• Roll the rear wheel as far forward as possible and
loop the chain over the sprocket.
• Insert the quick-release axle along with the chain
tensioner from left side of the swing arm while
ensuring that the axle is seated properly into all
1 the components.
• Assemble the left side chain tensioner.
• Assemble the axle nut along with the washer and
hand tighten it.
2
• Adjust the chain slackness and tighten the lock
Fig. 73 nuts, and the axle nut to the specified torque (ref.
page 202).
Reassembly
• After tightening the axle nut, once again check
• Carefully roll the rear wheel on the support into
and confirm the chain slackness.
the swing arm, along with LH & RH spacers and
• Assemble the speed sensor (2) and mounting
sprocket, as far as necessary to allow the brake-
screw (1) in rear caliper (ref. Fig. 69).
caliper to be inserted while taking care of wheel
speed sensor.
• Push the brake pads away from together to ease
the rear wheel entry into swing arm.
• Place the brake-caliper (1) on the guide (2) of the
swing arm as shown (ref. Fig. 73).
• Roll the rear wheel further into the swing arm,
while pushing the brake-caliper assembly forward
at the same time.
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Caution
Chain can be adjusted when vehicle is supported by
centre stand (if applicable) or side stand or auxiliary
stand (paddock stand) in no load condition.
Always have these tightening torques to be checked
at TVS Motor Company Authorised Main Dealer after
assembly for safety.
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169
Battery • Remove the mounting bolt and take the battery
Ensure the safety precautions listed in the page holder (A) (ref. Fig. 74).
147 are followed properly. • Disconnect the negative terminal (1) first followed
Since the maintenance free battery is used in by the positive terminal (2) (ref. Fig. 75). Carefully
your motorcycle, it is not necessary to check the take out the battery.
battery electrolyte level or add distilled water.
If your battery seems weak ie. if you are facing
starting issues or other electrical issues, contact TVS
Motor Company Authorised Main Dealer.
Removal
• Turn OFF the ignition.
• Remove the pillion and rider seats as explained in
page 123 to access battery. 2 1
A
Fig. 75
Re-fitment
• Reinstall the battery in the reverse order of
removal.
• Connect the positive terminal first and then the
negative firmly to avoid any damages to electrical
system / battery. Make sure the rubber boot is
Fig. 74 intact with positive terminal.
170
Warning
Battery develop explosive gases. Keep it away from
heat sources. If charging is required, the battery must
charged in well ventilated area.
Unusable battery must be disposed in environment
friendly manner. Do not discard it with household trash.
Handover the battery to the battery Dealers or to a
recycling centre that accepts used batteries.
Caution
Never operate the motorcycle with discharged battery as
it may damage electrical components.
Do not push start the vehicle, use a good battery or jump
cable to start the vehicle incase of battery drain.
Note
If the motorcycle is to remain unused for a long time
(a month or longer), it is advisable to disconnect the
battery terminals or have the battery removed by a
skilled personnel.
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171
Fuses • Pull out the defective fuse and re-fix the new one
The electrical components of your motorcycle are with same rating.
protected by six fuses housed inside a fuse box and • Close the fuse box cover and ensure the proper
located below the rider seat. locking.
To access the fuses, park the motorcycle on a flat and You can identify a blown fuse by the interrupted
firm surface and remove the pillion and rider seats as centre link (1) (ref. Fig. 77).
explained in page 123. A ‘fuse puller’ is placed on
the battery holder can be used to pull out the fuse 1
from the fuse box during replacement.
Removal and replacement
• Turn OFF the ignition.
• Press the lock and open the fuse box cover (1)
(ref. Fig. 76).
1 GOOD FUSE BLOWN FUSE
Fig. 77
Fuse assignments
• Each fuse inside the fuse box are assigned for
different electrical load and it is listed the table
given below. Never change the fuse rating to
protect your electrical system and to avoid severe
damages.
Fig. 76
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Fuse Colour Electrical load Caution
F1 - 10A Red HECU Do not use the motorcycle by shorting the wires without
a fuse. Never use a fuse with a rating other than that
F2 - 10A Red EFI / USB (EMS) fuse
specified . Failure to observe above rules may damage
F3 - 15A Blue Load fuse the electric system or even cause fire.
F4 - 15A Blue HECU
F5 - 30A Green Main fuse Note
F6 - 7.5A Brown Fan fuse A sticker with fuse colour codes and rating is pasted
inside the fuse box cover which can be referred during
F7 - 10A Red EFI fuse fuse replacement.
F8 - 7.5A Brown Headlamp fuse Care should be taken not to spray water on electrical
components.
SPARE : 10A SPARE : 15ASPARE : 7.5A
FAN FUEL PUMP EMS
RELAY RELAY RELAY RELAY
SPARE : 30A
HEADLAMP FUSE EFI FUSE EFI FUSE MAIN FUSE
F8 - 7.5A F7 - 10 A F6 - 7.5A F5 - 30A
HECU LOAD FUSE EFI / USB (EMS) HECU
F4 - 15 A F3 - 15A F2 - 10A F1 - 10A
FUSE BOX
Fig. 78
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173
Spare fuse location
• Spare fuse for the each of the fuse is located
inside the fuse box (ref. Fig. 79).
Fig. 79
174
Mirror Assembly • Assemble the mirror assemblies to the adopter
Ensure the safety precautions listed in the page by rotating the mirrors either in clockwise or in
147 are followed properly. anti-clockwise based on the thread type.
Assembly
• Adjust the mirror to suitable position and tighten
• Assemble the adopter of the mirror assembly the lock nut using a open end spanner 14 mm
to the handle bar by rotating the adopter either from the tool kit (refer page 181).
in clockwise or in anti-clockwise based on the
thread type (ref. Fig. 80). Tightening torque 29 ± 6 Nm
• Release the lock nuts of the mirror assembly.
Fig. 80
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175
Diagnostic Connector Re-fixing
The diagnostic connector is located below the rider • Re-fix the cap of the connector and ensure the
seat. Follow the procedure given below to access the proper locking.
connector.
• Re-fix the connector to its location and lock it
Removal
properly.
• Park the motorcycle on a flat and firm surface and
remove the pillion and rider seats as explained in
page 123. Caution
• Turn OFF the ignition. Diagnostic connector to be accessed and used by the
trained personals of TVS Motor Company Authorised
• Gently pull out connector along with its cap from Main Dealer or by the other authorised persons of TVS
its location by releasing the lock (1) (ref. Fig. 81). Motor Company Limited during service. Do not fiddle
• Release the lock of the cap and take out the cap with system at unauthorised service location.
carefully.
Ensure to re-fix the diagnostic coupler cap after the
usage to avoid damages to the electric system due to
water entry. Secure the connector in it’s location without
fail to avoid getting damaged.
Fig. 81
176
Cleaning your Motorcycle • Transmission components can be rinsed with
For maintaining the original shine on metal parts warm water and dried with clean dry cloth.
surface and painted parts surface, wash and clean • Clean the radiator regularly. Use a hose with low
your motorcycle at regular intervals depending on water pressure to clean the radiator fins blockage.
usage and particular road conditions. This prevents the engine from overheating due to
• Use only specific products. Avoid aggressive insufficient cooling. Care should be taken not to
detergents and solvents. damage the radiator fins during cleaning.
• Use only water and natural soap to clean glass
and the seat. Warning
• To prevent stains, do not wash the vehicle There may be a loss of braking efficiency immediately
immediately after it has been exposed to strong after washing the motorcycle. Greasing or lubricating the
sunlight and do not wash it in the sun. brake discs leads of loss of braking. Oil-free solvent to
• If the parts of the engine are unusually dirty or be used for cleaning the brake discs.
greasy, use a de-greasing agent while taking care The head lamp may be get fogged up after washing, rain
of transmission components (like chain, front and or moisture. Switch ON the head lamp for a short period
rear sprockets, etc.). of time to dry any condensation.
Maintain minimum distance of 60cm between the water
Caution jet nozzle and the vehicle. Do not direct the jet onto
Never clean the motorcycle using hot or high pressure electrical component and connectors.
water jets. Cleaning the motorcycle with high pressure
water jet may lead to serious problems in front fork,
wheel assemblies, brakes, electrical systems, inlet and
exhaust systems which will result in reduced safety.
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177