Professional Documents
Culture Documents
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FOREWORD
Dear Customer,
FOREWORD
We congratulate you on your choice of TVS XL Super / XL Super HD and welcome you to the family of millions of
satisfied TVS Customers.
We take care to ensure that every TVS XL Super / XL Super HD leaving our factory is in first class operating
condition. All you have to do is to fill up the fuel and get going.
To help you get the best performance from your TVS XL Super / XL Super HD, we have prepared this manual. This
manual gives you riding instructions and other maintenance information. Please follow them and your vehicle will
give you best utility.
As part of our company policy, you are entitled to certain benefits for maintenance of your vehicle. You can avail of
your free services other warranty repairs from the TVS Motor Company Authorised Main Dealers / Authorised
Dealers nearest to you. The staff of these Authorised Main Dealers / Authorised Dealers have been trained by us
to take care of your after sales / service requirements.
With your TVS XL Super / XL Super HD we wish you pleasant riding, for years.
-II-
NOTICE
This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when
NOTICE
resold or transferred to a new owner.
All information, illustrations, photographs and specifications contained in this owners 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 owners 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
owners manual.
Note
Accessories shown in the picture may not be part of the standard equipment.
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CONTENTS
CONTENTS
Safety information 01
Running-in information 02
Maintenance 16
Technical specifications 53
General information 55
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SAFETY INFORMATION
Operating this vehicle safely is an important responsibility of the rider. To help you make decisions about safety,
SAFETY INFORMATION
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.
RUNNING-IN INFORMATION
The first 1000 km is a crucial part of your TVS XL Super / XL Super HD. Proper running-in operation during this
RUNNING-IN INFORMATION
period helps in ensuring a longer life and smooth performance of your vehicle.
The TVS XL Super / XL Super HDs reliability and performance depends on the special care and restrain exercised
during the running-in period. It is especially important that you avoid operating the engine in a manner, 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 - 1000 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. Transmission oil to be
replaced. Timely performance of the first free service will ensure optimum service life and performance from the
Caution
Replacing transmission oil during first free service is most important for better life of engine. Always use TVS
TRU4 PREMIUM, 4T oil for better performance and life.
Note
Use 40 ml of two stroke FC grade self mixing oil with one litre of petrol during running-in period (first
1000 km) and 25 ml there after.
KNOW YOUR TVS XL Super / HD
The frame serial number is stamped on the right side of The engine serial number is stamped on the right side of
the steering head tube. engine, at bottom side, below the carburettor mounting.
Frame number
Engine number
4 5 6 7 8 9 1. Choke lever
2. Horn switch
3. Turn signal lamp switch
4. Rear brake lever
5. Headlamp ON / OFF switch
6. High / low beam switch
7. Speedometer assembly
3 8. Ignition switch
2 9. Front brake lever
10
10. Throttle grip
1 11. Fuel tank cap
11
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KNOW YOUR TVS XL Super / HD
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KNOW YOUR TVS XL Super / HD
KNOW YOUR TVS XL Super / HD
Caution
Always use choke for starting the cold engine.
5 6 Never open the throttle fully when the choke is
4 applied. It may lead to flooding of engine and
difficulty in starting.
Warning
Always use the appropriate turn signal lamps when
you intend to change lanes or take turns. Always be
sure to switch OFF the turn signal lamps after
3 2 1 negotiating the turns or lanes.
-4-
KNOW YOUR TVS XL Super / HD
Warning
Use appropriate head lamp beam high / low as per 2
the traffic and road conditions for your safety and to
avoid inconvenience to other riders.
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KNOW YOUR TVS XL Super / HD
KNOW YOUR TVS Super / HD
Warning
Never attempt to move the vehicle when the * Fuel tank is not a measuring instrument and capacity of the fuel
steering is locked, you may lose balance. tank may slightly vary from the indicated capacity.
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KNOW YOUR TVS XL Super / HD
Warning
Caution
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.
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KNOW YOUR TVS XL Super / HD
Caution
KNOW YOUR TVS XL Super / HD
1a
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KNOW YOUR TVS XL Super / HD
Warning
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KNOW YOUR TVS XL Super / HD
KNOW YOUR TVS XL Super / HD
Note
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 Main
Dealer / Authorised Dealer.
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RIDING YOUR TVS XL Super / HD
Warning
Reduce speed to a safe limit before turning /
cornering. It is not advisable to apply brakes while
turning / cornering.
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RIDING YOUR TVS XL Super / HD
MAINTENANCE SCHEDULE
MAINTENANCE
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 is operated in dusty climate, certain jobs should be performed more often
to ensure reliability of the vehicle. Cylinder, 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
XL Super / XL Super HD, it is recommended that you use only the TVS Motor Company Genuine parts.
Caution
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 owners manual.
In more dusty areas, the air filter element may required more frequent cleaning and early replacement than the
mentioned kilometers to avoid costly damages to the engine.
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MAINTENANCE
MAINTENANCE
PERIODIC SERVICES
Period 1 month 2 months 4 months 6 months 8 months 10 months 12 months
Item Km 500 - 1000 2000 4000 6000 8000 10000 12000
Transmission oil R I&T R I&T R I&T R
Air cleaner elements4 I&C I&C I&C I&C I&C I&C I&C
Filter element SAI R
Spark plug C&A C&A C&A R C&A C&A R
Carburettor assembly2 I&C I&C I&C I&C I&C I&C I&C
Fuel filter I I I I I I R
Fuel hose Replace every three years
Head cylinder / piston D D
Exhaust pipe & silencer D D
Clutch shoe & housing clutch3 I
Kick starter I
Throttle cable free play I&A I&A I&A I&A I&A I&A I&A
All control cables I I I I I I I
Brakes I&A I&A I&A I&A I&A I&A I&A
Drive chain3 I, C, L & A I, C, L & A I, C, L & A I, C, L & A I, C, L & A I, C, L & A I, C, L & A
Steering play & freeness2 I&A I&A I&A C, L & A
Front fork assembly I I I I
Front fork oil (only in HD) R
Tyre pressure I&S I&S I&S I&S I&S I&S I&S
Spokes and nipples I&A I&A I&A
Headlamp beam I&A I&A I&A I&A I&A I&A I&A
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MAINTENANCE
PERIODIC SERVICES
MAINTENANCE
LUBRICATION SCHEDULE
Interval Initial Every Every Every Every
Item 500 - 1000 km 2000 km 4000 km 6000 km 12000 km
Throttle grip Grease
Brake cam Grease
Drive chain TRU SPRAY TRU SPRAY
Control levers Grease Grease
Centre stand and side stand pivot Grease Grease
Speedo hub drive Grease
Fork tube inner Grease
Kick starter lever 4T oil 4T oil
Steering stem bearings .........Clean and lubricate with fresh grease every 12000 kms ........
Swing arm bearings ............... Grease every 2 years ...............
All control cables ............... Lubricate at ends using grease in all services ...............
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MAINTENANCE
RECOMMENDED LUBRICANTS
MAINTENANCE
Application Qty Manufacturer Brand
Engine oil 40 ml per litres (during running-in period) IOC Servo 2T Supreme
25 ml per litres (there after) Castrol JETT-X
Bharat petroleum MAK 2T
Hindustan petroleum HP racer 2 low smoke
Valvoline cummins ltd. Valvoline racing 2T
Tide water oil company ltd. Veedol take off 2T
Transmission oil 350 ml TVS Motor Company TVS TRU4 PREMIUM, 4T oil
Front fork oil* 100 ml 20W40 oil
Grease Bharath petroleum MP Grease no. 3
IOC Servo Gem no. 3
Bechem Bechem premium grade 3
Kluber lubrication Kluber Centoplex 2
Chain lubricant TVS Motor Company TRU SPRAY
Fuel additives As recommended IFTEX
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MAINTENANCE
MAINTENANCE
Caution
Always use only the recommended make and type
of spark plug. Replace spark plug every 6000 km.
Caution
MAINTENANCE
If the vehicle is driven with less transmission oil,
transmission components will be severely
damaged.
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MAINTENANCE
Warning
MAINTENANCE
A B C
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MAINTENANCE
MAINTENANCE
Warning
Brakes are items of personal safety and should
ON
always be maintained in proper condition.
TWI
HARD SOFT
Warning
Use of a tyre other than the standard may cause
instability.
MAINTENANCE
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MAINTENANCE
MAINTENANCE
Warning
Always make sure that whenever the wheel is
removed, axle nut is properly re-tightened to the
specified torque.
1 3 2
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WARRANTY AND SERVICES
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WARRANTY AND SERVICES
-28-
WARRANTY AND SERVICES
Periodic maintenance always helps good performance of an automobile and our services are planned to keep your
Service Department
TVS MOTOR COMPANY LIMITED
P.O.Box No. 4, Harita, Hosur - 635 109,
TAMILNADU, INDIA.
Toll free no:- 18004252077
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PREFERRED INSURERS
Dear Customer,
PREFERRED INSURERS
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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DELIVERY CERTIFICATE
DELIVERY CERTIFICATE
(To be given by the customer to TVS Motor Company authorised dealer at the time of taking possession of new vehicle)
Certified that I have taken possession of the TVS XL Super / TO BE FILLED IN BY THE DEALER
XL Super HD bearing engine no. and frame no. as mentioned
along side from M/s .............................................................. Engine No. :
............................................................................................. Frame No. :
........................................................today in good condition.
Dealer code :
I have understood operations, controls and general
maintenance instructions including rear wheel removal and Dealer stamp :
engine oil specifications. The terms of warranty have been
Date of delivery :
explained to me and I agree to abide by the same.
I have also received the following items along with my Colour :
TVS XL Super / XL Super HD without extra charge. Mode of purchase by customer
o Tool kit and first aid kit o Show room - cash sales
o Owners manual o Show room - hire purchase sales
o Set of two keys o Institutional sales
Dealer to get the Customer information coupon filled by the
The location of the tool kit in the vehicle has been shown to
customer and hand it over to Market Research, TVS Motor
me.
Company Limited, Hosur.
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DELIVERY CERTIFICATE
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-32-
EXTENDED WARRANTY
SERVICE INITIATIVE
Peace of mind for 5 years
-33-
EXPRESS SERVICE
SERVICE INITIATIVE
Get your vehicle serviced in 1 hour at no additional cost. Contact your nearest Dealership for details.*
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EXPERT ON WHEELS
SERVICE INITIATIVE
Busy Life?
Easy Servicing!
Now, service your bike anywhere, anytime.
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PICKUP AND DROP
SERVICE INITIATIVE
Busy Life?
Easy Servicing!
Now, Avail Pickup & Drop of your vehicle for service.
Vehicle picked up & delivered from/to your office or residence at prefixed appointed time.
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TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
P.B. No. 4, Harita, Hosur - 635 109, India.
ENGINE CHASSIS
Type : Single cylinder, 2 stroke, air Overall length : 1870 mm
cooled Overall width : 600 mm
Cylinder bore : 46 mm Overall height : 1060 mm
Stroke : 42 mm Ground clearance : 140 mm
Piston displacement : 69.9 cc Wheel base : 1222 mm
Compression ratio : 6.7 : 1 Kerb weight (with toolkit
Carburettor : Spaco AX and 90% of fuel) : 65 kg (TVS XL Super)
Air filter : Polyurethane foam filter : 75 kg (TVS XL Super HD)
element Pay load : 130 kg
Lubrication system : Self mixing 2T oil added in fuel Maximum laden weight : 195 kg (TVS XL Super)
Maximum power : 2.6 kW (3.5 bhp) @ 5000 rpm : 205 kg (TVS XL Super HD)
Maximum torque : 5.0 Nm @ 3750 rpm Frame : Welded tubular step through
Maximum speed : Around 55 km / hr construction
Engine idling rpm : 1600 100 rpm* Front suspension : Telescopic spring type
Starting system : Kick starter Rear suspension : Swing arm fitted with
hydraulic shock absorber
TRANSMISSION with variable rated spring.
Clutch : Centrifugal shoe type wet clutch
Primary transmission : Single speed gear box
Secondary transmission : Chain and sprockets
Total reduction : 13.4 : 1 * Under warm condition
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TECHNICAL SPECIFICATIONS
TYRE CAPACITIES
TECHNICAL SPECIFICATIONS
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GENERAL INFORMATION
GENERAL INFORMATION
1. TVS Motor Company Limited 5. TVS Motor Company Limited 9. TVS Motor Company Limited
1st Floor, SPL - Sriram Nivas, Ambady Towers, Second floor, Door No. 58-2-35, NCK Plaza,
No. 38, Venkatakrishna Road, Door No. 27/631 A6, NTR Circle, Patamata,
Mandaveli, Chennai - 600 028. Edappally-Pookkattupady Road, Vijayawada - 520 010.
Phone : 044-24951652/24950018 Edappally Po., Cochin - 682 024. Phone : 0866-6575100
Email : AO.Chennai@tvsmotor.com
Phone : 0484-2544578/2556938 Email : AO.Vijayawada@tvsmotor.com
2. TVS Motor Company Limited
Email : AO.Cochin@tvsmotor.com 10. TVS Motor Company Limited
No.10, 2nd floor,
6. TVS Motor Company Limited #401, 4th Floor,
Shree Shanmugapriya Towers,
#600, Anand Surya, 2nd Floor, 5th Cross, The Chambers, Plot No. 4/12/3,
Kannuswamy Street,
6th Phase, JP Nagar, BMTC Stop, Near Ganapati Chowk,
Behind Hotel Annapoorna,
Bangalore - 560 078. Viman Nagar, Pune - 411 014.
RS Puram, Coimbatore - 641 002.
Phone : 080-42455000/25118000 Email : Service.Pune@tvsmotor.com
Phone : 0422-4350060/2541035
Email : AO.Bangalore@tvsmotor.com 11. TVS Motor Company Limited
Email : AO.Coimbatore@tvsmotor.com
7. TVS Motor Company Limited Plot No. 206, House No. 241,
3. TVS Motor Company Limited
BDP Plaza, 3rd floor, New Cotton Market, Ward No. 73, 1st floor,
D-09, Srinidhi Block, Agrini Apartments,
Karnataka Bank Road, Hubli - 580 029. West High Court Road,
Andalpuram, TPK Road,
Phone : 0836-4250617/4250618 Dharampeth, Nagpur - 400 010.
Madurai - 625 003.
Email : AO.Hubli@tvsmotor.com Phone : 0712-2569932
Phone : 0452-4208690
8. TVS Motor Company Limited Email : AO.Raipur@tvsmotor.com
Email : AO.Madurai@tvsmotor.com
D-19, 302-3rd floor, Gayathri Arcade, Email : Service.Nagpur@tvsmotor.com
4. TVS Motor Company Limited
Vikrampuri, Secunderabad - 500 003. 12. TVS Motor Company Limited
No. 37, 1st Floor,
Phone : 040-27840590/27844419 Magneto the Mall, Offizo 6th Floor,
West Brindavanam,
Email : AO.Hyderabad@tvsmotor.com Office No. 627-628, Labhandi,
Near Le Royal Park Hotel,
GE Road, Raipur - 492 010.
Puducherry - 605 013.
Phone : 0771-4260006
Email : AO.Pondicherry@tvsmotor.com
Email : AO.Raipur@tvsmotor.com
-39-
GENERAL INFORMATION
13. TVS Motor Company Limited 17. TVS Motor Company Limited 21. TVS Motor Company Limited
211-212, 2nd floor, 1st floor, Cyber Tower, TC-34/V-2, N-Plaza, Jamal Road,
Chinar Incube Business centre, Vibhuti Khand, Gomti Nagar, P.S. Kotwali, Patna - 800 001.
Chinar Fortune City, Lucknow - 226 010. Phone : 0612-2200068/2200069
Near Brindavan Dhaba, Phone : 0522-4918300 Email : AO.BNJ@tvsmotor.com
Hoshangabad Road, Bhopal - 462 026. Email : AO.Upe@tvsmotor.com 22. TVS Motor Company Limited
Phone : 0755-2499406/2499306 Email : AO.Upc@tvsmotor.com 2nd Floor, Lucas Building,
Email : AO.Bhopal@tvsmotor.com 18. TVS Motor Company Limited Argora Bypass Road, Ranchi - 834 002.
14. TVS Motor Company Limited SCF-10-11, Kalghaidhar Encalve, Phone : 0651-2244715
301, 3rd Floor, Shagun Arcade, Balatana Road, Zirkapur, Email : AO.Ranchi@tvsmotor.com
Vijay Nagar, Indore - 452 010. District Mohali - 140 603. 23. TVS Motor Company Limited
Phone : 9826388896 Phone : 01762-653477/653480 #303, 3rd floor,
Email : AO.Indore@tvsmotor.com Email : AO.Chandigarh@tvsmotor.com Creative Plaza, Rasulgarh,
15. TVS Motor Company Limited 19. TVS Motor Company Limited Bhubaneshwar - 751 010.
109, Ayana Complex, Plot No. 16-17, Phone : 0674-2580018/2580019
Opp : Suvarna Villa Bungalows, Top Floor of National Motor, Email : AO.Bhubaneshwar@tvsmotor.com
100 ft Thaltej Hebatpur road, Jhotwara Industrial Area, 24. TVS Motor Company Limited
Off : S.G. highway, Thaltej, Jaipur - 302 012. 9/2, Dover lane, Ground floor,
Ahmedabad - 380 054. Phone : 0141-5150900/5150901
Phone : 079-65443748 Gariahat, Kolkata - 700 029.
Email : AO.Jaipur@tvsmotor.com Phone : 033-24617092/24617096
Email : AO.Ahmedhabad@tvsmotor.com 20. TVS Motor Company Limited
16. TVS Motor Company Limited Email : AO.Kolkata@tvsmotor.com
204, 2nd floor, 25. TVS Motor Company Limited
K-23, 1st floor, Lajpat nagar, Part II, Daulet Chambers, 4-D,
New Delhi - 110 024. 147, Udayan, Ganesh Guri,
Saradapura, Udaipur - 313 004. Opp. Punjab National Bank,
Phone : 011-29834773/29834640
Phone : 9001897485 R G B Road, Guwahati - 781 005.
Email : AO.Delhi@tvsmotor.com
Email : AO.Udaipur@tvsmotor.com Phone : 0361-2202030/2202031
Email : AO.Haryana@tvsmotor.com
Email : AO.Upw@tvsmotor.com Email : AO.Guwahati@tvsmotor.com
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