PARTS CATALOGUE - EXPORT

NOTICE

The description and illustrations in this booklet are not to be taken

as binding on the manufacturers. The essential features of the

type described and illustrated herein remains unaltered, TVS

MOTOR COMPANY LIMITED, reserves the right to carry out any

moment, without being obliged to bring this booklet up-date

modifications, on the vehicle, parts or accessories, as may be

convenient and necessary.

2

FOREWORD

We have pleasure in presenting the

spare parts Catalogue for TVS StaR,

DLX, City, City Refresh & StaR Sport/DLX.

The catalogue has been specifically

designed to assist you in selecting the

correct parts to maintain the vehicle in

the best possible condition.

TVS

MOTOR

COMPANY,

Genuine

Parts have been subjected to stringent

standards of quality control to ensure long

life

of

the

vehicle.

It

is

therefore

necessary that only TVS Genuine Parts

are

used.

In

continuous

efforts

to

improve the performance and efficiency of

the

vehicle,

design

specifications,

diagram / illustrations and part numbers

can

change

without

notice.

Consequently,

the

description

in

this

spare parts catalogue cannot therefore be

final and binding on us.

While ordering spare parts ensure that

correct part numbers, parts description

and quantity are clearly mentioned.

Please note that the drawings and

the illustrations are for ready reference of

spare part numbers and description only.

It is not designed to be used as an

assembly or servicing reference manual.

For servicing please use “TVS STAR

SERVICE MANUAL”.

This parts catalogue is exclusively for

“TVS

MOTOR

COMPANYs”

Authorised

Outlets:- AMD / AD / ASC /APS.

In case of any assistance, please

contact us.

TVS MOTOR COMPANY LIMITED

Parts Business

INDEX

CAMSHAFT ASSEMBLY

COVER CLUTCH ASSEMBLY

CRANKCASE ASSEMBLY

FIG.No.02

PAGE No.10

CLUTCH ASSEMBLY

FIG.No.06

PAGE No.17

MAGNETO ASSEMBLY (ES)

MAGNETO ASSEMBLY

FIG.No.05

PAGE No.16

FIG.No.04

PAGE No.14

FIG.No.7A

PAGE No.19

FIG.No.07

PAGE No.18

CYLINDER HEAD COMP.

FIG.No.01

PAGE No.09

CYLINDER BLOCK & CRANKSHAFT ASSY.

FIG.No.03

PAGE No.12

- 01 -

INDEX

CARBURETTOR ASSEMBLY

SECONDARY AIR INJECTION ASSY.

FIG.No.13

PAGE No.28

KICKSTARTER ASSEMBLY

AIR CLEANER ASSEMBLY-SAI

AIR CLEANER ASSEMBLY (ES)

FIG.No.09

PAGE No.21

FIG.No.12

PAGE No.27

FIG.No.11B

PAGE No.26

GEAR SHIFT ASSEMBLY

FIG.No.08

PAGE No.20

AIR CLEANER ASSEMBLY (KS)

FIG.No.11

PAGE No.24

FIG.No.11A

PAGE No.25

TRANSMISSION ASSEMBLY

FIG.No.10

PAGE No.23

- 02 -

INDEX

HANDLE BAR ASSEMBLY

FIG.No.18

PAGE No.37

CENTER STAND & FOOTREST ASSY.

FIG.No.16

PAGE No.35

PILLION FOOTREST ASSEMBY LH, RH

FIG.No.17

PAGE No.36

MUFFLER ASSEMBLY

FIG.No14

PAGE No.32

FRAME ASSEMBLY

FIG.No.15

PAGE No.33

CARBURETTOR ASSY. (KEIHIN MAKE)

FIG.No.13A

PAGE No.30

FRAME ASSEMBLY DLX & CITY

FIG.No.15A

PAGE No.34

HANDLE HOLDER ASSEMBLY

FIG.No.19

PAGE No.39

- 03 -

SPEEDOMETER ASSEMBLY

FIG.No.24A

PAGE No.48

5

4

INDEX

REAR BRAKE ASSEMBLY

FIG.No.20

PAGE No.40

HEADLAMP ASSEMBLY

FIG.No.21

PAGE No.41

FIG.No.22A

PAGE No.44

FIG.No.21A

PAGE No.42

HEADLAMP ASSEMBLY (CITY)

COVER FRAME & SEAT ASSEMBLY

COVER FRAME & SEAT ASSEMBLY

FIG.No.22

PAGE No.44

FIG.No.23

PAGE No.46

FUEL TANK ASSEMBLY

SPEEDOMETER ASSEMBLY

FIG.No.24

PAGE No.47

7

6

- 04 -

INDEX

FIG.No.27

PAGE No.53

FRONT WHEEL ASSEMBLY

UNDER BRACKET ASSEMBLY

FIG.No.25

PAGE No.49

FRONT FORK ASSEMBLY

FIG.No.26

PAGE No.51

REAR WHEEL ASSEMBLY (ALLOY)

FIG.No.28A

PAGE No.57

WIRING HARNESS & BATTERY ASSY.

FIG.No29

PAGE No.59

REAR WHEEL ASSEMBLY (SPOKE)

FIG.No.28

PAGE No.55

21

5

WIRING HARNESS & BATTERY ASSY.

FIG.No29A

PAGE No.60

REAR COMBINATION LAMP ASSY.

FIG.No.30

PAGE No.62

- 05 -

INDEX

REAR FENDER ASSEMBLY

FIG.No.31A

PAGE No.65

REAR COMBINATION LAMP ASSY.

FIG.No.30A

PAGE No.63

REAR FENDER ASSEMBLY

FIG.No.31

PAGE No.64

TOOL KIT

FIG.No.34

PAGE No.68

SHOCK ABSORBER & CHAIN COVER

FIG.No.33

PAGE No.67

SWING ARM ASSEMBLY

FIG.No.32

PAGE No.66

3

1

2

3

5

2

1

4

6

7

8

10

9

11

12

5A

13

13

10A

9A

1

2

1A

6

7

2

13

8

11

- 06 -

1

3

2

4

5

8

10

9

11

6

7

2

12

11

4,4A

1

2

5,5A

6

7

3

8

9

11

12

13

10

15

16

17

11

12

14,14A

INDEX

KIT & KIT CONTENTS

PAGE No.69

PAGE No.73

PAINTED PARTS

ABBREVIATIONS

N.I

:

NOT ILLUSTRATED

N.S

:

NOT SERVICED

KS

:

KICK START

ES

:

ELECTRIC START

STD

:

STANDARD

O/S

:

OVER SIZE

13T

:

13 TEETH

TSL

:

TURN SIGNAL LAMP

LH

:

LEFT HAND SIDE

RH

:

RIGHT HAND SIDE

HL

:

HEAD LAMP

BRKT

:

BRACKET

MTG

:

MOUNTING

F.IND

:

FUEL INDICATOR

FGP

:

FUEL GUAGE PROVISION

FWD

:

FORWARD, ie LOOKING BACK FROM

RIDER POSITION

- 07 -

FIG.NO. 01

CYLINDER HEAD ASSEMBLY

- 09 -

23

21

22

21

20

18

6

17

20

16

15

8

14

13

11

12

5

7

4

10

9

CYLINDER HEAD ASSEMBLY

21

14A

19

1

2

3

FIG.No. 01

REF.

NO.

PART

NO.

DESCRIPTION

NO. OFF

ALLOY

REF.

REMARKS

OLD

STAR SPORT

STAR

BASIC

1

S1010320

COTTER VALVE

4

4

4

4

2

N2011040

RETAINER VALVE SPRING

2

2

2

2

3

N2010620

VALVE EXHAUST

1

1

1

1

4

N2010340

SPRING VALVE INNER

2

2

2

2

5

N2010350

SPRING VALVE OUTER

2

2

2

2

6

M1010620

SEAL VALVE STEM OIL

2

2

2

2

7

K3010680

SEAT VALVE SPRING

2

2

2

2

8

N3011140

VALVE INTAKE

1

1

1

1

9

N8010240

CAP INSPECTION HOLE

2

9A

N8010700

CAP INSPECTION HOLE

2

2

2

10

N8010260

O RING CAP INSPECTION HOLE

2

2

2

2

11

N8010350

SHAFT VALVE ROCKER ARM

2

2

2

2

12

S1010240

SCREW TAPPET ADJUSTING

2

2

2

2

13

S1010250

NUT TAPPET ADJUSTING

2

2

2

2

14

N2010320

ARM VALVE COMP. ROCKER

2

14A

N8010080

ARM VALVE ROCKER ASSY.

2

2

2

15

N8200090

CRR CSK SCREW M6x16

1

1

1

1

16

N8010340

STOPPER ROCKER ARM SHAFT

1

1

1

1

17

N5200340

HEX SCREW M6x16

2

1

1

1

18

N8010230

HEAD CYLINDER COMP. (WITH SAI)

1

18A

N8321310

HEAD CYLINDER COMP. (W/O SAI)

1*

18B

N8010460

HEAD CYLINDER COMP.

1

1

1

19

N2180040

SPARK PLUG (UR4 AC)

1

1

1

1

20

N8010310

BOLT CYLINDER HEAD

4

4

4

4

21

S1010130

WASHER CYLINDER HEAD UNIT

3

3

3

3

22

M1010360

GASKET CYLINDER HEAD NUT

1

1

1

1

23

N8010290

GASKET CYLINDER HEAD

1

1

1

1

* - APPLICABLE FOR VEHICLES PRODUCED BEFORE APRIL 2005

FIG.NO. 02

CAMSHAFT ASSEMBLY

- 10 -

REF.

NO.

PART

NO.

DESCRIPTION

NO. OFF

ALLOY

REF.

REMARKS

OLD

STAR SPORT

STAR

BASIC

1

8200130

PUNCHED WASHER 6.5x11x1.6

2

2

2

2

2

A200050

HEX SH. HEAD CAP SCREW M6x25

2

2

2

2

3

0331748

CRR PAN HEAD SCREW M6x16

2

2

2

2

4

0335578

PUNCHED WASHER 6.5x13x1

2

2

2

2

5

N2041400

ADOPTER COMP. CARBURETTOR

1

1

1

1

SPACO CARB.

5A

N8040700

ADOPTER COMP. CARBURETTOR

1

1

1

KEIHIN CARB.

6

A054190

HOSE CLIP 35

1

1

1

1

7

N8040430

PIPE INTAKE (W/O SAI)

1

#

7A

N8040760

PIPE INTAKE

1

1

1

KEIHIN CARB.

7B

N3040340

PIPE INTAKE

1

1

1

1

SPACO CARB.

8

N2040940

O RING PIPE INTAKE

1

1

1

1

9

N8010440

CAMSHAFT ASSY.

1

9A

N8010480

CAMSHAFT ASSY.

1

1

1

10

M1010490

PIN SPROCKET KNOCK

1

1

1

1

11

N5010400

WASHER SPROCKET

1

1

1

1

12

N8010330

TENSIONER CAM CHAIN KS

1

1

1

1

12A

N8010690

TENSIONER CAM CHAIN ES

1

13

N5010790

CAM CHAIN (ROLLER CHAIN)88LINK

1

1

1

1

14

N2010960

WASHER CAM CHAIN TENSIONER

1

1

1

1

15

N2010710

BOLT CAM CHAIN TENSIONER

1

1

1

1

16

N8010320

GUIDE CAM CHAIN

1

1

1

1

17

N5200340

HEX SCREW M6x16

2

2

2

2

18

N8010280

COVER CYLINDER HEAD LH

1

18A

N8010500

COVER CYLINDER HEAD LH

1

1

1

FIG.No. 02

CAMSHAFT ASSEMBLY

9

17

18

19

14

21

20

16

11

10

13

12

15

8

7

6

1

2

3

4

5

12A

* ‘ - APPLICABLE ONLY FOR THE VEHICLE FITED WITH SPACO CARBURETTOR

# ‘ - APPLICABLE ONLY VEHICLE PRODUCED BEFORE APRIL 2005

FIG.NO. 02

CAMSHAFT ASSEMBLY

- 11 -

REF.

NO.

PART

NO.

DESCRIPTION

NO. OFF

ALLOY

REF.

REMARKS

OLD

STAR SPORT

STAR

BASIC

FIG.No. 02

CAMSHAFT ASSEMBLY

9

17

18

19

14

21

20

16

11

10

13

12

15

8

7

6

1

2

3

4

5

12A

19

N5010080

O RING COVER CYLINDER HEAD

1

19A

N3010550

O RING COVER CYLINDER HEAD

1

1

1

20

M1200940

HEX SCREW M5x10

2

2

2

2

21

N5010320

SPROCKET 34T CAMSHAFT

1

1

1

1