India is in the midst of an electric vehicle (EV) transformation. With EV sales in 2024 crossing 1.6 million units, up 46% from the previous year, it’s clear that electric mobility is not just a trend—it’s becoming the default. Brands like Tata Motors, Mahindra Electric, BYD, and MG are dominating the EV space with models like the Nexon EV, Tiago EV, ZS EV, and eVerito. But amid this fast-paced adoption, one area that often gets ignored is routine EV maintenance.
Unlike petrol or diesel vehicles, EVs have fewer moving parts and no need for oil changes, spark plug replacements, or transmission fluid flushes. This leads many first-time EV owners in India to assume that their electric cars require no servicing at all. That assumption is proving costly.
According to data from the Society of Indian Automobile Manufacturers (SIAM), over 31% of EV breakdowns reported in 2024 were due to neglected software updates, battery mismanagement, and avoidable part wear. These issues could have been prevented with a basic annual EV service.
As EVs grow more sophisticated and India’s climate and road conditions remain challenging, a structured yearly service is not optional—it’s essential. Here’s your comprehensive, news-style guide to what every Indian EV owner should be checking annually in 2025.
1. Battery Health Evaluation: The Single Most Important Check
“Battery failures lead to 14% of EV repairs in 2024 – SIAM Report”
The lithium-ion battery in your EV isn’t just the most expensive component—it’s also the one that dictates range, performance, and resale value. And it degrades over time due to usage patterns, temperature, and charging behavior.
🛠️ What to inspect:
- State of Health (SoH): Check for percentage degradation. A battery below 80% SoH after 3 years may need warranty evaluation.
- Charge cycles & Depth of Discharge (DoD): Excessive fast charging and full 0–100% discharges reduce battery life.
- Thermal Management System: Essential in Indian heatwaves. Ask service centers to test coolant circulation or passive air systems.
Red Flag:
EVs in north India saw increased degradation in 2024 due to prolonged high temperatures. If you’re from Delhi, Rajasthan, or Uttar Pradesh, make this your top priority.
2. Software & Firmware Updates: Your EV’s Digital Lifeline
“Outdated BMS firmware caused 8 Tata Nexon EVs to misreport range—Company issues OTA patch”
In the EV world, your Battery Management System (BMS) and Vehicle Control Unit (VCU) are just as important as brakes. These systems control everything from regenerative braking to charging efficiency and power distribution.
What to ensure:
- BMS Update: Most OEMs issue periodic patches to improve charging times or battery safety.
- ECU/VCU firmware check
- Infotainment system & ADAS calibration (if available)
Pro Tip:
Don’t rely only on OTA (Over-The-Air) updates. Some patches require manual flashing. Insist your service center confirms all modules are up to date.
3. Tyre Wear & Rotation: Often Overlooked, Always Critical
EVs are heavier due to their battery packs. That leads to faster tyre wear, especially on the front axle.
Inspection checklist:
- Tread depth analysis
- Sidewall cracks or bulges
- Rotation pattern (front ↔ rear) every 10,000 km
- Wheel alignment & balancing
What EV owners said:
In a recent Bengaluru EV owner survey, 41% reported uneven tyre wear within 18 months due to skipping scheduled rotations.
4. Brake Health & Fluid Check: Regenerative Doesn’t Mean Zero-Wear
Regenerative braking helps reduce pad usage—but not eliminate it. Brake fluid still ages, especially in humid Indian cities.
Key annual tasks:
- Check pad thickness (≥ 3mm minimum)
- Brake fluid replacement every 2 years or moisture test
- Rust prevention on discs during monsoon (especially in Kerala, Mumbai)
News Insight:
Mahindra recalled over 300 e-Verito units in early 2024 due to a moisture-induced brake failure in coastal areas.
5. Charging Port Inspection & Cable Diagnostics
A damaged port or overheating during charge cycles can cause long-term damage. With India’s unstandardized public charging infra, these checks are more important than ever.
Checklist:
- Visual inspection of CCS2/Type 2 port
- Connector heating during fast charging
- Portable charger cable check (insulation wear, plug pin strength)
- Grounding test of home charger (AC/DC safety compliance)
Stat Alert:
Over 1,200 EV charging cable malfunctions were recorded in India in 2024—many traced to dust, rust, or improper storage.
6. HVAC & Cabin Filter Health: Don’t Ignore Interior Wellness
Your AC system needs love too—especially if you use your EV in smog-prone cities like Delhi or industrial zones like Ghaziabad.
What to inspect:
- Cabin air filter or HEPA filter
- AC refrigerant top-up
- AC compressor performance test
- Heater & defogger check for hilly regions
Owner Alert:
Unclean cabin filters reduce range by up to 4% due to blower overuse, especially in the Tata Tiago EV and BYD e6.
7. High-Voltage System Diagnosis: For Safety and Efficiency
Only certified EV technicians should handle this section.
What it includes:
- High-voltage insulation testing
- Inverter & DC-DC converter diagnostics
- Main fuse testing
- Battery coolant leak check
Legal Angle:
As per India’s CMVR 2025 updates, only OEM-authorized centers may perform HV diagnostics. This ensures safety compliance for both technician and owner.
8. Digital Logs, Warranty & Insurance Sync
Before leaving the service center, verify that:
- Service records are updated in digital logs
- Extended battery warranty is intact
- Telematics & roadside assistance details are synced
Failing to maintain documentation could affect future warranty claims and reduce your car’s resale score on platforms like Spinny or Cars24.
Annual EV Service Summary Table (India-Specific)
| Area | Inspection Task | Frequency | Risk if Skipped |
|---|---|---|---|
| Battery Health | SoH Report, Cell Balancing | Annual | Range drop, premature degradation |
| Software & Firmware | BMS/VCU Updates | Annual or OTA | System bugs, incorrect charging rates |
| Tyres | Rotation, Pressure, Alignment | 10,000 km | Uneven wear, range reduction |
| Brakes | Fluid Change, Pad Check, Rotor Cleaning | Annual | Brake failure, ABS malfunction |
| Charging System | Cable & Port Diagnostics | Annual | Connector damage, charging faults |
| HVAC | Filter, Refrigerant, Performance Test | Annual | Low cooling, blower failure |
| HV System | Safety Diagnostics | Annual | Shock risk, system failure |
| Docs & Warranty | Log Update, Telematics Sync | Annual | Warranty void, claim rejection |
Expert Tips for Indian EV Owners in 2025
- Avoid Fast Charging Daily: Use DC fast chargers only when necessary. Overuse leads to heat buildup and battery stress.
- Use Certified Charging Equipment: Say no to roadside “jugaad” charging hacks.
- Service at Authorized Centers Only: This isn’t like fixing a Maruti. Only OEM-certified workshops have insulated tools and trained personnel.
- Consider a Pre-Monsoon Check: Moisture-related failures spike from June to September.
FAQs: EV Service Checklist in India (2025 Edition)
Q1. How often should EVs be serviced in India?
At least once every 12 months or 10,000–15,000 km, whichever comes first. Regular servicing helps preserve battery life and ensures road safety.
Q2. What’s the average cost of annual EV servicing in 2025?
Costs vary by model. Entry-level EVs like the Tata Tiago EV may cost ₹2,000–₹4,000, while premium EVs like the Hyundai Ioniq 5 or Kia EV6 may cost ₹8,000–₹15,000 depending on diagnostics.
Q3. Will skipping service void my battery warranty?
Yes. Most OEMs, including Tata, BYD, and MG, require logged service history to honor warranty claims—especially for batteries and drive motors.
Q4. Can I service my EV at a multi-brand garage?
Not recommended. High-voltage systems and proprietary software demand specialized tools and training. Non-OEM work may void warranties.
Q5. Do I need to get the home charger serviced too?
Yes. Yearly inspection of your AC wallbox charger ensures safety, reduces fire risk, and maximizes charging efficiency.
Conclusion: Don’t Let Silent Motors Mean Silent Maintenance
As India’s roads hum quietly with EVs, their needs are also quietly evolving. Just because your EV doesn’t rattle or overheat doesn’t mean it doesn’t need care.
Following a well-documented annual EV service checklist in India, especially in 2025 and beyond, ensures you stay ahead of costly repairs, retain warranty protection, and extend the overall life of your electric vehicle.
Whether you own a city commuter or a highway cruiser, a yearly visit to your service center can be the difference between confident EV ownership and an unexpected service nightmare.