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
UNIQUE FEATURES OF TVS ZEST 5
FOREWORD 10
NOTICE 11
SAFETY INFORMATION 12
RUNNING-IN INFORMATION 13
SAFE RIDING TIPS 14
KNOW YOUR TVS ZEST 18
RIDING YOUR TVS ZEST 34
MAINTENANCE 38
WARRANTY AND SERVICES 62
TECHNICAL SPECIFICATIONS 69
GENERAL INFORMATION 72

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 : [email protected]

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 : [email protected] Phone : 080-26653433 Phone : 0712-2569932
[email protected] Email : [email protected] Email : [email protected]
[email protected]
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- 380058.
Phone : 0422-4350060/2541035 Email : [email protected]
Phone : 079-65443748
Email : [email protected] [email protected]
Email : [email protected]
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 : [email protected]
Email : [email protected]

2
MADHYA PRADESH-1 & 2 PUNJAB & CHANDIGARH WEST BENGAL
9. TVS Motor Company Limited 12. TVS Motor Company Limited 15. TVS Motor Company Limited
No. 211-212, 2nd Floor, 4th Floor, Royal Business Park, Ground Floor & First Floor,
Chinar Incube Business Centre, Chandigarh Ambala Highway, 133 A. S. P. Mukherjee Road,
Chinar Fortune City, Zirkapur - 140 603. Opp. Tollygunge Police Station,
Near Brindhavan Dhaba, Phone : 01762-464777/465777 Kolkatta - 700 026.
Hosangabad Road, Email : [email protected] Phone : 033-24617096/24617092
Bhopal - 462 026. Email : [email protected]
Phone : 0755-2499406/2499306 UTTAR PRADESH WEST
Email : [email protected] 13. TVS Motor Company Limited BIHAR
[email protected] D-3 & D-4, 2nd Floor, 16. TVS Motor Company Limited
Sector - 10, Noida, N-Plaza, Jamal Road,
RAJASTHAN-1 & 2 Uttar Pradesh - 201 301. P.S. Kotwali,
10. TVS Motor Company Limited Phone : 011-29834640/29834773 Patna - 800 001.
Plot No. 17-18, Email : [email protected] Phone : 0612-2200068/2200069
2nd Floor of National Motors Building, Email : [email protected]
Jhotwara Industrial Area, UTTAR PRADESH CENTRAL & EAST
Jaipur - 302 012. 14. TVS Motor Company Limited
Phone : 0141-5150901/5150902 1st Floor, Cyber Tower, TC-34/V-2,
Email : [email protected] Vibhuti Khand, Gomti Nagar,
[email protected] Lucknow - 226 010.
Phone : 0522-4918300/4918301
DELHI & HARYANA Email : [email protected]
11. TVS Motor Company Limited
D-3 & D-4, 2nd Floor,
Sector - 10, Noida,
Uttar Pradesh - 201 301.
Phone : 011-29834640/29834773
Email : [email protected]

3
ORISSA & JHARKHAND
17. TVS Motor Company Limited
No. 303, 3rd Floor,
Creative Plaza, Rasulgarh,
Bhubaneshwar - 751 010.
Phone : 0674-2580019
Email : [email protected]

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 : [email protected]

4
 UNIQUE FEATURES OF TVS ZEST
ZEST for POWER LEAF-SHAPED MIRROR
Next-Gen 110cc CVTi ENGINE The leaf-shaped mirrors enhance
Your scooter is powered by a Next the style quotient of your scooter.
Gen 110cc CVTi ECO Tuned Fuel Style comes with performance
Injection technology engine. as these mirrors can be adjusted
Your scooter also has Best in class easily. You can adjust them up-
Power-to-weight ratio with Best in down, forward-backward and
class pickup. It makes your scooter rotate as well, for enhanced
smooth and zip through traffic with visibility & safety.
ease.
LED TAIL LAMP CUM BRAKE
ZEST for STYLE LAMP
Your scooter comes in vibrant Your scooter has an LED tail lamp
colour ensuring you always arrive that makes it look stylish at night
in style. also.

BACK-LIT SPEEDOMETER TWILIGHT LAMP

Your scooter comes with a stylish Your scooter has twin twilight
back-lit speedometer. lamps located on the front panel,
for you to choose your stylish
lighting on the go.

NEW TEXTURED FLOOR BOARD

Your scooter comes with a stylish
textured floor board.

5
STAINLESS STEEL MUFFLER FRONT TELESCOPIC SHOCK
GUARD ABSORBERS & REAR DOUBLE
The stainless steel muffler guard RATED HYDRAULIC MONO-
on your scooter not only protects SHOCK SPRING SUSPENSION
you from hot muffler but also adds Your scooter comes with superior
a dash of style to its sporty looks. suspension that enhances ride
comfort even when you ride over
SPORTY DOUBLE STITCHED potholes, bumps or bad roads.
SEAT

PAINTED SWITCH PANEL WIDE COMFORTABLE SEAT

A wide comfortable seat ensures
that your posture while riding is
relaxed and your pillion is seated
comfortably too.
ZEST for COMFORT
RIGHT ERGONOMICS
Your Scooter comes with right
weight of 103 kgs for easy handling ABS BODY
and zippier rides. Also, Right Seat The ABS body of your scooter is
height of 760 mm on your scooter tough and ensures comfort while
ensures good ground reachability riding.
while adding safety.

6
ZEST for CONVENIENCE PARKING BRAKE (REAR BRAKE
LARGEST UNDER-SEAT LOCK)
STORAGE (UTILITY BOX) The parking brake is another unique
Your scooter has the largest 19 litre safety feature which protects your
under-seat storage space to carry scooter from falling when it is
your bags, books, and belongings. parked on a slope.

TUBELESS TYRE MFR HEADLAMP

Your scooter has tubeless tyres for Your scooter has a “Multi Focal
enhanced convenience. You can Reflector” – the bright headlamp
run the vehicle for a few more kms with a ‘Halogen bulb’ for better
even after the tyre is punctured. visibility in the dark.

RETRACTABLE BAG HOOK

EaZy® CENTRE STAND
Your scooter has a retractable bag
The patented EaZy® Centre Stand hook to carry light luggage, like
of your scooter reduces the effort carry bags weighing up to 3 kgs.
required to place the scooter on The hook is located below the
stand. handle bar.

SYNCHRONIZED BRAKING UNDER-SEAT LUGGAGE HOOK

TECHNOLOGY (SBT) For more convenience, another
Synchronized braking technology luggage hook is located just under
reduces the stopping distance, the seat of your scooter.
While keeping the stability intact.

7
HELMET HOOK SMART PHONE CHARGER
Your scooter has one helmet Your scooter has a Smart phone
hook under the seat assembly to changer enable to charge your
conveniently place the helmet. mobile phone when you are
traveling. The utility box light which
lights up the utility box whenever
the seat is open.
EASY KICKSTART
The kick lever in your scooter is ZEST for MILEAGE
designed such that the vehicle can BEST IN CLASS MILEAGE
be kick-started while you’re seated Your scooter is not only packed
on the vehicle. with features but also it is easy
on your pocket. Its best-in-class
HUGGER FENDER mileage ensures you spend lesser
The hugger fender in your scooter on fuel and save more pocket
keeps the engine protected & money.
helps to save the pillion rider from
mud splashes. ECONOMETER®
Your speedometer has an
ECONOMETER® which indicates
whether you are riding in Economy
Mode. This is a unique feature
of your scooter which enables
to manage your scooter fuel
efficiently.

8
ACCESSORIES FOR YOUR
VEHICLE
OPEN FRONT GLOVE BOX*
An open front glove box is
supplied as an accessory for your
scooter. It is specially designed to
accommodate a 1 litre bottle.

FOLDABLE PILLION SIDE FOOT

REST*
The foldable pillion side foot rest is
supplied as an accessory for your
scooter.

* Accessory will be charged extra

9
 FOREWORD
Dear TVS ZEST Owner,
Congratulations and welcome to the world of fun and exciting rides with your TVS ZEST.
You‘ve made a smart decision, choosing to ride ahead on the brand new TVS ZEST. You‘ll find that it meets all your
needs by striking the perfect balance between power, style, comfort, convenience and mileage.
The stylish new TVS ZEST is crafted especially for you. Its 110cc CVTi engine gives you awesome pick-up and zippy
rides.
The TVS ZEST is also easy to ride – with the right height and the right weight; it offers you the perfect balance of
speed and stability, so it‘s easy to handle on busy roads. With the least turning radius, it is easy to manoeuvre as well.
The benefits of TVS ZEST don‘t end there. With its largest under-seat storage of 19 litres, it gives you the all the
space to carry your world with you.
This manual explains in detail, the many features, benefits and operations of your TVS ZEST. Do read through your
manual carefully, it will help you get the best out of your vehicle, and keep it going strong for years to come. To ensure
reliable performance, we urge you to get your TVS ZEST serviced only at TVS Motor Company Authorised Main
Dealers / Authorised Dealers at regular intervals as specified by your service provider.
We wish you zippy, comfortable, safe and exciting trips for years to come! Get ready to zip ahead with Zest!

TVS MOTOR COMPANY LIMITED

10
 NOTICE
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.
Your scooter is provided with always glowing head lamp (AHO). The head lamp glows automatically once the engine
is started.
Since your vehicle is fitted with side stand cut-off system ensure to retract the side stand before starting the vehicle.

Revision 8, as on 05 Apr 2023

11
 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.

12
 RUNNING-IN INFORMATION
The first 1000 km is a crucial part for the life of your scooter. Proper running-in operation during this period helps in
ensuring a maximum life and smooth performance of your scooter.
The reliability and performance of your scooter depends on the special care and restraint 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 50 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 and 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 and transmission oil during first free service is most important for better life of engine. Always use TVS
TRU4 SKUUTA oil (SAE10W30 API-SL, JASO MB) for better performance and life.

13
 SAFE RIDING TIPS
SAFE RIDING RECOMMENDATIONS
Any two wheeler riding requires some precautions to be taken to ensure the safety of the rider, pillion and other road
users. These precautions are:
Familiarise yourself with new TVS ZEST
Riding skill and your mechanical knowledge form the foundation of safe riding practices. We suggest you to practice
riding TVS ZEST in a low-traffic condition until you are thoroughly familiar with your vehicle and its controls. Remember
practice makes you perfect.
Riding apparel
Loose, fancy clothing can be uncomfortable and unsafe when riding a two-wheeler. Choose good quality two wheeler
riding apparel.
Know your limits
Ride within the boundaries of your own skill at all times. Knowing these limits and staying within the limits will help
you avoid accidents.

Two wheeler safety starts with wearing a good quality helmet. One of the most serious injuries that can happen is a head
injury. Always wear an ISI approved helmet that should fit your head comfortably and securely. You should also have good
quality goggles to protect your eyes and help your vision.
To prevent or minimize accident, never consume alcohol or drugs before or during the operation of your vehicle. Even minimal
consumption of these will affect the rider’s ability to control the vehicle.

14
Posture Cornering
Proper vehicle riding starts with proper posture. When cornering, centrifugal force works in a direction
1. Keep your elbows relaxed and flexible. perpendicular to the direction in which the vehicle
2. Sit and adjust yourself on seat so that arms and is moving. Centrifugal force increases in proportion
shoulders are relaxed with speed and radius of the corner.
3. Look widely instead of gazing at one point. During cornering, reduce speed so as to lessen the
effects of centrifugal force. By all means, avoid abrupt
application of brake or sudden steering.
Braking
One-hand riding is dangerous. Keep both hands firmly For safe riding, it is very important to master the
on the handle bar and both feet securely on the floor braking techniques.
board. Under no circumstances should both the hands
1. Close / release the throttle.
be removed from the handle bar, as it is very dangerous.
2. Hold the vehicle upright as you apply the brake.
Avoid use of mobile phones while riding as it could 3. Progressive application of brake is safer.
lead to fatal accident.
4. Apply both the brakes. ‘SBT’ provides
Slow down to a safe speed before negotiating a corner. additional braking even when ‘Only Rear
If this is the first time that you are riding a vehicle of brake’ is applied, But applying ‘Both the
this type, we suggest that you practice on a safe, open brakes’ helps you to use the full potential of
area to thoroughly familiarise with the operation of the the brakes.
vehicle.
5. Riding down hills, while cornering and wet roads
close throttle and come to a slower speed to
avoid the loss of control over the vehicle due to
skidding.

15
Causes for poor braking ACCESSORY INSTALLATION AND SAFETY TIPS
1. If the brake shoes or drum are worn out or if there Use extreme caution while selecting and installing
is water or oil on them, sufficient friction does not the accessories for your scooter.
develop and brakes do not work well. The addition of unsuitable accessories can lead to
2. Even when the brake works normally, if the road unsafe operating conditions. Your friendly Dealer
surface is wet or the tyre surface is worn-out, will assist you in selecting quality accessories and
tyres do not take a firm hold on the surface, installing them correctly.
increasing the stopping distance. While selecting the accessories, make sure the
3. Approximately 60% braking effect is from front accessories should not obstruct lighting, steering,
brake. Non-usage of front brake causes poor suspension level and ground clearance.
braking. Additional electrical equipments is not acceptable
as it will void warranty terms of the vehicle.

As the vehicle speed increases, the stopping distance

also increases progressively. Be sure that, you have
sufficient distance between you and the vehicle or
obstruction ahead of you.
Using only the front or rear brake is dangerous and can
cause skidding and loss of control. Apply both the
brakes together and with great care on a wet road or
other slippery surfaces. Any abrupt braking on slippery
or irregular roads can cause loss of rider control.

16
EMISSION CONTROL
All the TVS vehicles are tested in the factory for
optimum fuel efficiency and CO levels. If the vehicle If there is any abnormal jerk, startability issue are felt in
needs any adjustments, please consult nearest the vehicle or noise due to sudden escape of gas during
opening of fuel tank cap, immediately report to the TVS
TVS Motor Company Authorised Main Dealer or
Motor Company Authorised Main Dealer / Authorised
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 the
scooter in good condition by getting it periodically Your vehicle is tested and certified for emission which
checked and serviced by TVS Motor Company meets BS VI emission norms and is valid for initial 12
Authorised Main Dealer / Authorised Dealer so months from the date of purchase. Get your vehicle
that the emission and fuel consumption levels 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
The engine of new TVS ZEST is equipped with a certificate obtained.
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 ZEST 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.

17
 KNOW YOUR TVS ZEST
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 frame, at The engine serial number is stamped on the left side of
the rear end below the seat assembly. Open the seat the engine, at the bottom, near center stand mounting.
assembly to read the frame number. See bottom to read serial number.

18
LOCATION OF PARTS - HANDLE BAR

1. Retractable bag hook

2. Horn switch
3. Turn signal lamp switch
6 7 8 9 4. Rear brake lever
5. Parking brake (rear brake lock)
6. Rear view mirror L
7. High/low beam switch
8. Speedometer assembly
5 9. Rear view mirror R
10 10. Front brake lever
4 11. Throttle grip
12. Lights ON/OFF switch
11
13. Electric starter switch
3 12 14. Ignition cum steering lock
15. Glove box*
2 13
1
14

15

* Accessory will be charged extra

19
LOCATION OF PARTS - VEHICLE LEFT SIDE

1. Rear brake adjusting nut

2. Lady foot rest - foldable*
8 9 3. Kickstarter lever
4. Effortless easy centre stand
5. Side stand*
6. Pillion foot rest L
7. Front brake adjusting nut
8. Seat lock
9. Pillion handle

7 6 5 4 3 2 1

* Accessory will be charged extra

20
LOCATION OF PARTS - VEHICLE RIGHT SIDE

1. Front wheel axle nut

2. Under-seat luggage hook
3. Cover front
4. Pillion foot rest R
8 9
5. Gauge oil level
6. Muffler assembly
7. Rear fender
8. Seat assembly
9. Retractable bag hook

7 6 5 4 3 2 1

21
CONTROL KEY 2. ‘ON’ position
TVS ZEST comes with a pair of identical control keys. In this position, all the electrical circuits are turned
These keys are to operate ignition cum steering lock ‘ON’ and the engine can be started. Key cannot be
and seat lock. removed in this position.
IGNITION CUM STEERING LOCK 3. ‘LOCK’ position
The ignition cum steering lock enables and disables TVS ZEST steering can be locked in both ‘left’ and
the electrical circuit and steering lock. The three ‘right’ directions.
positions of the lock are described below. To lock the steering, turn the handle bar all the way to
1. ‘OFF’ position the ‘left’ or ‘right’. Push the key IN and turn it to the
All the electrical circuits are turned ‘OFF‘ in this ‘LOCK’ position from ‘OFF, position. All the electrical
position. Engine will not start. Key can be taken out. circuits are deactivated and the steering is locked.
Control key can be removed from the lock.
Insert the key into the lock and push the key IN
and turn it to ‘OFF’ or ‘ON’ position to unlock the
steering.

When you switch on the key, the pump priming noise

may be heard, which is normal. Avoid frequent SWITCH-
OFF & ON of ignition key, to avoid unnecessary run of
fuel pump.
The license plate lamp and tail lamp glow automatically
once the ignition key is turned ‘ON’ without activating
any other switches.

22
 SPEEDOMETER ASSEMBLY
Never attempt to move the vehicle when the steering is 1. Speedometer
locked, you may lose balance. Indicates vehicle speed in kilometers per hour.
2. Odometer
Registers and displays the total distance covered by
the vehicle in kilometers. The last digit denotes one
Leaving the ignition cum steering lock in ‘ON’ position tenth of a kilometer.
for a prolonged time will drain the battery when the 3. Turn signal indicator lamp left ( )
vehicle is not in use. Switch ‘OFF’ and take the key out
Flashes when the left side turn signal indication is
when the vehicle is not in use.
activated.
Always lock the steering while parking for safety. 4. High beam indicator lamp( )
Glows when the head lamp high beam is activated.

4 5 6 7

3 8

2
1
9

23
5. Malfunction indicator lamp - MIL ( )
MIL will be turned ON when the ECU detects a
Always ride the vehicle in ‘Economy Mode’ for better
fault in the system and MIL will blink when the ECU
fuel efficiency.
detects a misfire* in the engine.
If the malfunction indicator lamp ‘ ‘ is glowing If the side stand is deployed the vehicle will not start.
continuously or blinking continuously* when Retract the side stand to start the vehicle.
the engine is started, immediately contact the If there is error in the side stand switch the indication
nearest TVS Motor Company Authorised Main will not glow and the vehicle will not start. In such a
Dealer or Authorised Dealer. condition, please visit the nearest TVS Motor Company
6. Economy indicator Authorized Main Dealer / Authorized Dealer.
Eco indicator (green lamp) indicates that the vehicle
is running in economy mode which gives better fuel
efficiency.
7. Side stand indicator Minimum 1.0 liter of fuel should be maintained in
the fuel tank to avoid engine getting ‘OFF’ / damage
The side stand warning indicator turns ‘ON’ to alert
to fuel pump which leads to replacement of pump
you whenever the vehicle‘s side stand is deployed
without warranty.
(vehicle parked condition).
8. Turn signal indicator lamp right ( )
Flashes when the right side turn signal indication is
activated.
9. Fuel gauge
Fuel gauge indicates the approximate quantity of fuel
available in the fuel tank.
* Mis-firing detection is applicable only for OBD II vehicle.

24
HANDLE BAR LEFT SIDE 3. Left hand brake lever (SBT brake lever)
1. Horn switch Synchronised Braking Technology (SBT) can be
Press the switch ‘ ’ to operate the horn. operated by pressing the left hand brake lever gently
2. Turn signal lamp switch towards the handle grip.
Slide the turn signal lamp switch to left ‘ ’ or right SBT technology helps to operate both front and rear
side ‘ ’ to operate respective turn signal lamps (LH brakes by distributing the force optimally between
/ RH). Press the switch to turn ‘OFF’. the two braking system.
4. Parking brake (rear brake lock lever)
Brake lock protects your scooter from rolling-off,
3 4 5 when parked on side stand (or) helps you relax while
waiting in a long traffic signal (or) a slope.
To activate brake lock, press the brake lever almost
half towards the grip and hold, then press the parking
brake lever to maximum and release the brake lever
slowly. Ensure the brake is locked properly. Pressing
the brake lever further releases the brake lock
automatically.
1
2
Since your vehicle is fitted with SBT brake system it is
essential to maintain the brake system in good condition.
Adjust the brakes system at regular intervals for the
Always use the appropriate turn signal lamps when you
proper working of SBT.
intend to change lanes or take turns. Be sure to switch it
‘OFF’ after negotiating the lanes or turns. Ensure to release the brake lock before riding the vehicle.

25
5. High/low beam switch 1. Right hand brake lever
The head lamp glows automatically once the engine Front brake system can be operated by pressing the
is started. Only the head lamp beam (high/low) can right hand brake lever gently towards the throttle
be controlled with the beam control switch grip. The brake lamp glows on application of either
Press switch the towards ‘ ‘ to operate head lamp right hand or left hand brake lever.
high beam or press it towards ‘ ‘ to operate head 2. Throttle grip
lamp low beam. Engine speed is controlled by the rotation of the
throttle grip. Twist it towards you to increase the
engine speed and twist it away from you or release it
Use appropriate head lamp beam ‘high / low’ as per to decrease the engine speed.
the traffic and road conditions for your safety and avoid
inconvenience to other riders.
3. Electric starter switch
Retract the side stand and press the starter switch
HANDLE BAR RIGHT SIDE ‘ ’ to start the engine electrically along with the
application of either front or rear brake.

1 2

It is not recommended to add any additional throttle

grip (cover).

26
SEAT LOCK FUEL TANK# CAP
TVS ZEST comes with a lockable seat which need Fuel tank is located at the rear end of the vehicle
to be opened to access the fuel tank cap, utility box, below the seat. Open the seat as explained earlier
helmet hook, tool kit and fuse. to access the fuel tank cap. Remove the fuel tank
Insert the control key into the seat lock and turn it in cap by rotating it in anti-clockwise direction and fill
clockwise direction. Now lift the seat assembly. the fuel as recommended. Re-fix the cap and close
To close the seat, gently press the seat in its position the seat.
and ensure the locking of seat by hearing a ‘click’
sound and take out the key.

# The fuel tank is not a measuring instrument and the capacity Never refill fuel near open flame. Do not smoke while
of the fuel tank may slightly vary from the indicated capacity. refueling. Do not use cell phones while refueling.

27
 KICKSTARTER LEVER
The kickstarter lever is located on the left side of
Ensure that the fuel gun is inserted fully in the tank neck the vehicle. To start the vehicle, keep the ignition in
while refueling.
‘ON’ condition and apply the rear brake as a safety
Whenever refueling, fill upto the bottom of neck portion precaution to prevent the rear wheel rotation.
(insert level) of the fuel tank. Filling above the neck may Keep your foot on the lever extension as shown in the
result in improper breathing of fuel tank and seepage figure. Kick the lever from top and stroke to bottom
of fuel. with rapid motion.
While refueling, avoid spillage of petrol on the tyre. If
fuel spills on tyre, the tyre will loose its grip on the road.
Ensure to close fuel tank cap without fail to avoid fuel
spillage.

28
EFFORTLESS E-Z CENTRE STAND
TVS ZEST is equipped with effortless centre stand.
The centre stand (1) has a pssivoted flexible spring
loaded lever arm (stand extension) (2) to increase the
lever ratio, which enables parking on centre stand
effortlessly and very conveniently.
To place the vehicle on centre stand, hold the handle
bar left grip with left hand. Place your foot firmly on
the centre stand extension (2) and press.

Side stand*

2
1

Never sit on vehicle when it is supported by stands.

Always park the vehicle on a flat, firm surface. *
Mandatory accessory will be charged extra

29
Side stand can be operated by sitting on vehicle with Lift the seat by unlocking the seat lock as explained
your left foot by pushing it away from the vehicle till in page no. 27, to access the tool kit. The tool kit
it stops. consists one number each of the following. Ensure
the contents of tool kit.
16x17 mm box spanner
Always retract the side stand to its full up position 10x12 mm spanner
before starting the vehicle. Else, the vehicle will not Combination screw driver bit
get start.
Screw driver handle
Tool bag
TOOL KIT AND FIRST AID 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 It is recommended to use the tool kit in case of any
below the seat base. emergency only. It is always advisable to take your
vehicle to TVS Motor Company Authorised Main Dealer
/ Authorised Dealer.

30
FRONT GLOVE BOX* UTILITY BOX
Open type front glove box is provided in your scooter Utility box is located below the seat. Lift the seat by
to store easy and quick access things like notebooks, unlocking the seat lock as explained in page no. 27
files, water bottles etc. to access the utility box.

Recommended not to keep valuable items inside the Utility box can be used to carry a load of 19 litres
glove box while leaving the vehicle unattended. maximum. Do not carry perishable items inside the
utility box. It is not fully sealed. Do not allow / spray
water to get inside the utility box.

* Accessory will be charged extra

31
 BAG HOOKS
There are two bag hooks provided with your scooter
Take care not to spill petrol or oil into the utility box. Do to carry light luggage like carry bags weighing upto
not keep heat-sensitive items inside as it may get hot
3 kg. One hook is located below handle bar on the
on long rides. Recommended not to keep valuable
rear panel which is retractable. Just pull out the hook
items inside the utility box while leaving the vehicle
from the top to hang your luggage. Push back the
unattended.
hook once it is free. The other hook is located on the
HELMET HOOK cover front below front end of the seat assembly.
A helmet hook is provided under the seat, at front
right side end of the utility box to secure your helmet.
Open the seat assembly as explained in page no.
27 to access the helmet hook. Hook the helmet
strap in the helmet hook and close the seat.

Care should be taken not to attach the luggage which

hangs out of your scooter. Please note that the luggage
attached to your scooter should not interfere your feet
movement.

32
SMART PHONE CHARGER DO’s
All new smart phone charging port and utility box light 1. Ensure that no water enters into the unit, by
has been provided in the utility box of your vehicle. closing the USB flap properly.
Please follow the guidelines mentioned below for 2. Use the USB, if approved standard USB cable
using it properly: used for charging mobile.
3. The chassis number of the vehicle can be
accessed by taking the smart phone charger unit
from its mounting. Ensure to refit the charger unit
properly.
4. 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 mobile phones. Only one mobile
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.
The charging time of the mobile may vary, depending on
the mobile’s battery state of charge. The rubber flap in 4. Do not charge your mobile when engine is off.
the unit has been designed to prevent water entry and
is not replaceable. No warranty for charger in case of
rubber flap cut.

33
 RIDING YOUR TVS ZEST
PRE RIDE INSPECTION
Check the following items before riding
ITEM WHAT TO CHECK FOR
Engine oil Availability of oil upto the level (page no. 49)
Transmission oil Availability of oil upto the level (page no. 50)
Fuel Enough fuel for the planned distance of running
Tyres Correct pressure (page no. 55)
Adequate tread depth / No cracks or cuts.
Battery Proper working of electric starter, horn, fuel gauge, pass by, brake lamp and turn signal
lamps.
Battery voltage (page no. 43)
Lighting Proper working of head lamp high / low beam, high beam indicator, position lamp,
speedometer back illumination, tail lamp and license plate lamp.
Steering Smooth movement / no play or looseness
Throttle Correct free play of cable / smooth operation
Brakes Correct front / rear brake lever play (page no. 51)
Wheels Free rotation of front and rear wheels

Do not switch ‘ON’ the ignition without minimum level fuel in the tank. It will cause damage to the pump.

34
Starting the engine Stopping and parking
Ensure the availability of fuel in the fuel tank. Insert 1. Close the throttle completely and apply both the
the control key into the ignition cum steering lock and brakes simultaneously.
turn it to the ‘ON’ position. In side stand retracted 2. Turn the ignition ‘OFF’.
condition, apply any one of the brake and press the 3. Park the vehicle on a firm, flat surface.
electric starter switch to start electrically or kick start.
4. Lock the steering and take out the control key.
Press the start button without applying the throttle.
As soon as the engine starts, release the start button.
The engine will not start if the throttle is opened full.
Setting the vehicle in motion Reduce speed to a safe limit before turning / cornering.
1. Twist the throttle grip towards you and Do not apply brake while turning / cornering.
simultaneously release the brake lever gently and
smoothly. The vehicle will start moving forward. FUEL RECOMMENDATION
2. As the vehicle picks up speed, increase the Use only BS VI petrol with minimum RON 91.
throttle slowly. BS VI petrol containing upto 20% of ethanol by
volume can be used.
Higher ethanol content in petrol can lead to
Do not keep the engine in idling rpm for long and do
• degrade plastic and rubber components of
not open excessive throttle when the vehicle is parked.
It leads to overheating of engine and damage to the
fuel system and vehicle parts
internal components. • cause corrosion damage to metal parts like
fuel tank, etc
• result in startability & drivability issues
Do not raise the throttle rapidly so the vehicle will move • decrease fuel economy
forward suddenly and lead to loss of control.

35
Ethanol absorbs water very easily, resulting fuel CHECKS AND TIPS FOR IMPROVING FUEL
separation. Extra care shall be taken to prevent ECONOMY
moisture entry into fuel tank while filling ethanol Regular checks
blended petrol and water washing of vehicle. Carry out the periodic maintenance checks as
Painted parts (viz. panels, covers) shall not come in specified in this manual (page no. 39).
contact with ethanol blended fuels. Regular maintenance checks will save fuel and
Manufacturer is not responsible for any warranty ensure trouble-free, enjoyable and safe riding besides
issues that results from using ethanol blend in excess keeping environment clean.
of 20% by volume. Spark plug
In case of any abnormalities observed due to use of A dirty or defective spark plug leads to wastage of fuel
ethanol blended fuels, customers are advised to use due to incomplete combustion. Clean and adjust the
a different fuel station / brand for standard E20 fuel or spark plug only if necessary. Replace the spark plug
contact authorised service centres. every 12000 kms (1 year). Always use recommended
spark plug only.
Air cleaner element
A dirty air cleaner element restricts airflow and
Never mix oil in petrol in the fuel tank. Always fill fuel
increases fuel consumption. Replace the element
from the reputed and reliable fuel stations.
every 12000 kms.
Since viscous filter is used in your scooter it is not
recommended to clean the filter. Replace the filter
incase of any abnormalities.
Engine oil and Transmission oil
Dirty or less engine oil increases friction between
various parts of the engine and reduces the engine
life, thereby increases the fuel consumption.

36
Running with low transmission oil will cause damage Wheel freeness
to the gears and bearings. Regularly inspect the Inspect and ensure the wheel freeness by rotating
engine oil and the transmission oil for correct level the wheel at least once in a week to avoid wastage
and top-up if necessary. Get it replaced at regular of fuel.
intervals as per the maintenance schedule. Avoid unnecessary idling
Fuel leak While waiting for someone or stopping in signals for
Inspect and arrest fuel leaks if any from tank and fuel long time, if the engine is kept running at idle speed,
lines. Loss of fuel due to leak may drain the fuel tank it causes unnecessary wastage of fuel.
completely.
Avoid frequent braking
Evaporation
Anticipate corners and slopes as well as the traffic
Vehicle parked in the hot sun leads to wastage of fuel
conditions. Unnecessary and frequent braking will
through evaporation. Also, lower fuel levels in the tank
reduce the fuel economy. Never accelerate and
will have increased evaporation and condensation of
apply brake simultaneously. It leads clutch shoes
moisture inside. Ensure to close fuel tank cap after
wear and wastage of fuel.
every filling. If the fuel tank cap kept open for long
time, it leads to safety and fuel loss.
Tyres
Low tyre pressure has adverse effect on the vehicle. The on-road mileage of TVS ZEST is dependent on
The drag on the vehicle increases resulting several factors like road condition, quality of fuel, riding
decreased fuel economy. Further more, handling may speed, operation of throttle and brake, tyre inflation,
be adversely affected. maintenance / timely servicing of vehicle, load etc.. and
Inspect the tyre pressure regularly (weekly) and hence will differ from the mileage given under standard
inflate it to the recommended pressure (refer page test conditions such as made in recognised institutes.
no. 55). Never use tyres which are worn beyond
the permissible limit.

37
 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 is used / operated in dusty area, certain jobs should be performed more often to
ensure reliability of the vehicle. Cylinder head, steering components, suspension 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 ZEST, 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. Make 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 required early inspection than the mentioned kilometers to avoid costly damages
to the engine.

38
PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier)
Item In free service After free service
Service 1st 2nd 3rd 4th Every Every
Remarks
km 500 - 750 2500 - 3000 5000 - 6000 8500 - 9000 3000 km 6000 km
Period from the date of sale 2 months 4 months 8 months 12 months 4 months 8 months
Engine oil R I &T R I &T I &T R
Oil filter (strainer) C – C – – C
Transmission oil R I &T R I &T I &T R
Inspect, Clean and adjust if
Spark plug I – – – – –
required. Replace every 12000 km
Air cleaner element I – – – – – Replace every 12000 km
Air cleaner oil collection tubes – I & DR I & DR I & DR I & DR – Drain oil if necessary
CVT filter element1 – – I&C – – I&C Replace every 12000 km
Inspect for any noise / starting
Tappet clearance I – I&A – – I&A
trouble and adjust if required
Drive belt and CVT rollers – – – – – – Replace every 24000 km
Cover variator2 – – I, C & L – – I, C & L
Clutch shoe – – – – – – Replace every 24000 km
Hose fuel – – – – – – Replace every 3 years
Front and rear suspension I I I I I – Inspect for proper functioning
All control cables3 I, A & L I, A & L I, A & L I, A & L I, A & L –

R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; DR - Drain; L - Lubricate; TI - Tighten; S - Set
1
Inspect for damage
2
Clean the cover with air. Lubricate kick starter with Bechem grease
3
Inspect for proper operation and adjust play. Lubricate ends using grease Contd...

39
Item In free service After free service
Service 1st 2nd 3rd 4th Every Every
Remarks
km 500 - 750 2500 - 3000 5000 - 6000 8500 - 9000 3000 km 6000 km
Period from the date of sale 2 months 4 months 8 months 12 months 4 months 8 months
Throttle grip – – L – – L Lubricate using grease
Steering smooth operation C, L & A with fresh grease
I&A – – – – –
/ play every 12000 km
Speedo hub drive / cable – – L – – L Lubricate using grease
Front fork oil – – – – – – Replace every 24000 km
All fasteners I & TI I & TI I & TI I & TI I & TI –
All bulbs, horn and switches I I I I I – Inspect for proper functioning
Head lamp beam I&A I&A I&A I&A I&A –
Battery electrolyte level I &T I &T I &T I &T I &T –
Specific gravity & voltage4 I I I I I –
Refer page No. 58 & 61 for
Brake effectiveness / play I&A I&A I&A I&A I&A –
details
Brake cam – – C&L – – C&L Lubricate using grease
Wheel freeness I I I I I –
Lubricate using grease
Front wheel bearing – – – – – –
every 12000 km
Tyre pressure at cold
I&S I&S I&S I&S I&S –
condition
Check and resolve the errors using
Malfunction indicator lamp I I I I I – diagnostic tool if the lamp is ON
even after starting the engine
4
Recharge if necessary Contd...

40
Item In free service After free service
Service 1st 2nd 3rd 4th Every Every
Remarks
km 500 - 750 2500 - 3000 5000 - 6000 8500 - 9000 3000 km 6000 km
Period from the date of sale 2 months 4 months 8 months 12 months 4 months 8 months
Evaporative emission control Check for intactness of hoses
I I I I I –
system and canister
Fuel tank assembly** I&C I&C I&C I&C I&C –
Centre / side stand pivot L L L L L – Lubricate using TRU4 oil
Kick starter pedal pivot L L L L L – Lubricate using TRU4 oil
R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; DR - Drain; L - Lubricate; TI - Tighten; S - Set
** Check for abnormal vehicle jerk / noise while opening the cap / leak. If found any, contact TVS Motor Company Authorised Main Dealer
or Authorised Dealer.

41
RECOMMENDED LUBRICANTS

APPLICATION QTY MANUFACTURER BRAND

Engine oil 750 ~ 800 ml (during regular service) TVS Motor Company TVS TRU4 SKUUTA oil
800 ml (incase of disassembly) (SAE 10W30 API-SL, JASO MB)
Transmission oil 100 ml (during regular service) -do- -do-
120 ml (incase of disassembly)
Front fork oil 53 ± 1 ml / leg IOC / HPCL / Castrol Gabriel Premium front fork fluid
Grease – Bharat petroleum MP Grease no. 3
IOC Servo Gem no. 3
Bechem Bechem premium 3
Kluber Lubrication Kluber Centoplex 2

42
SELF - MAINTENANCE PROCEDURES 3. Take out the utility box along with the seat while
BATTERY carefully disconnecting the wiring socket of utility
Electrolyte level and the condition of battery must box lamp and diagnostic coupler (please note that
be inspected periodically to avoid failure of battery. the seat comes along with utility box since it is
Battery is located below the seat, at front end and mounted on the utility box).
enclosed by the utility box. Now, inspect the electrolyte level of the battery. The
To access and inspect the battery, utility box must be electrolyte must be between maximum and minimum
removed in the following manner. level. If the electrolyte level is below minimum level,
add only distilled water upto the maximum level by
1. Open the seat by unlocking the seat lock (refer
removing the filler caps.
page no. 27).
Reinstall the filler caps and clean the battery
2. Remove the mounting bolts of utility box using
throughly, apply petroleum jelly to the terminals of
suitable spanner.
battery to protect it from corrosion.

MAXIMUM

MINIMUM

43
While connecting the terminals, observe the correct Recommendations to maintain battery health
polarity. Connect the red wire to the ‘+’ terminal and during prolonged parking conditions
black wire to the ‘-’ terminal of the battery. While your vehicle is parked for prolonged duration,
Incase of any abnormality or for removal of battery battery continues to discharge and if left unattended
from the vehicle, contact TVS Motor Company can get completely discharged. It is recommended to
Authorised Main Dealer / Authorised Dealer. ride the vehicle for minimum 60 km every week to
keep the battery in healthy condition This could be at
a stretch in one ride or several rides during the week.
The vehicle speed will vary during the ride but an
Never check the battery charge by shorting the terminals. average speed of minimum 30 kmph will be helpful
Always connect the positive terminal first (red wire) to ensure proper battery charging. Use kick-starting,
and then negative (black wire) to avoid sparking. The if available, to conserve battery charge during such
inversion of the battery wires can damage the battery period. This is only a recommendation to maintain
and the recharging system. battery charge and regular service schedules must
be followed to maintain your vehicle in good running
condition.
The following is recommendations to users regarding
battery maintenance before, during and after long
storage of battery:
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

44
 c. Alternatively, battery connecting wires • Valve Regulate Lead Acid (VRLA) / Lead Acid
(positive and negative wires) can be batteries are prone to water damage. Any water
disconnected and fasteners can be secured entry, through vents or otherwise; will result in
with battery terminals.* irreparable damage to the battery or the vehicle.
2. During Storage
a. Store it at room temperature or lower.
b. Store the vehicle in the shade and protected
from rain and cover the vehicle to prevent Battery develop explosive gases. Keep it away from
heat sources. If charging is required the battery must be
rodents from entering and damaging the
charged in well ventilated area.
wires.
3. After Storage Unusable battery must be disposed in environment
a. Connect the wires and fuse, if disconnected friendly manner. Do not discard it with household
earlier, with ignition switch in OFF position* thrash. Handover the battery to the battery dealers or to
a recycle center that accept used battery.
b. Start the vehicle by kick starting.
(Above recommendations do not consider storage
effects on other systems such as induction and fuel
systems and wheels) Never operate the vehicle with discharged battery as it
Periodic Maintenance of Batteries: may damage electrical components.
• Keep top of battery clean Do not push start the vehicle, use a good battery to start
• Check cables, clamps, and case for obvious the vehicle.
damage or loose connections
• Clean terminals and connectors as necessary
Recharge battery if voltage is below 12.4 Volts.
* To be done by skilled personnel

45
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 cause for fuse failure.
Two different fuses are provided in TVS ZEST they
are:
• Main fuse - 15A
• Load fuse - 10A
• EMS fuse - 10A
The main fuse is located near the battery and the
EMS, load fuse are located below the cover front.
Follow the procedure given below to inspect and 5. Turn ‘ON’ the ignition lock and check for proper
replace the fuse: functioning of electrical systems. Incase the
Main fuse fuse fails again, consult the nearest TVS Motor
1. Open the seat assembly as explained in page Company Authorised Main Dealer / Authorised
no. 27. Dealer.
2. Fuse case fitted on the front left side of the utility Load & EMS fuse
box below seat contains a 15A fuse. Open the To access the load and EMS fuse, cover front need
fuse case and take out the fuse. to be removed. Follow the procedure given below for
3. Inspect the fuse for failure. If found defective, the removal of cover front.
replace the fuse with the extra fuse provided in 1. Remove the bottom mounting screw (A).
the wiring harness itself. 2. Open the seat by unlocking the seat lock (refer
4. Close the fuse case and re-fix into its location. page no. 27) and remove the top mounting
screw (B) from both the sides of the cover front.

46
3. Gently pull out the cover by dislocating its lugs. 7. Turn ‘ON’ the ignition lock and check for proper
4. Fuse case fitted on the left side of the battery functioning of electrical systems. Incase the
bellow the main fuse case which contains two fuse fails again, consult the nearest TVS Motor
10A fuses. Pull out the fuse case from the Company Authorised Main Dealer / Authorised
mounting. Open the fuse case and take out the Dealer.
fuse.
5. Inspect the fuse for failure. If found defective, Good Fuse Blown Fuse
replace the fuse with the extra fuse provided
inside the fuse case itself.
6. Close the fuse case and re-fix into the frame
bracket.

B Do not use vehicle by shorting the wires without fuse.

A This may result in overheating of electrical items / wiring
and may result in fire of vehicle.
Do not use fuse of higher amperage than specified for
the safety of electrical system.

47
SPARK PLUG Inspect the spark plug electrodes (A) and (B) for
To access the spark plug, cover front need to be any corrosion. If found any, replace the spark plug
removed (refer previous page). with a new. Inspect the spark plug gap with a wire
1. Clean the dust and mud around the spark plug gauge / feeler gauge. Readjust the spark plug gap to
mounting to avoid falling inside the cylinder. 0.9 ~ 1.0 mm if required.
2. Using spark plug spanner of tool kit, remove the After cleaning and adjusting the gap, reinstall the
spark plug. spark plug and tighten by hand to avoid cross
threading. Finally tighten using spark plug spanner.
A spark plug with heavy carbon deposits will not
produce strong sparks. Hence, only if necessary,
clean the carbon deposits from the spark plug with a
small wire brush or spark plug cleaning tool.
Always use only recommended make and type of spark
plug. Replace the spark plug every 12000 km.
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.
Do not try to adjust the spark plug as it may damage the
plug. Replace the plug if the gap is found more.
It is advisable to tighten the new spark plug by hand till
A 0.9 ~ 1.0 mm the end, using plug spanner tighten by 1/4 turn. Then
loosen the plug by 1/8 turn and re-tighten using plug
spanner.
B

48
ENGINE OIL LEVEL 5. If the oil level is less than the minimum level, add
Check the engine oil level periodically. TVS TRU4 SKUUTA oil only (SAE 10W30 API-SL,
1. Place the vehicle with the centre stand on a flat JASO MB) oil upto the maximum level mark.
surface. Wipe-off the surroundings of gauge oil 6. Wipe out the oil traces with a clean cloth to
level. prevent dust accumulation.
2. Remove the gauge and wipe it clean. 7. Assemble back the gauge oil level.
3. Fix the gauge back to its mounting hole. Do not
thread in.
4. Take out the gauge and check the oil level. The
level should be between minimum and maximum If the vehicle is driven with less engine oil, the engine
components will be severely damaged.
level marks of the gauge (shown in the figure).
Check the oil level as per the schedule to avoid costly
damage. Do not fill excess oil may cause oil leak. Always
use ‘TVS TRU4 SKUUTA (SAE 10W30 API-SL, JASO
MB)‘ oil only.

Maximum

Minimum

49
TRANSMISSION OIL LEVEL 6. Reassemble the oil level bolt with new fiber
Check the transmission oil level periodically. washer.
1. Place the vehicle on centre stand on a flat surface.
Wipe-off the surroundings of oil level screw.
2. Remove the transmission oil level screw along
with a gasket from the rear end of crankcase L. If the vehicle is driven with less transmission oil, the
transmission components of engine will be severely
3. Check for the flow of oil from oil level hole. damaged.
4. If the level is less (if there is no oil flow), top-up
with TVS TRU4 SKUUTA (SAE 10W30 API-SL, Check the oil level as per the schedule to avoid costly
JASO MB) oil till the it just starts to flow out from damage. Do not fill excess oil may cause oil leak.
the oil level hole. Always use ‘TVS TRU4 SKUUTA (SAE 10W30 API-SL,
5. Wipe out the oil traces with a clean cloth to JASO MB)‘ oil only.
prevent dust accumulation.

50
BRAKES
Front brake
1. Measure the free play of the front brake lever at
lever end as shown in the figure.
I
2. The free play of the brake lever before the 1
S
engagement of brake should be between
15 ~ 20 mm.
3. Turn the adjuster nut at the top (1) in the slot
marked as “I” in clockwise direction for reducing
the free play or in anti-clockwise direction for
increasing the free play.
4. After obtaining the necessary free play, inspect
for the clearance between the bullet (3) and slot
end (4) marked as “S” as shown in the figure.
15 ~ 20 mm

Clearance

1 I

2 S

3 4

51
5. If any clearance is found, turn the adjuster nut
(2) at the bottom side in the slot marked as “S”
in clockwise direction until there is no clearance Since the vehicle is fitted with Synchronised Braking
between the bullet bottom (3) and the slot bottom System (SBS) adjust the brakes with additional care. If
not it may result in brakes not working properly. Please
(4).
contact TVS Motor Company Authorised Main Dealer or
Authorised Dealer for any further assistance.

5 6

1 I

2 S

Clearance

6. After adjusting the bottom adjuster nut, if any

clearance is observed between the bullet top (5)
and the slot top (6) marked as “I” as shown, then
turn the adjuster nut (2) in anti-clockwise until
there is no clearance.
7. Once again check and confirm the brake play at
the lever end.

52
Brake shoe wear indicator - Front Rear brake
When the brake is applied, wear limit index mark (1) 1. Measure the free play of the rear brake lever at
on the front brake cam should be within the wear the lever end as shown in the figure.
limit indicator (2) on the front brake panel. 2. The free play of the brake lever before the
Incase the wear limit index mark (1) is going beyond engagement of brake should be between
wear limit indicator (2), index the lever to next slot 10 ~ 15 mm.
with the help of the Dealer to extend the shoe life.

10 ~ 15 mm

2
1

Replace the brake shoes as a set, if the wear limit Please remember that the rear brake lever free play
indicator shows beyond the wear limit even after adjustment to be done only after adjusting the front
indexing the lever. brake lever play.
3. If the measured free play is more than the limit, Brake shoe wear indicator - Rear brake
adjust the nut provided at rear wheel end to When brake is applied, the wear limit indication
obtain correct play. pointer (1) on the rear brake cam lever should be
4. Turn the adjuster nut in clockwise direction for within the wear limit indicator (2) on the crankcase
reducing free play or in anti-clockwise direction LH.
for increasing free play. In case the wear limit indication pointer (1) is going
beyond wear limit indicator (2), index the lever to next
slot with the help of Dealers to extend shoe life.

1
2

Check front brake (drum brake type) and rear brake

play periodically. However the brake play needs to be Replace the brake shoes as a set, if the wear limit
adjusted more frequently depending upon the usage. indicator shows beyond the wear limit even after
indexing the lever.

54
TYRES
Tyre pressure
Check the tyre pressure atleast once in a week if not B
more frequently. Insufficient air pressure in the tyres
not only hasten tyre wear, but also seriously affects A
the stability of the vehicle.

I
TW
Under inflated tyres make smooth cornering difficult
and over inflated tyres decrease the tyre contact with
the ground which can lead to skidding and loss of
control. Be sure that the tyre pressure is within the
specified limits at all times.
Tyre pressure in cold condition: Tyre rotation direction
While reassembling the tyres after removing from
Solo Dual the wheel rim or while assembling a new tyre ensure
Front 1.69 kg/cm² (24 PSI) 1.69 kg/cm² (24 PSI) that the arrow mark (B) provided on the tyre facing
the direction of wheel rotation.
Rear 2.00 kg/cm² (29 PSI) 2.53 kg/cm² (36 PSI)
Tyre puncture
Tyre tread condition Your scooter is fitted with a tubeless tyre on both the
wheel. Incase of any puncture / tyre damage, it is
Operating the vehicle with excessively worn tyres
advised to visit the nearest tyre manufacturer Dealer
will decrease riding stability and can lead to loss of
or the tyre repair shops who knows the repairing
control. It is recommended to replace the tyre when
method of tubeless tyre. It is not necessary to
the tyre wears off to the tyre wear indicator level
remove the tyre from wheel rim always to attend a
(indicated by TWI (A) on the tyre).
puncture.

55
Even though, if there is need of tyre removal, it is
strongly recommended to use a tyre removal / fitment
machine. If at all, tyre levers needs to be used, the
levers should be free from sharp edges. Care should
be taken not to damage the tyres and rims.

The tyre inflation pressure in cold condition and the

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
pattern on it. Use of a tyre other than the standard may
cause instability.

The side walls of the tubeless tyre which in contact with

the wheel rim are only seals the air inside the wheel
assembly. Hence care should be taken not to damage
the side walls of the tyres during removal / reassembly.

56
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.

57
FRONT WHEEL REMOVAL 6. Reverse the procedure for reassembling, while
1. Remove the axle nut (1) along with a washer. Take ensuring the proper seating of brake panel slot in
out the cover fork tube RH . the fork leg L lug (LH side) and hub drive lugs in
2. Pull out the axle (2) along with punched washer the slots of wheel hub (RH side).
and take out the cover fork tube LH.
3. Take out the spacer from the right side of the
wheel. Dislocate the hub drive from wheel hub.
4. Place a support below the foot board to prevent
vehicle from falling and lift the vehicle up.
5. Dislocate the wheel assembly along with brake
panel from front fork. Separate the brake panel
from the wheel and take out the wheel.

1 2

58
REAR WHEEL REMOVAL STORAGE PROCEDURES
1. Place the vehicle on the centre stand. For storage of your scooter for longer period of over
2. Hold the rear brake firmly and remove the wheel a month and above, we recommend to carry out the
mounting nut (A) along with a washer. following steps:
3. Slightly tilt the vehicle and take out the wheel 1. Clean the vehicle thoroughly. Park the vehicle on
from the rear axle. centre stand.
4. Reassemble the wheel in the reverse order 2. Warm up the engine. Drain engine oil and
of removal. Hold the rear brake firmly while transmission oil. Store the oil, if new, in a dust
re-tightening the mounting nut for easy locking free container.
of wheel. 3. Empty the fuel tank.
4. Remove the spark plug and feed in several drops
of engine oil through spark plug hole. Crank the
engine few times and reinstall the spark plug.

Do not park the vehicle on a slope or soft ground or else

1 it may fall down.
The exhaust system becomes hot after a run. Park the
vehicle in a place where pedestrians or children are not
likely to touch the vehicle.

Always make sure, whenever the wheel is removed, the During storage, the battery must be recharged at
axle nuts are tightened properly to the specified torque. recommended charger if stored more than a month.

59
5. Remove the battery, store it away from direct 5. Lubricate the parts as instructed in periodic
sunlight and freezing temperatures. maintenance schedule.
6. Place a suitable support at the bottom of the foot 6. Fill up fresh petrol in the fuel tank.
board so that both the tyres are off the ground. 7. Check and inflate the tyres to the specified tyre
This will ensure better tyre life. pressure.
7. Cover up the vehicle completely with a clean 8. Check and correct the points given in page No.
tarpaulin or any other suitable cover. Store the 34.
vehicle inside a garage or similar area to avoid 9. Turn the ignition switch to ‘ON’ position. Retract
damage due to dust and rain. Make sure that the the side stand if the vehicle is parked on side
storage area is well ventilated and free from any stand. Start the engine and let it idle for few
source of flame or spark. minutes and ride out.
TAKING THE VEHICLE OUT OF STORAGE FOR
REGULAR USE
1. Take the vehicle out of garage and clean it
thoroughly. Avoid using alkaline solution like detergent soaps for
washing. This may damage head lamp and other lamp
2. Remount the battery after bench charging if
assemblies.
required.
3. Fill the engine oil (TVS TRU4 SKUUTA - SAE
10W30 API-SL, JASO MB oil) and check the oil
level using gauge oil level.
4. Fill the transmission oil (TVS TRU4 SKUUTA -
SAE10W30 API-SL, JASO MB oil) and check the
oil level at the oil level inspection screw.

60
RECOMMENDED TIPS WHEN TAKING A LONG 6. Front / rear brake function and rear brake
TRIP OF MORE THAN 500 KM: lamp working.
A) Please keep the following items for use in case of 7. Front fork for any abnormality.
emergency: 8. Spark plug gap and condition of spark plug.
1. Tool kit complete. 9. Air filter element cleanliness.
2. Recommended spark plug one number. 10. Lubrication of all items mentioned in the
3. Head lamp and turn signal lamp bulb each periodic maintenance schedule.
one. 11. Any other job as necessary.
4. Throttle, front and rear brake cable each one. 12. Have your vehicle checked at any TVS
5. First aid kit. Motor Company Authorised Main Dealer or
B) Precautions to be taken for the journey: Authorised Dealer.
1. Ensure engine oil and transmission oil are up
to the level.
2. Adequate fuel in the fuel tank. Long journey are to be taken only after the running-in
C) Check your scooter for the following: period of 1000 km.
1. Tightness of all bolts and nuts with correct
torque value.
2. Fitness of tyres / tyre pressure / tread depth.
3. All bulbs, indicator lamps and horn
functioning.
4. Smooth functioning of all cables and their
free play.
5. Smoothness of steering operation.

61
 WARRANTY AND SERVICES
TVS Motor Company Limited (‘the Company’) give this warranty with respect to the TVS ZEST manufactured
by the Company.
While the Company has taken every care to maintain quality in the manufacture of the TVS ZEST, the above said
warranty is subject to other terms of warranty:
During 5 years from the date of purchase or during the first 50,000 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.

62
 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 ZEST. 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

63
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, AHO.
Service Maintenance Parts Oil filters, spark plug, air filter, SAI filter, oils 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.

64
List of parts not covered under warranty

ITEM WHAT TO CHECK FOR

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.

65
SERVICE INFORMATION
There are seventeen services for TVS ZEST during warranty period. Of these, first four services are free services for
which labour charges are free. In addition to these four free services, we have a scheme of thirteen pay services.
For keeping the maintenance track of your vehicle, free and pay service record sheets are attached in the Service
Handbook given to you during the time of your vehicle purchase. Please have the relevant record sheet filled by the
Dealer who is carrying out the maintenance service.
For availing any of the warranty services, please take your vehicle and your Service Handbook to any of our Authorised
Main Dealers 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 free or pay service record sheet of Service Handbook 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 ZEST 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 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

66
Planned Service Schedule (kms or month whichever of the two occurs early)*

Sl.No. Service Type Kms Months

1 1st Service 500 ~ 750 2

2 2nd Service 2500 ~ 3000 4

Free
3 3rd Service 5000 ~ 6000 8

4 4th Service 8500 ~ 9000 12

5 5th Service 11500 ~ 12000 16

6 6th Service 14500 ~ 15000 20

7 7th Service 17500 ~ 18000 24

8 8th Service Pay 20500 ~ 21000 28

9 9th Service 23500 ~ 24000 32

10 10th Service 26500 ~ 27000 36

11 11th Service 29500 ~ 30000 40

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 Sl.No. Service Type Kms Months

12 12th Service 32500 ~ 33000 44

13 13th Service 35500 ~ 36000 48

14 14th Service 38500 ~ 39000 51

Pay
15 15th Service 41500 ~ 42000 54

16 16th Service 44500 ~ 45000 57

17 17th Service 47500 ~ 48000 60

Free service 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, brake fluids, 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.

* 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.

68
 TECHNICAL SPECIFICATIONS
MANUFACTURER : TVS MOTOR COMPANY LIMITED
P.B. No1, Bythahalli, Kadakola post, Mysore - 571 311, India.

: TVS MOTOR COMPANY LIMITED

Village Bhatian, Bharatgarh Road, Tech Nalagarh, Dist. Solan,
Himachal pradesh - 174 101, India.
ENGINE TRANSMISSION
Type : Single cylinder, 4 stroke, fuel Clutch : Dry - Centrifugal clutch
injection, air cooled, spark Primary transmission : CVT (Continuos Variable
ignition engine Transmission)
Cylinder bore : 53.5 mm Primary reduction : 2.65 to 0.8
Stroke : 48.8 mm Secondary reduction : 9.09
Piston displacement : 109.7 cc
Compression ratio : 10 : 1 CHASSIS
Air filter : Viscous paper filter element Overall length : 1770 mm
Oil filter : Wire mesh Overall width : 660 mm
Lubrication system : Forced wet sump Overall height : 1139 mm
Maximum power in kW : 5.75 kW @ 7500 rpm Ground clearance : 135 mm (unladen)
Maximum torque in Nm : 8.8 Nm @ 5500 rpm Wheel base : 1250 mm
Maximum speed : 80 km/h Kerb weight (with toolkit : 102 kg
Engine idling rpm : 1450 ± 100 rpm and 90% of fuel)
Starting system : Electric starter / kick starter Pay load : 130 kg
Emission norms : BSVI Maximum laden weight : 232 kg
Under warm condition

69
CHASSIS ELECTRICAL
Frame : Duplex tubular frame Ignition system : ECU controlled ignition
Front suspension : Telescopic hydraulic type Spark plug : BOSCH UR5KCW /
Rear suspension : Toggle link, coil spring with CHAMPION RG8MC4
hydraulic damper Spark plug gap : 0.9 to 1.0 mm
Trail length : 95.4 mm Battery type : 12V, 5Ah Lead Acid
Steering angle : 90° Generator : Fly wheel magneto
Caster angle : 25° 12V, 130W
Head lamp : 12V, 35/35W
TYRE Tail / brake lamp : 12V, LED
Tyre size Turn signal lamp : 12V, 10W x 4
Front : 90/100-10 53J (Tubeless) Number plate lamp : 12V, 5W
Rear : 90/90-10 50J (Tubeless) Speedometer lamp bulb : 12V, 1.7W x 2
Tyre pressure Turn signal indicator lamp bulb : 12V, 1.7W x 2
Front : 1.69 kg/cm² (24 PSI) High beam indicator lamp bulb : 12V, 1.7W x 1
Rear - solo : 2.00 kg/cm² (29 PSI) Economy mode indicator
Rear - dual : 2.53 kg/cm² (36 PSI) lamp : 12V, LED
Malfunction indicator lamp : 12V, LED
BRAKES
Front : 110 mm dia drum
(hand operated)
Rear : 130 mm dia drum Using the bulb other than the specified rating can result in
(hand operated) overloading of the electrical system or premature failure of the
bulb.

70
ELECTRICAL
Side stand indicator lamp : 12V, LED
Horn : 12V, DC
Fuse (blade type) : 12V, 15A x 1
: 12V, 10A x 2

CAPACITIES
Fuel tank capacity# : 4.9 l
Fuel : BS VI petrol with minimum RON 91
(containing upto 20% of ethanol by volume)
Engine oil grade : TVS TRU4 SKUUTA oil
(SAE 10W30 API-SL, JASO MB)
Engine oil capacity : 750 ~ 800 ml (during regular service)
800 ml (incase of disassembly)
Transmission oil capacity : 100 ml (during regular service)
120ml (incase of disassembly)
Front fork oil grade : IOC / HPCL / Castrol, Gabriel Premium front fork oil
Front fork oil capacity : 53 ± 1 cc per leg

#
The fuel tank is not a measuring instrument and the capacity
Specifications are subject to change without notice. of fuel tank may slightly vary from the indicated capacity.

71
 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:

72