle on stand.
TVS XL 100 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.
Please remember that the vehicle can’t be started
even by using kickstarter with the drained battery
fitted in it. Disconnect the battery positive terminal
and tape properly to start the vehicle. Contact TVS
Motor Company Authorised Distributor or Dealer /
Authorised Service Centers immediately**.
Note
The kickstarter lever is located on the right side of
the engine. The engine can be started by kicking
the lever with the ignition key in ‘ON’ position
while applying the rear brake as a safety
precaution.
** Applicable for ‘i-Touch Start’ models only
KNOW YOUR TVS XL 100

KNOW YOUR TVS XL 100
11a
Warning
Always return the side stand to its full up position
before moving the vehicle.
Caution
Never sit on the vehicle when it is supported by
side stand. Always park the vehicle on a flat, firm
surface.
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. Insert the control key into the lock of lid tool box
and rotate it in anti-clockwise direction. Gently
take out the lid from the tool box.
2. While reassembling locate the lid at the bottom
of the tool box properly, press the top side
firmly and then lock it by rotating the key in
clockwise direction. Take out the key once the
lid is locked.
-12-
Cover tool box
Lid tool box
** Fuse and battery is applicable for ‘i-Touch Start’ models only.
The vehicle’s battery can be accessed only after removing the
cover tool box.
KNOW YOUR TVS XL 100

SEAT LOCK*
To access the carrier*, the pillion seat assembly*
need to be removed.
To remove the pillion seat assembly, insert the
control key into the seat lock which is located at the
left side rear end of the vehicle and rotate the key in
clockwise direction. Once the lock is released,
gently take out the seat from its mounting.
To assemble back the seat, locate the seat in its
position and push it towards the front and then
press down.
KNOW YOUR TVS XL 100
TOOL KIT
To assist you in performing certain aspects of
periodic maintenance and emergency repairs, a
tool kit is supplied along with the vehicle and it is
located inside the tool box.
To access the tool kit, open the tool box lid as
explained in the page no. 12.
The tool kit consists of the following :
1. Grip driver x 1
2. Bit (+) (–) x 1
3. 17 x 19 open end spanner x 1
4. Tool bag x 1
-13-
* Not applicable for Comfort models
KNOW YOUR TVS XL 100

It is recommended to use the tool kit in case of any
emergency only. It is always advisable to take your
vehicle to TVS Motor Company Authorised
Distributor or Dealer / Authorised Service Centers.
Note
KNOW YOUR TVS XL 100
SMART PHONE CHARGER**
A smart phone charger has been provided in your
vehicle for charging your smart phone even when you
are traveling and it is located in the cowl of
speedometer. Follow the guidelines given below to
use the charger properly.
DO’s
1. Ensure that no water enters into the USB charging
unit by closing the flap properly and by avoiding
the direct water jet towards the unit.
2. Use the USB chager only with standard approved
USB charging cable recommended for your smart
phone.
3. Do make sure the flap is not damaged while
opening / inserting the USB cable.
DON’TS
1. Do not leave the USB charging flap open / partially
closed.
2. Do not attempt to use / charge any other device,
other than smart 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.
-14-
** Applicable for ‘i-Touch Start’ models only
KNOW YOUR TVS XL 100

RIDING YOUR TVS XL 100
Before riding your vehicle, make yourself throughly
familiar with all the controls of the vehicle and their
functions.
Inspection before riding
l Check the following items before riding
- Enough fuel for the planned distance of
running.
- Correct tyre pressure and adequate tread
depth / no cracks or cuts.
- Proper working of all lamps and horn.
- Smooth movement of steering.
- Smooth operation of throttle.
- Correct free play of front and rear brake.
- Free rotation of wheels.
Starting the engine
l Turn the fuel cock lever to the ‘ON’ or
‘RESERVE’ position. Insert the control key into
the ignition switch and turn it to the ‘ON’
position.
l Hold any one of the brake and just Press the
electric starter switch to start the engine
electrically otherwise kickstart.
When the engine is cold
q Actuate and hold the choke by pressing it
towards left side.
q Start the engine using electrical starter / kick
starter with no opening / very less opening of
throttle.
q Once the engine is started and running stable,
release the choke lever and ride the vehicle
(when the engine is warm / hot do not use
choke).
Caution
‘In i-Touch Start’ vehicles, incase if the ESI lamp
glows after switching ‘ON’ the ignition and while
pressing the electric starter switch, turn ‘OFF’ the
ignition and once again repeat the procedure of
starting the vehicle using electrical starter. If the
ESI lamp still glows take the vehicle to TVS Motor
Company Authorised Distributor or Dealer /
Authorised Service Centers.
-15-
RIDING YOUR TVS XL 100

RIDING YOUR TVS XL 100
Riding
l After starting the engine, sit comfortably on the
seat and open the throttle gradually. Do not
open throttle suddenly to full.
l The clutch engages automatically.
l Keep your feet on the foot rest. From now on,
your road speed is controlled only by throttle.
l Always keep to the left of the road. This will
allow other fast moving vehicles to overtake you
safely and easily.
l To overtake other vehicles, look ahead of you
and into the rear view mirror to ensure that
there are no vehicles close by. Then open the
throttle and overtake from the right.
Stopping and parking
l Close the throttle completely. Apply both
brakes simultaneously.
l Turn OFF the ignition and fuel cock.
l Park the vehicle on a firm, flat surface.
l Lock the steering and take out the control key.
FUEL RECOMMENDATION
Use unleaded petrol only.
The petrol should be 85 to 95 octane by research
method. Use recommended fuel additives for
longer life of engine components and lower
maintenance. Petrol mixed with ethanol will have
impact on engine components. Contact your TVS
Motor Company Authorised Distributor or Dealer /
Authorised Service Centers for usage.
Caution
Never mix oil in petrol in the fuel tank. Always fill
fuel from the reputed and reliable fuel stations.
-16-
Caution
Do not keep the engine in idling rpm for long and do
not open excessive throttle when engine is idling,
else it leads to overheating and damage to internal
components.
RIDING YOUR TVS XL 100