FOREWORD TVS

Dear Friend,

Thank you for choosing the TVS HLX 150 5GEAR, strongest and most reliable motorcycle.

As a proud ownerofTVS HLX 150 5GEAR, you are now part of a family of millions of satisfied TVS customers.

TVS HLX 150 5GEAR is designed to deliver superior durability, best in class power and host of other features. It also
comes with refreshing looks.

This manual explains the features and operations of your TVS HLX 150 5GEAR. Please read it carefully and follow the
instructions to enjoy years of safe riding.

To ensure reliable performance, we urge you to get your TVS HLX 150 5GEAR serviced only at TVS Motor Company
Authorised Dealers/ Authorised Service Centers at specified regular intervals.

Happy Riding!

TVS MOTOR COMPANY LIMITED

NOTICE TVS
Always keep your Owner's Manual in the motorcycle and give it to the new owner if you ever sell your TVS HLX 150
5GEAR.
Take time to familiarize yourself with your TVS HLX 150 5GEAR and its performance characteristics.
This Owner's Manual contains a host of useful information. Please take the time to read this manual before you ride
your new TVS HLX 150 5GEAR. Get familiarised with the operation of your motorcycle for maximum safety and
pleasure. The better you know your vehicle, the more pleasure you will experience riding your new vehicle. Ensure
that anyone else riding your TVS HLX 150 5GEAR does the same.
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.

vote
Accessories shown in the picture may not be part of the standard equipment.

Part Number:- N6211450 Revision 1, October 2020

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SAFETY INFORMATION TVS
Operating this vehicle safely is an important responsibility of the rider. To help you make decisions about safety, we
have provided operating procedure and other information in this manual. This information alerts you on potential
hazards that could hurt you or others. Since it is not possible to warn you about all hazards associated with operating or
maintaining the vehicle, you must use your own judgement.
You will find important safety information in following form with corresponding connotations in this manual:

Warning
Disregarding this message might result in injury to the rider.

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

O vote
This message provides further clarification for clearer understanding of any particular information.

II
CONTENTS TVS

Running-In Information 05

Safe Riding Tips 06

Know your TVS H LX 1 50 5G EAR 09

Riding your TVS HLX 150 5GEAR 24

Maintenance 29

Services Record Sheet 44

Technical Specifications 46

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RUNNING-IN INFORMATION TVS
The first 1000 km is a crucial part for the life of your TVS HLX 150 5GEAR. Proper running-in operation during this period
helps in ensuring a maximum life and smooth performance of your motorcycle.

The reliability and performance of your TVS HLX 150 5GEAR 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 service at 500 ~ 750 km is most important. During running-in period all the engine components and other
parts will have set in. All adjustments to be restored, all fasteners to be tightened. Engine cum transmission oil to be
replaced. Timely performance of the first service will ensure optimum service life and performance from the engine.

l caution
Replacing the engine cum transmission oil during first service is most important for better life of engine. Always use
TVS TRU4 DURAL/FE oil (SAE 20W50 API-SL) for better performance and life.

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SAFE RIDING TIPS TVS
SAFE RIDING RECOMMENDATIONS
Any two wheeler riding requires some precautions to be taken to ensure the safety of the rider, pillion rider and other road
users. These precautions are:

Riding apparel
Loose, fancy clothing can be uncomfortable and unsafe when riding a two-wheeler. Choose good quality two wheeler riding
apparel.
Familiarise yourself with new TVS HLX 1505GEAR
Riding skill and your mechanical knowledge form the foundation of safe riding practices. We suggest you to practice riding in a
low-traffic condition until you are thoroughly familiar with your vehicle and its controls. Remember perfect practice makes you
perfect.

Know your limits

Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you to avoid
accidents.
Posture

/ Warning
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 good quality 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.

II
SAFE RIDING TIPS TVS
Proper vehicle riding starts with proper posture. / Warning
1. Keep your elbows inside close to the body and kept
A void use of mobile phones while riding as it could lead to
flexible.
fatal accident.
2. Hold your arms at an angle of about 120°.
3. Hips should be in a position so that arms and shoulders Do not downshift the gears in the midst of cornering. Slow
are relaxed. down to a safe speed before negotiating a corner. If this is
4. Look widely instead of gazing at one point. the first time that you are riding a vehicle of this type, we
suggest that you practice on a safe, open area to become
5. Relax to guard against a sudden impact.
thoroughly familiar with the operation of the vehicle.
6. Holdthetanktightlywith knees.
7. Point the toes straight ahead. Braking
Cornering For safe riding, it is very important to master the braking
When cornering, centrifugal force works in a direction techniques.
perpendicular to the direction in which the vehicle is 1. Close/ release the throttle.
moving. 2. Hold the vehicle upright as you apply the brake.
Centrifugal force increases in proportion with speed and 3. Progressive application of brakes is safer.
shorter the radius of the corner, the greater it becomes. 4. Never depress the clutch lever while braking at higher
During cornering, reduce speeds so as to lessen the effects speeds.
of centrifugal force. By all means, avoid abrupt application 5. Apply both the brakes.
of brakes or sudden steering. 6. Riding down hills and while cornering, close throttle
and down shift the gear to take advantage of gearbox
/\ Warning and engine which acts as an additional brake. This will
avoid the loss of control over the vehicle due to over
One-hand riding is dangerous. Keep both hands firmly on
speed.
the handle bar and both feet securely on the foot rest.
Under no circumstances should both the hands be
removed from the handle bar, as it is very dangerous.

II
SAFE RIDING TIPS TVS
Causes for poor braking ACCESSORY INSTALLATION AND SAFETY TIPS
1. If the brake shoes or drum are worn out or if there is Use extreme caution while selecting and installing the
water or oil on them, sufficient friction does not accessories for your TVS HLX 150 5GEAR.
develop and brakes do not work well. The addition of unsuitable accessories can lead to unsafe
2. Even when the brake works normally, if the road operating conditions. Your friendly dealer will assist you in
surface is wet or the tyre surface is worn-out, tyres do selecting quality accessories and installing them correctly.
not take a firm hold on the surface, prolonging the While selecting the accessories, make sure the
stopping distance. accessories should not obstruct lighting, steerability and
3. Approximately 60% braking effect is from front suspension level.
brake.Non-usage of front brake causes poor braking. Additional electrical equipments and controls should not
exceed the specified electrical system load of the vehicle.

Warning EMISSION CONTROL

As the vehicle speed increases, the stopping distance also All the TVS motorcycles are tested in the factory for
increases progressively. Be sure that, you have sufficient optimum fuel efficiency and lowest possible CO levels.
distance between you and the vehicle or obstruction ahead Kindly do not disturb the Carburettor settings as this may
of you. lead to higher fuel consumption and also higher CO levels.
If the vehicle needs any adjustments, please consult
Using only the front or rear brake is dangerous and can nearest TVS Motor Company Authorised Dealer or
cause skidding and loss of control. Apply both the brakes Authorised Service Centre.
together and with great care on a wet road or other slippery While adequate care is exercised at the factory to ensure
surfaces. Any abrupt braking on slippery or irregular roads that the emissions are within the limits, it is essential for the
can cause loss of rider control. owner to always maintain TVS HLX 150 5GEAR motorcycle
in good condition by getting it periodically serviced and
checked by TVS Motor Company Authorised Dealer or
Authorised Service Centre so that the emission and fuel
consumption levels are maintained as per norms.

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KNOW YOUR TVS HLX 150 5GEAR TVS
VEHICLE IDENTIFICATION NUMBER
Serial numbers of both frame and engine are required for vehicle identification. They are also required to assist your dealer for
operating parts or referring to special information.

The frame serial number is stamped on the left side of the The engine serial number is stamped on the top surface of
steering head tube. left hand side crank case near the cylinder block
mounting.

Frame number
I I I I I I I I I I I I I I I I I I
Engine number
I I I I I I I I I I I I I
Control key number
Please fill the above box now for future reference

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KNOW YOUR TVS HLX 150 5GEAR TVS
LOCATION OF PARTS-HANDLE BAR

1. Choke lever
2. Horn switch
3. Turn signal lamp switch
4. Clutch lever
5. Pass by switch
6. Rear view mirror L
7. High/ low beam switch
8. Speedometer assembly
9. USB Charger
10. Ignition switch cum steering lock
11. Hazard switch
12. Rear view mirror R
13. Front brake lever
14. Throttle grip
15. Headlamp switch
16. Electric starter switch
17. Fuel tank cap

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KNOW YOUR TVS HLX 150 5GEAR TVS
LOCATION OF PARTS- VEHICLE LEFT SIDE

1. Pillion foot rest L

2 Rear shock absorber L
3. Chain inspection window
4. Gear shift lever
5. Fuel cock
6. Speedometer cable
7. Front brake cable
8. Lock cover frame L
9. Handle pillion

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 KNOW YOUR TVS HLX 150 5GEAR TVS
LOCATION OF PARTS- VEHICLE RIGHT SIDE
cr
$ 1. Spark plug
8 2. Gauge oil level
8
�
3. Rear brake pedal
4. Kick starter lever
5. Cover frame R screw
6 Muffler guard
7. Rear shock absorber R
8. Pillion foot rest R
9. Muffler assembly

O7OI@) OIO) (OIO) [@IO

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KNOW YOUR TVS HLX 150 5GEAR TVS
LOCATION OF PARTS
VEHICLE FRONT SIDE

1. Front turn signal lamp L

2 Head lamp assembly
3. Crash guard
4. Rider foot rest
5. Front turn signal lamp R

6. Housing head lamp front

visor

VEHICLE REAR SIDE

1. Tail/ brake lamp assembly
2. Rear turn signal lamp R
3. Rear number plate
4. Reflex reflector
5. Rear turn signal lamp L

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KNOW YOUR TVS HLX 150 5GEAR TVS
CONTROL KEY
lVS HLX 150 5GEAR comes with a pair of identical control
keys. These keys are to operate ignition switch cum
steering lock, fuel tank cap and cover frame L.

IGNITION SWITCH CUM STEERING LOCK

The ignition switch cum steering lock has three positions:
1. 'OFF' position
All the electrical circuits are turned 'OFF' in this position.
Key can be taken out.

2. 'ON' position
In this position you can start the engine and operate turn
signal lamp, gear position indicators and horn. Key cannot
A, caution
Leaving the key in 'ON' position will drain the battery when
be removed in this position.
vehicle is not in use . So "Switch off" and take the key out
when the vehicle is not in use.
3. 'LOCK' position
lVS HLX 150 5GEAR steering can be locked in both left and
right directions. A warning
To lock the steering, turn the handle bar all the way to the Never attempt to move the vehicle when the steering is
left or right. Insert the key into the lock, push in, hold and locked, you may lose the balance.
turn it to 'LOCK' position. Take out the key once the
steering is locked.
Turning the key to 'OFF' or 'ON' position unlocks the
steering.

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KNOW YOUR TVS HLX 150 5GEAR TVS
SPEEDOMETER ASSEMBLY l
) ( a:
1. Speedometer
Indicates the road speed in kilometers per hour.
00 0 «<t
LA
c
Lo

2.0dometer e o
Lo
•
Registers the total distance covered by the vehicle in X
kilometers. 0 6

O
l
,,,
r
Last digit of the odometer denotes one tenth of a kilometer.
i:!
3. High beam indicator
When the head lamp high beam is 'ON', a blue indicator
(iD )glows. ',,
I
et
"@
I

4 -
a:
0
>
3
0
4. Turn signal indicator z
4
6. Fuel gauge
When the turn signal lamp switch knob is operated to the
Fuel gauge indicates the approximate quantity of fuel
left side or right side, the turn signal indicator lamp (r)
available in the fuel tank.
flashes.

5. Gear position indicators

Indicates the gear position. When the gear position
becomes neutral, a green colour neutral indicator ( N )
glows. All other gear positions (ie. 1,2,3", 4" and 5") are
indicated with the number and glows in amber colour.

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KNOW YOUR TVS HLX 150 5GEAR TVS
HANDLE BAR LEFT SIDE
1. Choke lever
Choke is required for starting a cold engine.
Choke lever is provided on the left side of handle bar. Pull
the lever to switch 'ON' the choke. Once the vehicle is
started and engine is running at stable speed, release the
lever to its original position.

2. Horn button
Press the knob')'to operate the horn.

3. Turn signal lamp switch

When the turn signal lamp switch knob is pushed to the left
side (<,_) or right side (c,>), the turn signal lamps flashes warning
along with the indicator. Always use the appropriate turn signal tamps when you
intend to change lanes or take turns. Be sure to switch
4. Clutch lever 'OFF' the lamps after negotiating the lanes or turns.
Use clutch lever to disengage the drive to the rear wheel
while shifting the gears. Pressing the lever disengages the 5. Pass by switch
drive. The head lamp high beam glows when the pass by switch
knob (PASS )is pressed.
A caution
Press the knob intermittently while overtaking another
Always use choke for cold starting.
vehicle during day time to give signal to the opposite
Never open the throttle when the choke is applied, it may vehicles.
lead to flooding of engine and difficulty in starting.

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KNOW YOUR TVS HLX 150 5GEAR TVS
6. Head lamp high/low beam switch
Press the knob towards ·di 'to operate the head lamp high
beam.
Press the knob towards 'Gd 'to operate the head lamp low
beam.

/ warning
Use appropriate head lamp high/low beam as per the traffic
and road conditions for your safety and to avoid
inconvenience to the riders.

HANDLE BAR RIGHT SIDE

1.ElectricStarter Switch
3. Throttle grip
Press the switch ' @\ ' to start the engine electrically even
when the vehicle is in any gear. Engine speed is controlled by the rotation of the throttle
grip. Twist it towards you to increase the engine speed.
2. Head lamp switch Twist it away from you or release it to decrease the engine
Head lamp switch has two positions 'and'pe' to control speed.
headlamp.
Off: Head lamp, speedometer lamps and tail lamp 4. Front brake lever
are 'OFF' when the knob is positioned at The front brake is applied by pressing the front brake lever

On:
·•··
Head lamp, speedometer lamps and tail lamp
gently towards the throttle grip. Brake lamp also glows on
application of brake.
glows when the knob is positioned at' A '
and engine is running.

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 KNOW YOUR TVS HLX 150 5GEAR TVS
cr
5.Hazard switch
Hazard switch is provided to use whenever you find it
A warning
$ necessary to park the motorcycle in a hazardous location
Avoid spilling of fuel on the hot engine. Never refill fuel near
8 due to emergency situation. Pressing this switch away
open flame. Do not smoke while refueling. Do not use cell
8 phones while refueling.
� from you with the ignition 'ON' condition makes all the turn
signal lamps to flash simultaneously to make other road
users aware of the presence of the vehicle. A caution
Whenever refueling the bike, fill upto the bottom of neck
FUEL TANK CAP portion of the fuel tank. Filling above the neck may result in
To open the fuel tank cap, move away the lid from its improper breathing of fuel tank.
position, insert the control key into the key hole, turn it
clockwise and lift the cap. Press the cap back to its original FUELCOCK
position for closing. Take out the and move the lid back to its Fuel cock has the following three positions:
original position. ON: Fuel flows in this position when the fuel is above
the reserve level in the tank.
RES: Switch over the fuel cock lever to this position
when the fuel stops flowing in 'ON' position.
OFF: Fuel flow cuts off from the tank to carburettor.

While riding with fuel cock lever in 'ON' position and if the
fuel in the tank reaches reserve level, you may experience
engine sluggishness and Jerky feeling. Take the vehicle to
the left side of the road while taking care of traffic and
change the fuel cock lever position to 'RES'.
KNOW YOUR TVS HLX 150 5GEAR TVS
KICKSTARTER LEVER
The kickstarter lever is located on the right side of the
engine. The engine can be started by kicking the lever while
the ignition key in 'ON' position and keeping the
transmission in neutral.

A caution
Do not position the fuel cock lever between 'ON' and 'OFF'
position as this may drain off entire fuel while riding the
vehicle.

O woe A warning
It is good practice to turn the fuel cock lever "OFF" position, It is recommended always to start the vehicle keeping the
when the engine is not running. gear in neutral position.

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 KNOW YOUR TVS HLX 150 5GEAR TVS
GEAR SHIFT LEVER
cr
$ Gear shift lever is located on the left side of the vehicle.

8 There are three types of Gear shift pattern in HLX150 All Gear
Down
8
5GEAR, (1)
(2) All
gear down and (3) 1 gear down

�
AI gear up,
applicable
4gear up. It is applicable depends upon countries.
for some
ALL GEAR UP: Shifting into the higher gears from neutral countries
position is accomplished by depressing the clutch lever and
pressing the rear end of shifting lever by heel and down
shifting to lower gears by pressing the front end of the lever
by toe once for each gear.
1GEAR DOWN 4GEAR UP: To shift the transmission from
neutral to first gear, before depressing the clutch lever and
pressing the front end of shifting lever by toe. To change it
All Gear to the second gear or all remaining, pressing the rear end of
Up the lever by heel once for each gear.
applicable
for some
countnies
Higher gears "
Lower gears
j 1Gear
Down
4Gear Up
ALL GEAR DOWN: Shifting into the higher gears from applicable
neutral position is accomplished by depressing the clutch for some
lever and pressing the front end of shifting lever by toe and countries
down shifting to lower gears by pressing the rear end of the
lever by heel once for each gear. Lower gears

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KNOW YOUR TVS HLX 150 5GEAR TVS
REAR BRAKE PEDAL Ensure both the legs of centre stand are touching ground
Rear brake pedal is located on the right side of the vehicle. before placing the vehicle on the stand.
Press the rear brake pedal with your right foot to apply the
rear brake. The brake lamp glows on application of brake. Side stand (2) can be operated with your foot by pushing it
away from the vehicle till it stops.

A\ Warning
/ warning
Brakes are items of personal safety and should always be
maintained in proper condition. Always release side stand to its full up position before
putting the vehicle in motion.
CENTRE STAND AND SIDE STAND
TVS HLX 150 5GEAR is equipped with centre and side
stand. To place the vehicle on the centre stand (1), hold the
A caution
Never sit on the vehicle when it is supported by side stand.
handle bar left grip with left hand and pillion handle with
Always park the vehicle on a flat, firm surface.
right hand. Place your foot firmly on the centre stand
extension (1 a) and press down with adequate effort.

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 KNOW YOUR TVS HLX 150 5GEAR TVS
COVER FRAMEL 2. Locate its lug (2) on the hole provided in the fuel tank
cr TVS HLX 150 5GEAR is provided with lockable cover frame while ensuring the availability of rubber cushion on the
$ on the left side. Open the cover frame to access tool kit and hole, gently press and lock with the key by rotating in
8 battery assembly. anti-clockwise direction.
8
�
COVER FRAMER
Cover frame R can be removed by removing the mounting
screw (A). Follow the procedure of cover frame L removal
and reassembly.

A caution
While reassembling the cover frames, see that the rubber
cushions provided for the cover lugs are in place.

Insert the key in the cover frame at lock (1) and rotate it
in clockwise direction.
2. Pull out the cover frame gently at (2), slide it forward at
(3) and take out.

Reassembly
1. Assemble the cover frame by carefully sliding the rear
portion (3) on to the hook on the frame while ensuring
the availability of rubber cushion on the hook.

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KNOW YOUR TVS HLX 150 5GEAR TVS
TOOLKIT DO'S
1. Ensure that no water enters into the unit, by
To assist you in performing certain aspects of maintenance
the USB flap properly.
and emergency repairs, a tool kit is supplied along with the
vehicle and is located below the cover frame L. 2. Use only mobile phone company's authorized USB
cable for mobile charging.
Remove the cover frame as explained earlier.
3. Ensure the flap is not damaged while opening/ inserting
The tool kit consists one number each of the following: the USB cable.
1. 16 mm box spanner
DONT'S
2. 14x17mmopenendspanner
3. 10x12mmopenendspanner 1. Do not leave the USB charging flap open/partially
4. Combination screw driver bit closed when not in use.
5. Screw driver handle 2. Do not attempt to use/charge any other device, other
6. Tool bag than one mobile phone at a given time.

A caution
It is recommended to use the tool kit in case of any
emergency only. It is always advisable to take your vehicle
to TVS Motor Company Authorised Distributor or
Dealer/Authorised Service Centre.

SMART PHONE CHARGERS

An all new smart phone charging port has been provided
above the speedometer assembly of your vehicle.
Please follow the guidelines provided for using it properly:
KNOW YOUR TVS HLX 150 5GEAR TVS
3. Do not try to force the USB connector in, check if it is
inserted in the appropriate direction, to prevent
damage.
4. Do not charge your mobile when engine is off.
5. Do not use other device, this port is for charging mobile
phones only.
The charging time of the mobile may vary, depending on the
mobile battery's state of charge.
The flap in the unit has been designed to prevent water
entry and is not replaceable.

l caution
TVS is not responsible for any damage to mobile phones in
the event of fall while charging during vehicle moving.

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RIDING YOUR TVS HLX150 5GEAR TVS
Inspection before riding
Check the following items before riding.

ITEM WHAT TO CHECK FOR

Engine cum Transmission oil Availability of oil upto the level. (page no. 38)

Fuel Enough fuel for the planned distance of running.

Tyres Correct pressure. (Page no. 41)

Adequate tread depth/ no cracks or cuts.

Battery Proper working of horn, brake lamp, turn signal lamps and neutral lamp.
Electrolyte level. (page no. 32)

Lighting Head lamp high/low beam, high beam indicator, speedo lamps and tail lamp.

Steering Smooth movement/ no play or looseness

Throttle Correct free play of cable/ smooth operation

Clutch Correct free play of cable. (page no. 39) Smooth and progressive action.

Brakes Correct lever and pedal play. (page no. 40)

Wheels Free rotation.

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RIDING YOUR TVS HLX150 5GEAR TVS
Starting the engine Setting the vehicle in motion
Turn the fuel cock lever to the 'ON' or 'RESERVE' position Depress the clutch lever and engage first gear by pressing
based on availability of fuel in fuel tank. Insert control key the front end of the gearshift lever downward by toe. Twist
into the ignition switch cum steering lock and turn it to 'ON' the throttle grip towards you and simultaneously release
position. Make sure that the transmission is in neutral the clutch lever gently and gradually.
position press the electric starter switch to start the engine
electrically and kick start the engine. The vehicle will start moving forward. As the vehicle picks
up speed, shift to the next higher gear by closing the
When the engine is cold throttle, pulling the clutch lever in and pressing the front
□ Pull the choke lever towards left and start the engine. end of the gear shift lever downwards once again. Release
Let the engine to idle in choke applied condition. the clutch lever and open the throttle again. Select the
required gears in similar manner.
D Once the engine is warm, release the choke lever to its
original position. Using the transmission
The transmission is provided to keep the engine run
/\ Warning smoothly in its normal operating speed range. The gear
ratios have been carefully chosen to meet the
Do not run the engine indoors where little or no ventilation
characteristics of the engine. The rider should always select
available. Exhaust gas is extremely poisonous.
the most suitable gear to achieve the necessary speed and
pulling power smoothly.
A caution
Do not keep the engine in idling rpm for long and do not
open excessive throttle when engine is idling, it leads to
overheating of the engine and damage to internal
components.

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RIDING YOUR TVS HLX150 5GEAR TVS
Riding on hills/ gradients FUEL RECOMMENDATION
When climbing steep hills, the motorcycle may begin to Use unleaded petrol only.
slow down and show lack of power. At this point you
The petrol should be 85 to 95 octane by research method.
should shift to a lower gear so that the engine will again be
Use recommended fuel additives for longer life of engine
operating in its normal power range. Shift gears rapidly to
components and lower maintenance.
prevent the motorcycle from losing momentum.
When riding down a hill, the engine may be used as braking
by shifting to a lower gear.
A caution
Never mix oil in petrol in the fuel tank.
Stopping and parking
1. Close the throttle completely and apply both brakes O vote
simultaneously. Use fuel additives in petrol as recommended by the
2. Down shift (Lower) the gears as road speed respective manufacturer for low carbon deposition.
decreases. Bring the engine to neutral position just
CHECKS AND TIPS FOR IMPROVING FUEL ECONOMY
before the vehicle stops. REGULAR CHECKS
3. Turn the ignition 'OFF'.
Carry out the periodic maintenance checks as specified in
4. Park the vehicle on a firm, flat surface. this manual. (page no. 31 to35)
5. Lock the steering and turn fuel cock to 'OFF' position. Regular maintenance checks will save fuel and assure you
of trouble-free, enjoyable and safe riding besides keeping
/ Warning environment clean.
Reduce speed to a safe limit before turning I cornering. It is
Spark plug
not advisable to apply brakes while turning I cornering. Do
not disengage the clutch while braking. A dirty or defective spark plug leads to wastage of fuel due
to incomplete combustion. Check, clean and readjust the
gap periodically.

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RIDING YOUR TVS HLX150 5GEAR TVS
Air cleaner element
A dirty air cleaner restricts airflow, increases fuel
l caution
Replace the sparkplug every 12000 km for better
consumption. Clean the air cleaner elements periodically.
performance of the vehicle.
Clutch Never drive the vehicle with half clutch. This will reduce the
Increase of engine rpm during acceleration, without life of clutch and affect the performance of the vehicle and
increasing the road speed indicates clutch slip. A slipping fuel economy.
clutch will cause high fuel consumption.
Fuel leak
If the condition persists even after adjusting the clutch lever Check and arrest fuel leaks if any from tank, carburettor and
play, immediately have the clutch checked by our TVS fuel lines.
Motor Company Authorised Distributor or Dealer /
Authorised Service Centre. Tyres
Low tyre pressure has the same adverse effect on a vehicle
Engine cum transmission oil
as of loading the vehicle heavily. The drag on the vehicle will
Dirty or less engine cum transmission oil will increase be increased resulting decreased fuel economy.
friction between various parts of the engine and reduce
engine life, thereby increase fuel consumption. Further more, handling may be adversely affected. Check
the tyre pressure regularly and inflate it to the
Regularly check the oil for contamination and level. It should recommended pressure. Never use tyres, which are worn
be between the minimum and maximum level on the beyond the permissible limit.
gauge. Get it replaced at regular intervals as per
maintenance schedule. Chain slackness
Check and ensure the drive chain slackness. Excess
slackness leads to higher fuel consumption (refer page no.
42).

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RIDING YOUR TVS HLX150 5GEAR TVS
Wheel freeness
Check and ensure the wheel freeness by rotating the wheel
O vote
at least once in a week to avoid wastage of fuel. Switch 'OFF' the engine during long waits to protect
environment and to reduce the fuel consumption.
Fast starting from rest wastes fuel
A racing start from rest at full throttle can waste fuel and
damage the engine. It also creates a potentially dangerous
traffic situation.

Fast acceleration wastes fuel

Fuel is wasted whenever you suddenly accelerate or apply
brake.

Avoid unnecessary idling

While waiting for someone or stopping in signals for long
time, if the engine is kept running at idle speed, it causes
unnecessary wastage of fuel.

Avoid frequent braking

Anticipate corners and slopes as well as the traffic
conditions. Unnecessary frequent braking will reduce the
fuel economy.

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MAINTENANCE TVS
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 operated in dusty climate, certain jobs should be performed more often to ensure reliability of the vehicle.
Cylinder head, steering components, suspension, chain and wheel components etc., are key items and require very special
and careful servicing. TVS Motor Company Limited strongly recommends that the jobs as per the maintenance schedule be
performed by your TVS Motor Company Authorised Distributor or Dealer/ Authorised Service Centre.

Periodic inspections may reveal one or more parts that may need replacement. Whenever replacing parts on TVS HLX 150
5GEAR, it is recommended that you use only the TVS Motor Company Genuine parts.

l 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 owner's manual.

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MAINTENANCE TVS
PERIODIC MAINTENANCE SCHEDULE {months or km whichever occurs earlier)
PERIODIC SERVICES
Period 1 month 3 months 6 months 9 months 12 months
Km 500 - 750 2500 - 3000 5000 - 6000 8500 - 9000 11500 - 12000
Engine cum transmission oil R R R R R
Oil filter C - C - C
Centrifugal filter C - C - C
Spark plug C&A C&A C&A C&A R
Compression pressure - - I - I
Air cleaner elements I &C I &C &C I &C &C
Engine breather pipe - C C C C
Carburettor assembly' - C&A C&A C&A C&A
Tappet clearance l&A l&A I &A l&A l&A
Fuel cock sediment bowl C C C C C
Hose fuel' Replace every three years
Clutch cable l&A l&A I &A l&A I &A
Throttle cable - l&A I &A l&A I &A
Steering play l&A l&A I &A l&A I& A
All fasteners I &Tl I &Tl I &Tl l&TI I &Tl

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MAINTENANCE TVS
PERIODIC SERVICES
Period 1 month 3 months 6 months 9 months 12 months
Km 500 - 750 2500 - 3000 5000 - 6000 8500 - 9000 11500 - 12000
Drive chain C, L& A C, L& A C, L& A C, L& A C, L& A
All bulbs and horn I I I I I
Head lamp beam I &A l& A l&A l&A l&A
Battery electrolyte level I &T I &T I& T I &T I& T
5
Specific gravity and voltage I I I I I
Brakes I &A l& A l&A l&A l&A
Tyres (air pressure) I& A I& A I& A I& A I& A
ldling CO%° I &S I &S I &S I &S I &S

R- Replace; I- Inspect; T-Top up; C-Clean; A- Adjust; TI- Tighten; L-Lubricate; S-Set; D- Decarbonise

2
If necessary
3
Replace if necessary
4
Inspect for leak
5
Recharge if necessary
6
Idling CO% should be set with the help of exhaust gas analyser and tachometer only

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MAINTENANCE TVS
PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier)
PERIODIC SERVICES
Period 15 months 18 months 21 months 24 months 27 months 30 months
Km 14500-15000 17500-18000 20500-21000 23500-24000 26500-27000 29500-30000
Engine cum transmission oil R R R R R R
Oil filter - C - C - C
Centrifugal filter - C - C - C
Spark plug C& A C& A C&A R C&A C&A
Compression pressure - I I I I I
Air cleaner elements &C &C R &C &C l& C
Engine breather pipe C C C C C C
Carburettor assembly C&A C&A C&A C&A C&A C& A
Tappet clearance I& A I& A I& A I& A I& A I& A
Head cylinder / piston - D - - - -

Fuel cock sediment bow C C C C C C

Hose fuel' Replace every three years
Clutch cable I& A I& A I& A I &A I& A I &A
Throttle cable I& A I& A I& A I& A I& A I& A
Steering play I& A I& A I& A I& A I &A I& A

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MAINTENANCE TVS
PERIODIC SERVICES
Period 15 months 18 months 21 months 24 months 27 months 30 months
Km 14500-15000 17500-18000 20500-21000 23500-24000 26500-27000 29500-30000
Front fork oil' - R - - - -

All fasteners I &Tl I &Tl I &Tl I &Tl I &Tl I &Tl

Drive chain C, L&A C, L&A C, L&A C, L&A C, L&A C, L&A
All bulbs and horn I I I I I I
Head lamp beam l&A I &A l&A l&A l&A l&A
Battery electrolyte level I &T I &T I &T I &T I &T I &T
Specific gravity and voltage 5
I I I I I I
Brakes l&A I &A l&A l&A l&A l&A
Tyres (air pressure) l&A I &A l&A l&A l&A l&A
ldling CO%° I &S I &S I &S I &S I &S I &S

R- Replace; I- Inspect; T-Top up; C- Clean; A- Adjust; TI- Tighten; L-Lubricate; S-Set; D - Decarbonise

2 3 4
If necessary Replace if necessary Inspect for leak
5 6
Recharge if necessary Idling CO% should be set with the help of exhaust gas analyser and tachometer only

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MAINTENANCE TVS
LUBRICATION SCHEDULE
Interval Initial Every Every Every
Item 500 - 750 km 2500 - 3000 km 5000 - 6000 km 8500 -9000 km
Throttle grip - - - Grease
Speedometer gear - - - Grease
Speedometer cable - - - Grease
Brake cam - - Grease -
Drive chain TRU SPRAY TRU SPRAY - -
Brake pedal shaft Grease Grease - -
Kick starter pedal pivot 4Toil 4Toil - -
Steering stem bearings .......... Clean and lubricate with fresh grease every 12000 km .........
Swing arm shaft ............... Grease every 2 years ...............
Front brake and throttle cables ............... Lubricate at ends using grease in all services ...............

RECOMMENDED LUBRICANTS
Application Oty Manufacturer Brand
Engine cum transmission oil 1000 ml (after draining) - TVS TRU4 DURALIFE oil
1200 ml (after disassembly) (SAE 20W50 API-SL, JASO MA2)
Front fork oil 146 ± 2.5 ml/ leg - Teleshockab oil
Grease - Bechem Bechem premium

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 MAINTENANCE TVS
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SELF-MAINTENANCE PROCEDURES
BATTERY
A caution
z Once the battery is charged initially, never add diluted
Battery is located below the cover frame L. Check the
$
w electrolyte level of the battery. It should be between the
sulphuric acid. Use only distilled water for topping up.
l Never add tap water. Do not pull battery by its wires while
z maximum and minimum level. If the electrolyte level is
removing. Never check the battery charge by shorting the
a below the minimum level, add only distilled water upto the
terminals
z maximum level by removing the filler caps.
Always connect the positive terminal first and then
Clean the battery throughly, apply petroleum jelly to the
negative to avoid sparking.
battery terminals to prevent it from corrosion.
Do not obstruct, bend or change the routing of the air vent
While connecting the terminals, observe the correct
tube of battery. Make sure that the vent tube is firmly
polarity. Connect the red wire to the' + ' positive terminal
attached to the battery and the other end is open and clear.
and black wire to the''negative terminal of the battery.
FUSE REPLACEMENT
The fuse case fitted on the battery band contains a 10 A
fuse. If the fuse is blown off, turn the ignition switch to
'OFF' position. Open the fuse case and replace the fuse
(extra fuse is provided inside the fuse case itself). Turn 'ON'
the ignition switch and check for all the battery operated
electrical items. lncase the fuse blows off again, consult the
nearest lVS Motor Company Authorised Distributor or
Dealer/ Authorised Service Centre.

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MAINTENANCE TVS
l caution
Readjust the spark plug gap to 0.7 ~ 0.8 mm using a feeler
gauge / wire gauge. Replace the spark plug every 12000
Do not use vehicle by shorting the wires, without a fuse. km. The carbon deposits on the porcelain tip and its colour
This may result in overheating of electricals I wiring and tells you whether the combustion of the engine is good or
may result in fire. not.
Do not use fuse of higher amperage for the safety of If the colour of tip is white or glazed, dry black or wet black
electrical system. then have the vehicle checked by TVS Motor Company
Authorised Distributor or Dealer / Authorised Service
SPARK PLUG Centre.
A spark plug with heavy carbon deposits will not produce
strong sparks. Hence, as per schedule or, as and when Tip colour Condition of engine
necessary, clean the carbon deposits from the spark plug Light brown Good combustion
with a small wire brush or a spark plug cleaning tool.
White or Glazed Hot engine/Lean burn
Dry or wet black Rich mixture / High carbon
deposition

Spark plug removal

1. Pullout the suppressor cap from the spark plug.
2. Using the spark plug spanner remove the spark plug.

0.7 -0.8 mm -==::J"

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MAINTENANCE TVS
A caution
Always use only recommended make and type of spark
plug.
It is advisable to tighten the spark plug by hand till the end
and then tighten with the spark plug spanner. Do not over
tighten or cross thread the spark plug.
Cover the spark plug hole with cloth when the plug is
removed, to prevent dust/water entry.

ENGINE CUM TRANSMISSION OIL

Checking the oil level
Check the engine cum transmission oil level periodically. A caution
1. Place the vehicle on centre stand on a flat surface. If the vehicle is driven with less engine cum transmission
Remove the gauge oil level, wipe it clean and insert the oil, engine components will be severely damaged. Check
gauge oil level in its hole without threading in. the oil level before starting to avoid costly damage. Always
use recommended oil only.
2. Check the oil level. The oil level should be between the
minimum and maximum level markings as shown in
the figure. If the oil is less than the minimum level, add
recommended oil upto the maximum level mark.

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MAINTENANCE TVS
CLUTCH ADJUSTMENT REAR SHOCK ABSORBERS
w
Clutch lever free play is one of the most important TVS HLX 150 5GEAR is provided with 5 step adjustable rear c
adjustments, which you may need to check in between shockabsorbers to meet different road and load conditions. z
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services for better life of the clutch plates. There are 5 notches for adjusting spring load. If the spring is
w
adjusted to the minimum notch, then the shock absorber h
The free play of the clutch should be 10- 15 mm, as
will be softer which is good for plain smooth roads and light
z
measured at the clutch lever end, before the clutch begins <C
to disengage.
loads. If the spring is adjusted to maximum notch, then it z
will be stiffer which is good for rough, bumpy roads and
Adjust the clutch lever free play periodically by means of heavy loads.
clutch cable adjuster at arm clutch release.
Adjust the spring load by shifting the adjuster to the
If you find the play is more or less, adjust in the following required notch according to the different load and road
way: conditions. The more you compress the shock absorber
1. Ensure that the engine is cold. spring, the more it becomes stiff.
2. Loosen the lock nut (2) holding the clutch cable
adjuster (3) adjust the clutch cable adjusting nut (1) 'in'
or 'out' to give sufficient play in the clutch cable.
3. After adjusting the play, holding the adjuster nut in the
same position lock the lock nut. <:== ,>
HARD SOFT
A caution
Too much or too less clutch lever free play will damage the
clutch plates, thereby affecting the performance of the
vehicle.
clutch lever free play should be adjusted only when the
engine is cold.

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MAINTENANCE TVS
A warning
Front brake Avoid using front brake while cornering. Brakes are items of
1. Measure the free play of the front brake lever at the personal safety and should always be maintained in proper
lever end as shown in the figure. The distance condition.
measured should be 15-20 mm or as required.
Rear brake
If the measured distance is more than the limit then,
The travel of brake pedal can be adjusted by turning the rear
adjust the adjuster nut provided at the front wheel end brake adjusting nut 'in' or 'out'. Adjust the free travel of
to obtain the correct play. pedal to 15- 20 mm.
Turn the adjuster nut in clockwise direction for reducing
the free play or in anti-clockwise direction for increasing
the free play of the front brake lever.

/ Warning
Check the brake pedal play periodically. However the brake
play needs to be adjusted more frequently depending upon
the usage.

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MAINTENANCE TVS
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L

Brake shoe wear indicator TYRES

When the brake is applied, the index mark (1) on the cam Tyre pressure:
brake should be within the range on the wear limit indicator Check tyre pressure atleast once in a week if not more
(2) on the front and rear brake panel assembly. In case of the frequently. Insufficient air pressure in the tyres not only
mark going beyond, consult the nearest Authorised lVS hasten tyre wear, but also seriously affects the stability of
Motor Company Authorised Distributor or Dealer / the vehicle.
Authorised Service Centre. Under inflated tyres make smooth cornering difficult and
over inflated tyres decrease the tyre contact with the
A caution ground which can lead to skidding and loss of control. Be
sure that the tyre pressure is within the specified limits at all
Replace the brake shoes, if the wear indicator shows
times.
beyond the wear limit.

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MAINTENANCE TVS
maintenance schedule. Higher chain slackness consumes
Solo Pillion more fuel. Uncleaned and dry chain (unlubricated)
consumes more fuel.
Front 1.75kg/cm? (25 PSI) 1.75kg/cm? (25 PSI)

Rear 2.25kg/cm? (28 PSI) 2.53kg/cm? (32 PSI)

Tyre tread condition

Operating the vehicle with excessively worn tyres will
decrease riding stability and can lead to loss of control. It is
recommended to replace the tyre when the tyre wears off
to the tyre wear indicator level (indicated by lWI on the
tyre).

Tyre rotation direction

While reassembling the tyre, after removing from the
wheel rim, ensure that the arrow mark on the tyre facing the
If the vehicle is used under severe conditions and more
direction of wheel rotation.
dusty area, the drive chain must be attended more
frequently.
DRIVE CHAIN
Proper lubrication and adjustment of drive chain gives long Check, clean, lubricate and adjust the drive chain in the
service life of chain. Poor maintenance of chain causes following manner:
premature wear or damage to the drive chain and
1. Place the vehicle on centre stand with the transmission
sprockets.
in neutral.
The drive chain must be cleaned, checked, lubricated and 2. Remove the dust seal chain cover.
adjusted at specified intervals mentioned in the

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MAINTENANCE TVS
3. Inspect the drive chain slackness (vertical movement)
using the finger as shown in the figure.
4. The slackness of the drive chain should not exceed the
limit (20 - 30 mm).
5. If the slackness found more, consult the nearest
Authorised TVS Motor Company Authorised Distributor
or Dealer /Authorised Service Centre.
6. If the slackness found is within the limit, lubricate the
drive chain using TRU SPRAY / TRU4 oil and re-fix the
dust seal chain cover.

FRONT WHEEL REMOVAL

1. Remove axle nut (1) along with a washer from front REAR WHEEL REMOVAL
wheel axle.
1. Remove the rear brake adjuster (1) and disconnect the
2. Pull out the axle (2) along with a washer from wheel brake rod.
assembly.
2. Remove the split pin (2) and the nut (3) from torque link
3. Remove a spacer from right side of the wheel. mounting with the brake panel and disconnect the
4. Place a support (wooden block) below the frame to torque link.
revent the vehicle from falling. 3. Removetheaxlenut(4). Pullouttheaxle(5).
5. Lift the front fork assembly up, dislocate the brake 4. Tilt the vehicle to the left and take out the wheel
panel along with cables and slide the wheel out. assembly along with the brake panel assembly.
6. Reverse the procedure for reassembling. Locate the 5. For locating and reassembling the rear wheel easily,
lug on fork leg L to the slot in the brake panel while engage gear. This will arrest the free movement of the
reassembling. drum sprocket.

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MAINTENANCE TVS

Reverse the procedure for reassembly.

Always make sure that whenever the wheel is removed, L

and refitted axle nut is properly retightened to the specified
torque and chain slackness is adjusted to the specified limit.
Once the split pins are removed, replace them with new
ones.

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SERVICE RECORD SHEET TVS
SERVICE RECORD SHEET

SI.No. Description Odometer Job card no. / Date Servicing Dealer's

reading stamp and sign.

1 1st service
between (a) 500- 750 km or (b) 1 month from the date
of purchase, whichever of the two occurs earlier.

2 2nd service
between (a) 2500 - 3000 km or (b) 3 months from the
date of purchase, whichever of the two occurs earlier.

3 3rd service
between (a) 5000 - 6000 km or (b) 6 months from the
date of purchase, whichever of the two occurs earlier.

4 4th service
between (a) 8500 - 9000 km or (b) 9 months from the
date of purchase, whichever of the two occurs earlier.

5 5th service
between (a) 11500- 12000 km or (b) 12 months from
the date of purchase, whichever of the two occurs
earlier.
6 6th service
between (a) 14500 - 15000 km or (b) 15 months from
the date of purchase, whichever of the two occurs
earlier.

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SERVICE RECORD SHEET TVS
SERVICE RECORD SHEET

SI.No. Description Odometer Job card no. / Date Servicing Dealer's

reading stamp and sign.

7 7th service
between (a) 17500- 18000 km or (b) 18 months from
the date of purchase, whichever of the two occurs
earlier.
8 8th service
between (a) 20500 - 21000 km or (b) 21 months from
the date of purchase, whichever of the two occurs
earlier.
9 9th service
between (a) 23500 - 24000 km or (b) 24 months from
the date of purchase, whichever of the two occurs
earlier.
10 10th service
between (a) 26500 - 27000 km or (b) 27 months from
the date of purchase, whichever of the two occurs
earlier.
11 11th service
between (a) 29500 - 30000 km or (b) 30 months from
the date of purchase, whichever of the two occurs
earlier.

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TECHNICAL SPECIFICATIONS TVS
MANUFACTURER : TVS MOTOR COMPANY LIMITED
P.B. No 4, Harita, Hosur - 635 109, India.

ENGINE TRANSMISSION
Type : Single Cylinder, 4 stroke, air Clutch : Wet- Multi plate type
cooled spark ignition engine Transmission : 5 Speed, constant mesh
Cylinder bore : 57mm Gear shift pattern : 1. All up heel-toe shift
Stroke : 57.8mm 2. All down heel-toe shift
Piston displacement : 147.49cc 3. 1 Gear Down 4Gear Up
Compression ratio : 9.7±0.3:1 Primary transmission : Spur gears
Carburettor : MIKUNI BS 26 (CV type) Secondary transmission : Chain and sprockets
Air filter : Paper filter with Polyurethane
foam element
Lubrication system : Positive displacement gearotor GEAR RATIOS
pump I Gear : 2.917 (35/12) : 1
Maximum power : 9.0kW@7500rpm II Gear 1 .857 (26/14) : 1
Maximum torque 12.4 Nm @4500 rpm Ill gear : 1 .333 (24/18) : 1
Maximum speed 110 km/hr IV gear : 1.050 (21/20): 1
Engine idling rpm* 1400 ± 100 rpm ( u n d e r w a r m V gear : 0.880 (22/25) : 1
condition) Primary reduction : 3.25 (65/20) : 1
Starting system Kick starter and Electric starter Final reduction : 3.143 (44/14): 1

Under warm condition

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TECHNICAL SPECIFICATIONS TVS
CHASSIS TYRE
Dimensions and weights Front tyre 2.75X 17, 41P, DURAGRIP
Overall length : 2040 mm Rear tyre 100/90X 17, 51P, DURAGRIP
Overall width : 745 mm Tyre pressure
Overall height : 1150mm Front 1.73 kg/cm2 (25 PSI)
Wheel base : 1295 mm Rear-Solo 2.0 kg/cm2 (28 PSI)
Saddle height : 834 mm Rear-Pillion 2.25 kg/cm2 (32 PSI)
Ground clearance : 195 mm BRAKES
Steering angle : 84° Front Hand operated, internally expanding
130 mm dia. drum
Caster angle : 24°
Rear Foot operated, internally expanding
Frame : Single cradle tubular frame
130 mm dia. drum
Kerb weight : 125 kg
(with tool kit & 90% of fuel)
ELECTRICALS
Pay load : 130 kg
Ignition system 12V(AC/DC), TCI
Maximum laden weight : 255 kg
Spark plug BOSCH UR5KC
Front suspension : Telescopic oil damped
Spark plug gap 0.7-0.8mm
Rear suspension : 5 step adjustable hydraulic shocks
with rectangular swing arm Magneto 12V, 11 OW (fly wheel magneto)

Trail length : 77mm 12V, 130W (fly wheel magneto) * *

Battery 12V,5Ah
Earthing Negative terminal

** Applicable only for HLX150 BLACK THEME

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TECHNICAL SPECIFICATIONS TVS
Head lamp
Tail/ brake lamp
: 12V, 35/35W, S2
: 12V,5/21Wx 1
l caution
Using the bulb other than the specified rating can result in
Turn signal lamps : 12V, 10Wx4
overloading of the electrical system or premature failure of
Speedometer lamp : 12V,3.4Wx2 the bulb.
High beam indicator lamp :12V,1.7Wx1
Neutral indicator lamp : 12V, 1.7Wx 1 vote
Turn signal indicator lamps : 12V, 1.7Wx 1 Specifications are subject to change without notice.
Gear indication : 12V, 1.7Wx5
Horn : 12V, DC
Fuse : 12V, 1 0Ax 1

CAPACITIES
Fuel tank including reserve : 12 litres (reserve 2.0 litres)
Engine cum transmission oil
and capacity : 1000 ml
Front fork oil and capacity : IOC teleshockab oil,
146 ± 2.5 ml per leg

The fuel tank is not a measuring instrument and the capacity

of fuel tank may slightly vary from the indicated capacity.