TRAINING HAND BOOK /

SERVICE INFORMATION MANUAL

CONTENTS

DESCRIPTION PAGE NO.

VIEW OF TVS STRYKER 125 1

VEHICLE IDENTIFICATION NUMBERS 2
FRAME NUMBER LOCATION 2
ENGINE NUMBER LOCATION 2
FRAME AND ENGINE NUMBER CODIFICATION 2
YEAR AND MONTH CODES 3
CODE FOR THE PRODUCTION YEAR 3
CODE FOR THE PRODUCTION MONTH 3
UNIQUE FEATURES OF TVS STRYKER 4
TECHNICAL SPECIFICATIONS 10
DIMENSIONS AND WEIGHT 10
ENGINE 10
TRANSMISSION 10
GEAR RATIO 10
CHASSIS 11
ELECTRICAL 12
CAPACITIES 12
ELECTRICAL SYSTEM 13
WIRE COLOUR CODE 13
IGNITION SYSTEM 14
LIGHTING SYSTEM 15
DC SYSTEM 16
ELECTRICAL STARTER SYSTEM 17
ELECTRICAL COMPONENTS CHECKING 19
CHECKING OF IGNITION COIL WITH POCKET TESTER 19
CHECKING OF PULSAR COIL WITH POCKET TESTER 19
CHECKING OF STATOR COIL WITH POCKET TESTER 20
CHARGING PERFORMANCE CHECK 20
DIODE MODULE 21
SERVICE REMINDER RESETTING PROCEDURE 22
CONTROL SWITCHES CHECKING PROCEDURE 23
OTHER IMPORTANT CHANGES 24
EXCLUSIVE PARTS 25
STYLE PARTS 25
ELECTRICAL PARTS 25
CHASSIS PARTS 25
EXCLUSIVE PARTS INTER CHANGEABILITY MATRIX 26
FAQ’S & TROUBLE SHOOTING 27
IMPORTANT FUNCTIONS OF TCI TO BE REMEMBERED 28
TVS Stryker 125

RIGHT SIDE VIEW

LEFT SIDE VIEW

-1-
VEHICLE IDENTIFICATION NUMBERS

LOCATIONS

FRAME NUMBER

l The frame serial number is engraved on the

frame at the left side of the steering head tube.
(Refer arrow)

ENGINE NUMBER

l The engine serial number is engraved on the

top surface of the left hand side crankcase near
cylinder block mounting. (Refer arrow)

FRAME AND ENGINE NUMBERS

FRAME NUMBER M D 6 2 5 B F 4 X F 1 K 0 0 0 1 0

World manufacturer Vehicle type Month code

identifier
Frame type Check digit Plant code

Variant identifier Engine type Year code Manufacturing serial no.

Year code
Engine type Month code
Plant code Manufacturing serial no.
Filler

F F 4 K F 1 0 3 3 7 7 8
ENGINE NUMBER

-2-
YEAR AND MONTH CODES

CODE FOR THE PRODUCTION YEAR CODE FOR THE PRODUCTION MONTH

CODE YEAR CODE MONTH

A 2010 A JANUARY
B 2011 B FEBRUARY
C 2012 C MARCH
D 2013 D APRIL
E 2014 E MAY
F 2015 F JUNE
G 2016 G JULY
H 2017 H AUGUST
J 2018 K SEPTEMBER
K 2019 L OCTOBER
L 2020 N NOVEMBER
M 2021 P DECEMBER
N 2022
P 2023
R 2024
S 2025
T 2026
U 2027
V 2028
W 2029
X 2030

-3-
UNIQUE FEATURES OF TVS STRYKER 125

ROTO PETAL DISC BRAKE FULLY ATTENTION SPEEDOMETER

Prevention is better than cure. The thinking Special attention has been given even to the
behind the disc brakes that allow instant stopping (minute) detailing while designing this meter.
in any situation. In case of the worst, you’ll have If reminds you timely service for up keep of the
the best at your disposal. bike and its optimum reformance. Informs the
reduced charge in battery & displays fuel level too.

MUSCULAR HOUSING HEAD LAMP

Aerodynamically designed housing headlamp. For FUEL TANK
further enhancement of looks added cover on TVS STRYKER 125 Fuel tank is sculpted to
both LH & RH sides. improve the fame hugging. Improves in handling
of vehicle.

DC HEAD LAMP
Like a crown on a masterpiece, it sits a top and 125CC ECO THRUST ENGINE
lights up your ride. With a flicker-free constant Tailor made to belt out maximum power with
beam headlamp, every single ride is Safe one on minimum consumption. Turn the key. Ignite and
the roads. Furthermore, with a nifty pass-by day feel the engine come alive. All of 11 PS in it. And
& night switch for forewarning opposite vehicles. you get a whopping mileage out of it.

HAZARD LAMPS DUAL TONE COVER FRAME

Be if fog, rain, sleet & mist. The TVS STRYKER A stylish dual tone cover frame enhances the
125 is equipped with hazard lamps for visibility in aesthetics of the bike.
all weather conditions.

-4-
UNIQUE FEATURES OF TVS STRYKER 125

COMPOUND PADDED DUAL STITCH SEAT

Some journeys call for long rides. And long rides TUBELESS TYRES
call for unparalleled comfort. So, we installed Safety first. Tubeless tyres make sure there is no
compound padded seat which ensures the most sudden loss in air pressure at any speed. You can
relaxed ride. Dual stitch seat enhances the beauty easily reach the nearest service station or home.
of vehicle. To simply put, stop only when you want.

STYLISH PILLION FOOT REST

PDC pillion footrest holder for comfortable riding.
Dampers provided on both sides of pillion
footrests to limit vibration.

SERIES SPRING SUSPENSION

TVS STRYKER 125 is provided with adjustable,
series spring rear shock absorbers to meet
different road and load conditions and provide
unmatched comfort.

LED TAIL LAMP

A stylish LED tail lamp with fully clear lens to give
more bright light and safe ride in night.

-5-
UNIQUE FEATURES OF TVS STRYKER 125

Intelligent DC Head Lamp

Brighter
Headlamp
DC Supply, better visibility no
fluctuations during acceleration or
deceleration.

Day
Battery Saver Feature
Flasher Feature
Head lamp dims automatically if
When the head lamp pass-by is
the vehicle is in idle for more than 20
operated in day time the high beam
seconds. It gets life back immediately
flashes for better visibility.
on opening the throttle

Better Night
Switch Life Flasher Feature
Voltage to the head lamps is routed When head lamp pass-by is
through TCI therefore better switch operated at night time the opposite
life. beam of head lamp flashes for safety.

TCI
Controlled
All functions of head lamp are
controlled through TCI for better battery
life.

Note:
When the head lamp is turned ‘ON’, it glows only when the engine is running.
If the head lamp pass-by is operated during engine ‘OFF’ condition, the head lamp glows with 50% of illumination
(dim) only to save battery life.
-6-
UNIQUE FEATURES OF TVS STRYKER 125

FULLY DIGITAL SPEEDOMETER

• Digital Speedometer with Digits (Bar type)
• Bar type Tachometer (One bar will indicate 250 rpm)
• Bar type Fuel Gauge
• Digital Odometer
• Trip-meter function
• Low Battery Warning icon
• Low Fuel Warning icon
• Service Reminder icon
• LED indications for High Beam / Turn Signal Lamp / Hazard Lamp and Neutral Lamp
• Constant LED backlit for better visibility - both day and night condition
Digital Meter with Fuel Level Indicator cum Low Fuel Warning
Full tank is indicated by 8 bars in the fuel level indicator (>10 litres)
5 bars indicates half tank petrol - 6 litres
4 bars indicates 5 litres in the tank
3 bars indicates 4 litres in the tank
2 bar indicates 3 litres in the tank
1 bar indicates 2 litres in the tank
Fuel Tank Symbol Starts blinking when fuel reaches below 1.5 litres in the tank
Fuel Tank Symbol Starts glowing Continuously when the fuel level reaches 1 litre in the tank
• When there is a loose connection or faulty fuel gauge then all fuel level indicating bars on the speedometer will
start blinking.
1. Low Battery Warning Indicator
• Warning indicator works when the battery Voltage is less
than 10.5 Volt for more than 30 seconds.
1
• Warning indicator stops glowing when the battery input
Voltage is more than 11.5 Volt for more than 30 seconds. 3 2
• Battery warning indicator glows immediately after turning
the ignition ‘ON’ (after self check when the battery Voltage is
less than 10.5 Volt)
2. Service Reminder
• Service reminder gets activated when ‘ODO’ meter reaches 500 kms.
• Next reminder gets activated when ‘ODO’ meter reaches 2500 kms and so on.
• Since the service schedule is stored in the speedometer, the reminder indicator reminds as per schedule
based on Kms.
3. Tachometer
• Very easy to access the tachometer on the go.
• Accurate RPM reading.
• Sporty look with white backlit display.
• One bar indicates 250 rpm.

If there is a loose connection or faulty speed sensor then all ODO /TRIP segments on the speedometer
with start blinking

-7-
UNIQUE FEATURES OF TVS STRYKER 125

REAR SUSPENSION WITH SERIES SPRING

• Specially designed spring on spring - 5 step adjustable rear
suspension for different road & load conditions.
Benefits:-
• Series spring to handle different loads with same comfort
• Suits most of the terrain

HAZARD SWITCH
• Safety – warning signal to other vehicles during emergency
parking.
• It makes sure that your vehicle keep visible in fog, rain, mist
scenarios

-8-
TECHNICAL SPECIFICATIONS

DIMENSIONS AND WEIGHT

Overall length 1993 mm
Overall width 747 mm
Overall height 1075 mm
Seat height 815 mm
Wheel base 1263 mm
Ground clearance 188 mm
Kerb weight (with toolkit and 90% of fuel) 117 kg
Pay load 130 kg
Maximum laden weight 247 kg

ENGINE
Type Single cylinder, 4 stroke, air cooled, spark ignition engine
Cylinder bore 57.0 mm
Stroke 48.8 mm
Piston displacement 124.53 cc
Compression ratio 9.4 : 1.0
Carburettor UCAL UCD 25
Air filter Paper filter element
Lubrication system Positive lubrication
Maximum power in KW 8.1 (11 bhp) @ 7500 rpm
Maximum torque in Nm 10.8 @ 5500 rpm
Maximum speed Around 100 km / hr
Engine idling rpm 1400 ± 100 rpm (Under warm condition)
Starting system Kick starter / Electric starter

TRANSMISSION
Clutch Wet - multi plate type
Transmission 4 speed constant mesh
Gear shift pattern All up heel-toe shift
Primary transmission Spur gears
Secondary transmission Chain and sprockets

GEAR RATIOS
I Gear 3.273
II Gear 1.765
III Gear 1.238
IV Gear 0.958
Primary reduction 3.250
Final reduction 3.214

Specifications are subject to change without notice

-9-
TECHNICAL SPECIFICATIONS

CHASSIS
Frame Single cradle tubular frame
Front suspension Telescopic oil damped
Rear suspension Twin 5 step adjustable series spring with
rectangular swing arm
Steering angle 88°
Caster angle 25°
Trail length 65 mm
Brakes Front Hand operated 240 mm dia. disc
Rear Foot operated internally expanding shoe type 130 mm dia. drum
Tyre Front 2.75 x 17 (tubeless)
Rear 90/90 X17 (tubeless)
Tyre pressure Front 1.75 kg/cm² (25 PSI)
Rear Solo 2.25 kg/cm² (32 PSI)
Pillion 2.53 kg/cm² (36 PSI)

ELECTRICAL
Type Fly wheel magneto, AC
Ignition system DC - Digital TCI
Spark plug BOSCH UR4KC
Spark plug gap 0.6 ~ 0.8 mm
Battery type 12V, 5 AH (Lead acid type)
Generator Fly wheel magneto, 12V, 130W
Body earthing Negative terminal
Head lamp HALOGEN 12V, 35/35W x 1
Position lamps 12V, 10W x 1
Tail / brake lamp LED
Turn signal lamp 12V, 10W x 4
Instrument panel LCD / LED Indicators
Horn 12V, DC x 1
Main fuse 12V, 10A x 1
Head lamp fuse 12V, 10A x 1

Specifications are subject to change without notice

-10-
TECHNICAL SPECIFICATIONS

CAPACITIES
Fuel tank capacity 14.5 litres (reserve 2.7 litres)**
Fuel Unleaded petrol
Engine cum transmission oil grade TVS TRU4 PREMIUM oil (SAE 10W30 API-SL, JASO MA2 )
Engine cum transmission oil capacity 1000 ml
Front fork oil grade IOC / Castrol teleshockab oil / Gabriel premium oil
Front fork oil capacity 155 ± 2 ml per leg
Brake fluid TVS Girling, DOT 3 / DOT 4

** The fuel tank is not a measuring instrument and the capacity of fuel tank may slightly vary from the
indicated capacity.

Specifications are subject to change without notice

-11-
ELECTRICAL SYSTEM

WIRING COLOUR CODES

S.NO. CODE WIRE COLOUR

01 B BLACK
02 BW BLACK WITH WHITE TRACER
03 BY BLACK WITH YELLOW TRACER
04 BR BLACK WITH RED TRACER
05 BI BLUE
06 BIB BLUE WITH BLACK TRACER
07 BIW BLUE WITH WHITE TRACER
08 BlR BLUE WITH RED TRACER
09 Br BROWN
10 BrW BROWN WITH WHITE TRACER
11 G GREEN
12 GB GREEN WITH BLACK TRACER
13 GR GREEN WITH RED TRACER
14 GY GREEN WITH YELLOW TRACER
15 Gr GREY
16 GrR GREY WITH RED TRACER
17 LBI LIGHT BLUE
18 Lg LIGHT GREEN
19 Or ORANGE
20 OrBI ORANGE WITH BLUE TRACER
21 OrR ORANGE WITH RED TRACER
22 OrW ORANGE WITH WHITE TRACER
23 R RED
24 RBI RED WITH BLUE TRACER
25 V VIOLET
26 W WHITE
27 WG WHITE WITH GREEN TRACER
28 WR WHITE WITH RED TRACER
29 Y YELLOW
30 YB YELLOW WITH BLACK TRACER
31 YBI YELLOW WITH BLUE TRACER
32 YR YELLOW WITH RED TRACER
33 YW YELLOW WITH WHITE TRACER

-12-
TVS STRYKER 125 electrical system consists of five systems (circuits) namely.

1. Ignition system 2. Lighting system

3. DC system 4. Electric starter system

IGNITION SYSTEM

The ignition system consist of magneto assembly, regulator cum rectifier unit (RR unit), battery, ignition lock, TCI
unit, ignition coil and spark plug.

The stator coil in the magneto assembly produces alternate current (AC) and supplies it to the RR unit through the
yellow wires (Y). The RR unit converts this AC current to DC current and charges the battery through red wire (R).
A DC output red wire (R) from the battery is connected to the ignition lock.

The output from the ignition lock is connected to the TCI unit through a orange wire (Or). Magneto assembly
pulsar coil is directly connected to the TCI unit through the white (W) and brown (Br) wires. A negative connection
is given to the TCI unit from a common earth junction through a black white wire (BW).

When the ignition lock is in ‘OFF’ condition, the DC output from the battery to the TCI unit is disconnected, thus
the vehicle will not start. Whenever the ignition lock is turned ‘ON’ the DC current flows to the TCI unit. Output
from the TCI unit is connected to the ignition coil (primary winding) through orange (Or) and blue (BI) wires.

The pulsar coil of the magneto assembly produces signals whenever the pip on the magneto periphery passes the
coil. Based on these signals, the micro controller equipped in the TCI unit collapses the ignition coil primary
winding voltage for fraction of a second. This in-turn develops a high voltage across the secondary winding of
ignition coil due to mutual induction. This high voltage is given to the spark plug through the HT lead for producing
spark.

FUSE 10A (DC)

R R BW
MAGNETO ASSEMBLY
12V - 130W
Y Y TO SPEEDOMETER
R BATTERY
R
Y Y R 12V, 5AH
R

BW
RR UNIT IGNITION TO RELAY
PULSAR COIL 12V DC LOCK
FUSE 10A STARTER MOTOR
BW OFF
(HEAD LAMP)
Or TO
W ON
W BW DC CIRCUIT
Br
R
Br BW
Or

Or Or Or Or

BI BI YBl
FROM PASS BY SWITCH

TO SPEEDOMETER BIR YW
(FOR TACHOMETER) TCI UNIT FROM SWITCH LIGHTING
BR YR
IGNITION COIL TO STARTER RELAY FROM SWITCH BEAM CONTROL
BIB BrW
FROM ES SWITCH FROM NEUTRAL SWITCH

HT CORD
WR
RB
YB
TO HEAD LAMP
(FOR LOW BEAM)
FROM CLUTCH SWITCH
TO HEAD LAMP
SPARK PLUG (FOR HIGH BEAM)

-13-
LIGHTING SYSTEM

The lighting system of new TVS STRYKER 125 works completely on DC which is entirely different from all
other TVS Models.

The lighting system consists of magneto assembly, regulator cum rectifier unit (RR unit), battery,
Ignition lock, fuse 10A (head lamp), TCI unit and the control switches. The working of lighting system of the new
TVS STRYKER 125 are as follows.

A DC output red wire (R) from the RR unit is directly connected to the TCI unit through a 10A fuse (head lamp).
When the ignition lock is turned ‘ON’ the DC output from the lock is supplied to TCI unit, switch lighting, switch
beam control and pass-by switch through an orange wire (Or).

When the switch lighting knob is slid to ‘PO’ position, the DC current from the switch is supplied to the position
lamps and tail lamp through the grey wires (Gr).

Similarly, when the switch knob is slid to the ‘HL’ (head lamp ‘ON’) position, the DC current from the switch is also
supplied to the TCI unit through a yellow white wire (YW) along with the above mentioned lamps. Once the signal
is received from the switch lighting, the TCI checks for the input from the pulsar coil to determine the engine
running condition (head lamp works only when the engine is running) and the switch beam control to determine
the head lamp beam (‘High’ or ‘Low’). If the beam control switch is in ‘LOW’ position, the TCI will not get any input
from the switch and supplies the power to the head lamp ‘low beam’ through a white red wire (WR). If the beam
control switch is in ‘HI’ position, the TCI gets an input through a yellow red wire (YR) and supplies power to the
head lamp ‘high beam’ through a yellow black wire (YB).

When the pass-by switch is pressed a DC signal is sent to the TCI unit through a yellow blue (YBI) wire. Now, the
TCI unit checks for the input from the switch lighting to determine the head lamp condition (‘ON’ or ‘OFF’). If the
head lamp is in ‘OFF’ condition then the TCI supplies the power to the head ‘high beam’ and makes it to glow. If
the head lamp is in ‘ON’ and glowing in ‘low beam’, the TCI unit cuts ‘OFF’ the power supply to the ‘low beam’ and
supplies to the ’high beam’ (toggles). If the head lamp is glowing in ‘high beam’ the TCI does it in vice-versa.

FUSE 10A (DC)

R R BW
MAGNETO ASSEMBLY
12V - 130W
R
Y Y TO SPEEDOMETER

R BATTERY
R 12V 5AH
Y Y R
R
BW RR UNIT
12V DC IGNITION TO RELAY
FUSE 10A
(HEAD LAMP)
LOCK OFF STARTER MOTOR
BW
Or
R ON

W BW TO
FROM PULSAR COIL DC CIRCUIT
BW
Br Or
FROM PULSAR COIL Or
Or POSITION LAMP
PASS BY 12V LED
Or Or SWITCH PO Gr Gr
TO IGNITION COIL
BI YBl YBl BW
TO IGNITION COIL Or
SWITCH
BIR YW YW HL LIGHTING
TO SPEEDOMETER TCI UNIT
YW POSITION LAMP
BIB YR YR 12V LED
FROM ES SWITCH Gr
BR BrW LOW
TO STARTER RELAY FROM NEUTRAL BW
SWITCH Or

YR
HI
RB YB WR TAIL LAMP
HEAD LAMP SWITCH 12V 5W
12V 35/35W BEAM CONTROL Gr
FROM CLUTCH SWITCH WR
BW
YB
BW

TO SPEEDOMETER

-14-
DC SYSTEM

The DC system consists of magneto assembly, regulator cum rectifier unit (RR unit), battery, Ignition lock, fuse
10A (main fuse) and the control switches.

A DC output red wire (R) is directly connected to the speedometer for data storage purpose. Another DC output
red wire (R) from the battery is connected to the ignition lock through a 10A fuse. When the ignition lock is turned
‘ON’ the DC output from the ignition lock is supplied to brake lamp switches front and rear, horn, speedometer
assembly and other DC operated systems through an orange wires (Or).

When the brake lamp switch front or rear is operated (brake applied), the DC current from either of the switch is
supplied to the brake lamp through a white wire (W). A negative earth connection from the common earth junction
is connected to the lamp and hence the lamp glows. Similarly, when the horn button is pressed, the negative
output from the common junction is connected to the horn through a black white wire (BW). Since the horn is
connected to the ignition lock’s DC output directly, it blows.

Two DC input are connected to the speedometer assembly through orange wires (Or). One input is given for
speedo back lit glowing (glows continuously when the ignition lock is turned ‘ON’) and the other one is given for
the normal working of speedometer assembly and indicators.

A positive supply is directly given to the neutral indicator LED of the speedometer. When the vehicle is in neutral,
a negative input is given from the neutral switch and the indicator works. A fuel level indicator in the speedometer
gets input signal in the form of variable resistance from the fuel sender unit through a green with yellow wire (GY).
Based on these signal the fuel level indication is shown.

A input voltage through an orange with red wire and a negative through a black with yellow wire is given to the
speed sensor from the speedometer. The output signal from the speed sensor is received through a white with
green wire by the speeometer. Based on these signals the speed indication is shown. Speedometer shows
engine rpm based on the engine speed signal is received from the TCI unit through a blue with red wire.

FUSE 10A (DC)

R R BW
MAGNETO ASSEMBLY
12V - 130W
Y Y

R R BATTERY
R 12V 5AH
Y Y R

R IGNITION
BW RR UNIT LOCK TO RELAY
12V DC STARTER MOTOR
R OFF
BW TO FUSE HEADLAMP

ON
BRAKE SWITCH FRONT
Or Or W BRAKE LAMP
12V 21W
W
Or Or R Or BRAKE SWITCH REAR
Or W BW
FROM
TURN SIGNAL LAMP SWITCH / R
HAZARD SWITCH Or
BlR FROM TCI SWITCH HORN
Lg (FOR RPM INDICATION)
HORN G
Or
V FUEL SENDER UNIT BW
GY
OrR SPEEDOMETER
BW TO SWITCH LIGHTING
WG
YB FROM TCI TO SWITCH BEAM CONTROL
Or
(FOR HIGH BEAM INDICATION)
SPEED
SENSOR BY TO PASS BY SWITCH

BW BrW TO ES SWITCH TO TCI

BW TO STARTER RELAY
NEUTRAL
SWITCH
TO TCI TO FLASHER UNIT

-15-
ELECTRIC STARTER SYSTEM

Electric starter system consists of a battery, ignition lock, electric starter switch, neutral switch, clutch switch, TCI
unit, relay starter motor and the starter motor assembly. The working of electric starter system of the new TVS
STRYKER 125 is as follows.

A DC output red wire (R) from the battery is connected to the ignition lock through a 10A fuse. When the ignition
lock is turned ‘ON’, this DC output is connected to the TCI unit, electric starter switch and relay starter motor
through an orange wire (Or).

A DC output from the battery is directly connected to the relay starter motor through a thick red wire (R) and the
output of the relay is connected to starter motor through another thick red wire ®. A negative black white wire
(BW) is connected to the starter motor from common earth junction. When the relay energies, the battery input is
supplied to the starter motor through the above mentioned red wires thus the motor works. A brown white wire
(BrW) from the neutral switch is connected to the TCI unit. When the vehicle is in neutral condition a negative
input from the neutral switch is supplied to the TCI unit.

Similarly, a red black wire (RB) from the clutch switch is connected to the TCI unit. When the clutch switch is
operated (clutch applied) a negative input from the clutch switch is supplied to the TCI unit. The clutch switch gets
this negative input from the common earth junction through a black white wire (BW).

While pressing the electric starter switch, the DC supply from the electric starter switch flows to the TCI unit
through a blue black wire (BIB). On receipt of this DC input signal, the TCI unit checks the availability of negative
input either from the neutral switch or from the clutch switch. If any one of these input is available, then the TCI
unit connects a negative supply to the relay starter motor through a black red wire (BR) and energies the
relay.Even all the above conditions are met by the TCI unit, if the engine is in running condition (if there is a pulsar
coil input to the TCI unit), then the TCI unit cuts ‘OFF’ the negative supply to the starter relay to avoid the cranking
of starter motor during engine running condition and protect the motor from getting damaged.

If the ES Switch is pressed continuously either in neutral or clutch pressed condition (by applying clutch) the TCI
unit will trigger Stater relay for 3 secs and switches OFF automatically after 3 secs.
FUSE 10A (DC)
MAGNETO ASSEMBLY R R BW
12V - 130W
Y Y R
TO SPEEDOMETER R

Y Y R R
R
BATTERY
BW IGNITION 12V 5AH
RR UNIT LOCK
BW 12V DC FUSE 10A
(HEAD LAMP) OFF
R R
ON
W

TO PULSAR COIL Br R BW BW BW TO
DC CIRCUIT
Or
Or Or Or
TO IGNITION COIL BI YBl
FROM PASS BY SWITCH RELAY STARTER
MOTOR
TO BIR YW R
SPEEDOMETER TCI UNIT FROM SWITCH LIGHTING
BR Or
YR
FROM SWITCH BEAM CONTROL
BIB BrW BR
FROM NEUTRAL SWITCH

Or R
YB WR
TO HEAD LAMP
RB LOW BEAM BW STARTER
BR BlB TO HEAD LAMP
HIGH BEAM
CLUTCH SWITCH M MOTOR
RB BW BR

BlB BlB Or
BW
ELECTRIC START SWITCH
BR BR

-16-
ELECTRICAL COMPONENTS CHECKING

CHECKING THE IGNITION COIL ASSEMBLY WITH

POCKET TESTER
l Ignition coil is mounted on the right side of the frame
near the carburettor assembly. (Fig. 1) Disconnect
the wiring sockets connecting TCI unit and ignition
coil. Also disconnect the HT cord from the spark plug.

Pocket tester

l Set pocket tester to 200 W range.

Fig. 1
l Connect the pocket tester ‘+ve‘ lead to the orange
wire (Or) and ‘–ve‘ lead to blue wire (BI) of the ignition
coil to measure the primary winding resistance.
(Fig. 2) If the resistance is not within the specified 3.5
BI Or
limit, replace the ignition coil assembly with a new
one.

Primary resistance > 3 ohms 10ADC

V mA
DIGITAL

l If the primary winding resistance is OK, then check MULTIMETER

COM

the secondary winding resistance.

l Set pocket tester to 20 K W range.
l Remove the suppressor cap from HT cord. Connect Fig. 2
the pocket tester ‘+ve‘ lead to the HT cord and ‘–ve‘
lead to the blue wire (BI) of the ignition coil. Measure
the resistance. (Fig. 5.3)
13.25
Pocket tester BI

Secondary resistance > 12 k ohms

10ADC

l If the resistance of winding is not within the limit, V mA

DIGITAL
replace the ignition coil assembly with a new one. MULTIMETER
COM

CHECKING THE PULSAR COIL WITH POCKET

TESTER

Pocket tester Fig. 3

l Set pocket tester to 2000 W range.

l Disconnect the pulsar coil socket from TCI unit.
180
l Connect the pocket tester ‘+ve‘ lead to the white
wire (W) and ‘–ve‘ lead to brown wire (Br) of the
pulsar coil. (Fig. 4)
l Measure the resistance. If the resistance is not
within the specified limit, replace the pulsar coil with 10ADC

VW mA
DIGITAL
a new one. MULTIMETER
COM

Pulsar coil (Br - W) 110 ~ 200 ohms

Fig. 4
-17-
CHECKING THE STATOR COIL WITH POCKET
TESTER

Pocket tester

l Set pocket tester to 200 W range.

l Disconnect the stator coil socket from RR unit.
180
l There are three wires coming out of the magneto
assembly. Connect the pocket tester ’+ve’ lead to
the yellow wire (Y) (1) and ’-ve’ lead to the yellow wire
(Y) (2) of the stator coil. (Fig. 5) Measure the
resistance. If the resistance is not within the 10ADC

specified limit, replace the stator assembly with a DIGITAL

VW mA 3
MULTIMETER
COM
new one. 2 1

Stator coil (Y - Y) 0.5 ~ 1.5 ohms

Fig. 5

CHARGING PERFORMANCE CHECK

l Set the pocket tester knob to DC 200 V range.

Tachometer

Pocket tester

l Remove the cover frame LH

l Connect the pocket tester ‘+ve’ lead of pocket tester
to positive terminal of the battery and the ‘–ve’ lead of
pocket tester to the negative terminal of the battery. 14.3
(Fig. 6)
l Start and warm up the engine. Switch on the head
lamp high beam.
l Connect the tachometer to find out the engine rpm
and increase it to the below specified limit.

Charging 14.3 ± 0.3V at 2500 rpm and Fig. 6

performance above

Note:
While checking the charging current, switch on
the head lamp high beam to know the correct
reading.
l If the reading measured is not within the limit, check
the stator coil resistance as explained earlier.
l If the stator coil resistance found OK, then replace
the RR unit with a new and re-check.

-18-
SERVICE REMINDER RESETTING PROCEDURE
l Make sure the speedometer is in ‘ODO’ mode and
then switch ‘OFF’ the ignition key.
A
l Press and hold the ‘MODE’ button (A) with the finger.
Without releasing the ‘MODE’ button turn the
ignition key to ‘ON’ position. Continue to hold the
‘MODE’ button pressed for about 30 to 60 seconds.
(Fig. 13)
l After self test, the service reminder blinks for 10
seconds and then continuously glows for 30 to 60
seconds then turns ‘OFF’ (disappears). Do not
release the ‘MODE’ button till the service reminder
disappears. Fig. 13
l Now, release the ‘MODE’ button. Switch ‘OFF’ and
again switch ‘ON’ the ignition key to ensure that the
service reminder is reset.

CONTROL SWITCHES CHECKING PROCEDURE

Check the following switches for continuity with the
pocket tester.
l Set the pocket tester in the continuity mode.

SWITCH LIGHTING

SWITCH POSITION Or Gr
OFF - ( )
ON - ( ) O O

SWITCH POSITION Or YW
OFF - ( )
ON - ( ) O O

SWITCH BEAM CONTROL

SWITCH POSITION Or YR
PRES UP ( ) - HIGH O O
PRESS DOWN ( ) - LOW

PASS BY SWITCH
SWITCH POSITION Or YBl
PRESS - ON O O
PRESS - OFF

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EXCLUSIVE PARTS
STYLE PARTS*

N5226039 Tail cover R

N5226029 Tail cover L
N5226069 Housing head lamp front
N5229690 Housing head lamp rear
N5226399 Housing headlamp L
N5226409 Housing headlamp R
N4220019 Fender front unpainted
NA140029 Fuel tank complete
N5225999 Cover frame front R
N5225989 Cover frame front L
N52260190D Cover frame rear R black
N52260090D Cover frame rear L black
NA130040 Seat complete assembly
N5226070 Pillion handle painted

ELECTRICAL PARTS

NC160010 Digital speedometer assembly

NA060020 Magneto assembly ES
NA160080 Regulator DC
NA060030 TCI unit assembly
NC160060 Wiring harness assembly

CHASSIS PARTS

N4090540 Shock absorbers

NC120020 Bracket TCI mounting

* All painted parts and graphics part numbers should be mentioned with the respective colour code only
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FAQ’s & TROUBLE SHOOTING
1) If the self starter button is operated continuously for more than three seconds why the starter motor
switches off?
Ans.) The TCI cuts of power supply to the self relay whenever the self starter is operated continuously for
more than 3 seconds to enhance the life of the battery, If the vehicle has not started within 3 seconds of
cranking the rider can release the switch and repress the switch to crank again. If held continuously also the
self motor will work after a gap of 3 seconds.
2) While driving at night, If the vehicle is kept in idling for some time the head lamp goes dim and regains
brightness on opening the throttle why?
Ans.) With the head lamp in ‘ON’ mode and vehicle left in idling for more than 20 seconds, the TCI unit is
programed to supply 50% voltage to head lamp to enhance the battery life. Also, the TCI supplies back the full
voltage once the rider opens the throttle to start riding. This feature reduces battery load during idling with
head lamp ‘ON’.
3) In ‘Day’ driving with the head lamp ‘OFF‘ condition, operating the pass-by switch will make which beam of the
head lamp to glow?
Ans.) With the head lamp in ‘OFF’ condition, on operating the pass-by switch, the TCI makes only the ‘HI’
beam of the head lamp to glow.
4) In ‘Night’ driving with the head lamp ‘ON’ condition, operating the pass-by switch will make which beam of
the head lamp to glow?
Ans.) With the head lamp in ‘ON’ condition, on operating the pass-by switch, the TCI toggles to the opposite
beam of operation
Eg: If the head lamp is in ‘Low beam’ the TCI toggles to the ‘HI beam’, else if the head lamp is in ‘Hi beam’ the
TCI toggles to the ‘Low beam’.
5) When the pass-by is applied with the engine in ‘OFF’ condition the head lamp glows with low brightness only
why?
The TCI is programmed to supply only 50% of voltage to the head lamp when the pass-by is operated with out
the engine running to save the battery life.
6) Why are the head lamp is DC powered?
Ans.) The head lamp is DC Powered to give constant brightness irrespective of engine RPM. In an AC system
the brightness reduces while decelerating / De-clutching / Braking etc.
7) Being DC powered will the head lamps drains the battery?
Ans.) There is no cause of worry as the TCI allows the head lamp to operate only when the engine is in running
condition, also the charging system is powerful with a 130 Watts magneto to take care of the charging needs.
IMPORTANT FUNCTIONS OF TCI TO BE REMEMBERED

The important functions of Intelligent TCI to be remembered are:-

l Post 3 seconds of cranking the TCI cuts off the relay supply (to save battery power).
l The TCI allows the head lamp to work only when the engine is running (to save the battery power).
l Post 20 seconds idling of the vehicle the TCI supplies only 50% voltage to head lamp and 100% once the
rider opens throttle (to save battery power).
l Day flasher (pass-by) function – operates ‘HI’ beam of the head lamp during day flashing
( for convenience / safety).
l Night flasher function (pass-by) – toggles head lamp beam between the ‘HI’ and ‘LOW’
(for convenience / safety).
l If the pass-by is operated with the engine in ‘OFF’ condition, the head lamp glows only with 50% of power

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