SERVICES SAMIAGHANG TVS MOTOR COMPANY — P-B.No.4, Harta, Hosur 635 109, Tamil Nadu, dia Tel +91 (4344) 276780 Fax: +91 (4344) 276878, 277311 TYPE: SCOOTER Ref, No: SER/SAM/SC/12/19 - 20 Dt. 13.12.2019 CIRCULATE TO: AMD(¥Y) ADD (¥) AD (Vv) MODEL(S): The New Jupiter classic SUBJECT: Launch of the new BSVI Compliant Jupiter classic BSVI Jupiter Classic We are Proud to announce our first Entry into BSVI era by the launch of BSVI Compliant Jupiter classic BSVI Jupiter classic has been launched with the following features — + ET-Fi (Eco thrust Fuel injection) Technology + LED head lamps © 21 lit utility box ‘+ Front glove box with USB mobile charging port + SBT braking system + 3~Step adjustable shock absorber ‘+ Elegant tinted windshield assembly & full chrome round mirrors + 12V, 4Ah MF battery (Front Side) CC: NSMs (Service) / RSMs (Service) / ASM (Service) / TM (Service) Works Manager Service Advisor Floor Supervisor ‘Spare Parts Manager| TVSM Personnel Signature / Date Signature / Date Signature / Date Signature / Date Signature / Date ‘TE-Tools & Equipment GN-General MP-Moped MC-Motorcycle $C-Scooter RF-Refit Page - 1SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS s&s EFISystem 1. Ensure that clean area is maintained when servicing the vehicles. EF! Parts are very sensitive to dirt and dust particles. These minute particles may clog the system leading to complaints such as Jerking, Poor Pickup, Misfiring, ete. 2. Ensure that clean industrial gloves are used when carrying out critical jobs such as fuel filter replacement, fuel pump inspection, fuel hose inspection or anything related to the fuel system. 3. Educate the customer and the sales staff thoroughly regarding the Do's and Don'ts of an EFI system and the sensitivity of the EFI system. The sales staff and customers have to be educated regarding — fuel quality, dead volume, reserve light glow, consequences of riding the vehicle with fuel level below dead volume -which willlead to pump damage, costs involved with EFI system, importance of periodic servicing of the vehicle, the need to avoid taking vehicles to Private garages, prevention of using non- genuine parts (ReferAnnexure 1 for detailed explanation) 4, Ensure that technicians follow standard troubleshooting procedure. This must be done without damaging any of the couplers 5. Ensure that battery terminals and all the grounding points in the vehicle are thoroughly tightened before the vehicle delivery. 6. Strictly maintain fuel level above dead volume (Ref. Annexure) before switching ON the ignition of the vehicle 7. During PDI, ensure that all couplers are connected before cranking the vehicle 8. Maintain PDI Check sheets for each vehicle to ensure easier tracking 9. Use the diagnostic tool if MIL glows in the vehicle continuously while riding 10. Follow established/ standard steps to troubleshoot issues in the vehicle. Do not follow trial and error method to troubleshoot issues as it might lead to vehicle having adaptation issues which will give rise to complaints such as jerking, starting trouble or running off 11, Faulttree will be provided for each model. Refer the fault tree for stepwise diagnosis of any issue. 12. ECU combine throttle body - Maintain storage temperature from -10°C/+50°C 13. Injector maintain storage temperature between -40°C /+60°C 14. Maintain storage temperature between -30°C/+85°C 15. ECU, Injector & Fue! Pump should be free from tensions and compressive stresses or other cause of deformation Page -2SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS s&s EFISystem 1 Do not dry run the fuel pump — Meaning, the vehicle ignition should not be switched on with empty fuel tank or fuel level below the dead volume. Ensure that all vehicles have fuel level above dead volume before switching the vehicle on. WARRANTY OF THE FUEL PUMP WILL BE VOID IF THE FUEL PUMP FAILS DUE TO DRY RUN Do not touch any EF! parts with dirty hands, this may clog the system and cause jerking issues in the vehicle Do not let untrained manpower attend the vehicles without proper supervision Do not use high pressure jet sprays for water wash of the vehicles, this will lead to water entry into few couplers causing short circuit. Do not direct water spray under the seat or near to the throttle body where all sensors are housed Do not deliver the vehicle without performing PDI (Ref. Annexure 1) Fuel used in the service center must be clean. All the jars and mugs used in servicing EFI vehicles must be clean and without dirtdust Page -3SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 10. " 12, 13. 14, 15. 16. 17. 18. 19. 20. 21 22 Mahle TVS >& Contact the respective product coordinator if there are queries regarding servicing of parts or regarding any issues. Do not experimentin the vehicles as each and every part is sensitive Do not crank the vehicle with any of the couplers disconnected - This will register DTC in memory and start lashing MILin the vehicle after the vehicle is delivered to the customer Do not deliver the vehicle to the customer without performing 4 ON/OFF Cycles. Only after 3 ONIOFF Cycles DTC if any will be displayed. ON/OFF Cycle constitutes — starting the vehicle, raising the vehicle to at least 4000 rpm, switching off the vehicle with ignition key and repeating the cycle again for 4 times. MIL lamp should turn OFF when vehicle is started (Malfunction indicator) Do not force probes that do not fit into the coupler, this may damage the coupler and might require replacementof the wiring hamess Do not use wrong tools to open couplers — for ex. using a cutting plier to pull open a coupler will damage a coupler which will require replacing wiring hamess Do not skin any of the wires for troubleshooting or any other purpose Do not touch the chip area of the components with bare hands. This will lead to electrostatic discharge (ESD) which will create electric short and damage the component Do not shorttwo wires during troubleshooting. This might in some cases short the ECU Donotstore ECU, injector & Fuel Pump in open condition Do not assemble ECU, Injector & Fuel Pump tampered condition No other contact than wiring harness is allowed with module connector pins ECU Module should not be exposed to alcohol/gasoline/any other liquid prior to assembly Do not connect disconnect the ECU, Injector & Fuel Pump with battery (White coupler near to front wheel) connected to harness Avoid welding operation near ECU, Injector & Fuel Pump Do not exceed the tightening torque for Injector & Fuel Pump during assembly Diagnostic tool has been installed across all AMDs, BSVI Software update will be sent to all the diagnostic tools. Ensure that updated software is available across all the diagnostic tool (Software update popup enabled popup wil be visible when app is opened with internet ON) The PDI Job cardis attached in the next sheet for your reference. Kindly ensure 100% PDI Checks are done on allthe new vehicles. (Annexure —1) Page -4SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS +& Jupiter Classic: Initial part kit S.No Component Part Number Object Description 4 6070470 ‘SPACER MOVABLE DRIVE 170 2 6070430 ROLLER MOVABLE DRIVE COMP. 3 K6070460 VBELT 4 K6070440 ‘CVT SET DRIVEN a 6070520 HOUSING CLUTCH COMP. 6 6070510 CVT DRIVEN ASSY_ 7 K6081570 ‘SPACER PLATE DRIVE 8 6060490 MAGNETO ASSY EFI 9 K6041210 CAP INJECTOR 10 6041220 COVER INJECTOR 1 K6060500 EFTINJECTOR 3 6170300 ‘CABLE THROTTLE ASSY_ 4 6060530 ‘OXYGEN SENSOR 5 K6150760 LOCK SET BSVI 16 K6140680 FUEL TANK COMP 7 3200010) ‘O-RING 6260 350 19 K6161190 FUEL SENDER ASSY EFI 20 K6140700 HOSE ASSY 24 6140710 ‘GUIDE HOSE 22 4140140 CANISTER COMP 23 6140750 HOSE PURGE VALVE 24 K6140760 HOSE CANISTER 25, 6140770 HOSE INDUCTION 26 K6060520 VALVE CANISTER PURGE 27 K6161170 WIRING HARNESS EFI BASIC 28 4060100 REGULATOR CUM RECTIFIER 29 NF 160590 ‘CONTROL RELAY EFI 30 6011320 ‘SPARK PLUG. 34 K6060550 TGNITION COIL ASSY 32 2320430 CAP OUTER IGNITION LOCK For any further clarification, kindly contact Technical section Sincerely Yours, For TVS Motor Company Limited, oe" MILIND ATUL GANDHI DEPUTY GENERAL MANAGER - SERVICE, Page -SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS s&s Annexure 1: Terminologies — 1. Dead Volume— Dead volume is the total Unusable volume in the fuel tank. Fuel acts as a lubricant for the pump. When fuel pump is run without fuel, the pump parts heat up excessively ultimately damaging the fuel pump. Recommended to ensure minimum fuel quantity for Jupiter series is 2 Litres while delivering vehicle to ‘customer, Ensure that customer is educated to maintain fuel level above 1.2 litres / whenever reserve light (LF! -Low Fuel Indicator) starts glowing in speedometer 2. Use of Non-Genuine Parts — Non-genuine parts usage will cause maffunction of muttiple parts in the vehicle. For ex. If Non-genuine fuel pump is used in the vehicle will cause damage to injector which will call fora replacement of throttle body assembly, Due to this, customer needs to be educated regarding the use of Non-Genuine parts. 3. Importance of periodic maintenance - ‘An EFI system comprises of multiple sensors and actuators which are controlled electronically. When the vehicle is poorly maintained — Air filter not serviced, Spark plug not replaced on time, Malfunctions ator (MIL) in the vehicle are not identified on time, etc. will lead to malfunction in the EFI system (Damage to injectors, Malfunction of sensors, Vehicle jerking & Starting trouble, etc.) 4, Mileage— No adjustment should be done in EFI Vehicles if the vehicles are reported for Low mileage issue Periodic checks have to be carried out and customer pattern of filing fuel has to be studied. Mileage can be checked in EFI Vehicles only through full tank to full tank method wherein customer notes down KM initially fills fll tank fuel. Ride the vehicle until LFI (Low Fuel Indicator) starts glowing, After LF — Low Fuel Indicator light starts glowing customers required to fil full tank again, note down the quantity of fuel filled and calculate mileage by Mileage = 12 KM Driven __ jon / Litre Total fuel filed (litre) Page -6SER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS ~& PDI JOB CARD Tvs =e js. Na Activity ‘Remark iy [sino Activity Remark IE Net OX Specify | (tester ope Check re remreand | ox wr ox 20 | opinaedrange) [Nor oe Annie ieee, | ox coaine) Nar * " oySER / SAM/ SC /12/ 19-20 DATED 13.12.2019 TVS +& SPARE PARTS CONSUMED. OUTSIDE LABOUR CHARG Se =—— ‘ TAFE FPFR REFNO, TPFRDATE PDI VEHICLE SPECIFICATION (BS IV) [Any Other Abnormality Parameter lum] Jupiter Tain RFR ander arm | pag] MSO® lnyre Pressure [Front | psi | 24 |S Rear | psi | 28 tyre pressure [Front | psi | 24 [Dead Rear | psi] 32 Front | mm 10-15 Brake Play rear | mm] 10-15 [Chain Play mm) - [ctutch Play mm) - Throttle play mm | 310 Axte nut Front [Nm] 50 axle Nut Rear [Nm] - Stearing Nut nm] - Engine mounting bolts | Nm] - [Swing Arm Nut nm] [Rear shock absorber wal Toggle tink bolt nm| 36 Signature of PDI Supervisor : Dati