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TVS XL 100 Parts Catalogue
TVS XL 100 Parts Catalogue
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
1
FIG.NO. 01 CYLINDER HEAD ASSEMBLY FIG.NO. 01
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
2
FIG.NO. 02 CYLINDER BLOCK & CRANK SHAFT ASSEMBLY FIG.NO. 02
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
3
FIG.NO. 03 DRUM CLUTCH ASSEMBLY FIG.NO. 03
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
4
FIG.NO. 04 CRANKCASE LH ASSEMBLY FIG.NO. 04
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
CRANKCASE LH ASSEMBLY
5
FIG.NO. 05 CRANKCASE RH ASSEMBLY FIG.NO. 05
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
CRANKCASE RH ASSEMBLY
6
FIG.NO. 06 MAGNETO ASSEMBLY FIG.NO. 06
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
MAGNETO ASSEMBLY
7
FIG.NO. 07 COVER CLUTCH ASSEMBLY FIG.NO. 07
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
8
FIG.NO. 08 KICK STARTER ASSEMBLY FIG.NO. 08
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
9
CARBURETTOR ASSY. FIG.NO. 09
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
10
FIG.NO. 10 AIRCLEANER ASSEMBLY FIG.NO. 10
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
AIRCLEANER ASSEMBLY
11
FIG.NO. 11 SECONDARY AIR INJECTION ASSY. FIG.NO.11
1
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
2 NO. NO. KS
5
7 1
8
9
12
FIG NO.12 MUFFLER ASSEMBLY FIG.NO. 12
1 NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
3 4 5
1 P7050020 MUFFLER SUB ASSY. BSIV 1 BSIV
2 N3200250 HEX SCREW M6x10 2
2 6
3 R2200160 SPRING WASHER 2
4 420001700 PUNCHED WASHER 6.5x13x1 2
5 P6220260 GUARD MUFFLER 1
6 P7050030 MUFFLER COMP. BSIV 1 BSIV
7 T4050180 GASKET EXHAUST 1
8 M1200890 U NUT M8x1.25 2
MUFFLER ASSEMBLY
13
FIG.NO. 13 FUELTANK ASSEMBLY FIG.NO. 13
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
FUELTANK ASSEMBLY
14
HEADLAMP & TSL FRONT ASSEMBLY FIG.NO. 14
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
15
FIG NO.15 FRAME ASSEMBLY FIG.NO. 15
6
9 NO. OFF
8 REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
FRAME ASSEMBLY
16
FIG.NO. 16 RIDER FOOTREST ASSEMBLY FIG.NO. 16
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
17
35
FIG.NO. 17 FRONT SUSPENSION ASSY. (HYDRAULIC FORK)FIG.NO. 17
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
1 P6320520 FORK LEG SET W/O OIL 1 NEW
2 T4100139 LOCK PLATE COMP. UPPER 2
3 T4100300 GUIDE BUSH 4
4 P6100100 SPRING OIL FORK 2 NEW
5 P6100110 SPRING ANCHOR COMP. 2 NEW
6 T4100280 BUMP STOPPER 2
7 T4100080 FORK TUBE COMP. LOWER RH 1
8 A054190 HOSE CLIP 35 2
9 P6100120 BELLOW DUST 2 NEW
10 M100050 HOSE CLIP 48 2
11 1257281 SNAP RING 2
12 1257466 WASHER 2
13 1257290 OIL SEAL 2
14 7100610 SLIDE METAL 2
15 0334548 HEX NUT M8 2
16 P6100090 FORK TUBE COMP. UPPER 2 NEW
17 T4100290 SLIDER 2
18 410115700 CONE BOTTOM PLATED 4
21
19 410073000 TOLLERENCE RING 1
18
35
FIG.NO. 17
FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO. 17
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
19
FIG.NO. 18 COVER FRAME & TOOL BOX ASSY. FIG.NO. 18
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
20
FIG.NO. 19 REAR FENDER ASSEMBLY FIG.NO. 19
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
R B17 4
5
P1200050
0335928
WAVE SPRING WASHER M6
PLAIN WASHER 18x6.5x1.6
4
4
6 1228880 CHSHION RC LAMP 2
7 N3160220 SPACER RC LAMP 2
8 P3120160 BRKT TURN SIGNAL LAMP 1
9 P6221240 BRKT TAIL LAMP. 1
10 M1200610 HEX SCREW M6x20 4
11 412069000 TANK REST COMP TOP 1
12 P6220500 MUDFLAP REAR 1
13 0332275 CRR PAN HD SCREW M6x16 2
14 420001700 PUNCHED WASHER A6.6 10
15 412092000 PAD 1
16 P121060 PAD FENDER REAR 1
17 420302700 HEX NUT M5 1
18 M7160120 REFLEX REFLECTOR ASSY. 1
19 N6222330 BRKT LICENSE PLATE REAR 1
21
FIG.NO.20 SEAT ASSEMBLY FIG.NO.20
6
NO. OFF
1 REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
SEAT ASSEMBLY
22
FIG.NO.20A SEAT ASSEMBLY - NEW FIG.NO.20A
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
2
1 P130050 SEAT ASSEMBLY 1
2 P130079 REXIN ASSEMBLY 1
3 P130069 SEAT FOAM 1
4 P130029 SEAT BASE 1
5 P130200 REINFORCEMENT REAR 1
1
6 P130190 REINFORCEMENT REAR 1
7 P130160 REINFORCEMENT FRONT 1
8 0258570 CLAMP REAR FENDER 2
3 9 420001700 WASHER 6.5x13x10 6
10 409047000 NYLON LOCK NUT 6
5
6
4
8
23
TAIL LAMP & TSL REAR ASSY. FIG.NO. 21
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
24
FRONT WHEEL ASSY. FIG.NO.22
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
25
REAR WHEEL ASSY. FIG.NO.23
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
26
REAR WHEEL ASSY. FIG.NO.23
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
27
FIG.NO.24 SPEEDO METER ASSEMBLY FIG.NO.24
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
28
FIG.NO.25 HANDLE BAR ASSEMBLY FIG.NO.25
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
29
FIG.NO.26 BRAKE LEVER ASSY. LH & RH FIG.NO.26
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
30
FIG.NO.27 WIRING HARNESS & IGNITION COIL ASSY. FIG.NO.27
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
31
FIG.NO.28 SWINGARM ASSEMBLY FIG.NO.28
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
SWINGARM ASSEMBLY
32
FIG.NO. 29 SHOCK ABSORBER ASSY. FIG.NO.29
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
33
TOOL KIT ASSEMBLY FIG.NO. 30
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REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS
34
FIG.NO. 31 TAPE SET FIG.NO. 31
Part No Sticker
Plastic
No. Name of Tapeset Black- Remarks
Part Black-Red
Yellow
1 TAPESET FUEL TANK TOP R P6221370 P6221470
2 TAPESET FUEL TANK BOT R P6221390 P6221480
Fuel Tank
3 TAPESET FUEL TANK TOP L P6221360 P6221460
4 TAPESET FUEL TANK BOT L P6221380 P6221490
5 TAPESET COV FRAME FRONT R P6221290 P6221410
7
6 Cover TAPESET COV FRAME REAR R P6221310 P6221430
7 Frame TAPESET COV FRAME FRONT L P6221280 P6221400
8 TAPESET COV FRAME REAR L P6221300 P6221420
9 TAPESET TOOLBOX FRONT R P6221330 P6221450
10 TAPESET TOOLBOX REAR R P6221350 P6221350
Tool Box
11 TAPESET TOOLBOX FRONT L P6221320 P6221440
12 TAPESET TOOLBOX REAR L P6221340 P6221340
10 12
TAPE SET
35
RED
SL NO PART NO DESCRIPTION
7
YELLOW
SL NO PART NO DESCRIPTION
7
36
XL - 100 KIT & KIT DETAILS
NEW CHILD
PART NO REMARKS MODEL DESCRIPTION Qty
S NO. PART NO
P6010020 CYLINDER HEAD COMP 1
P6010100 CAMSHAFT COMP 1
N2010340 SPRING VALVE INNER 2
P6010210 VALVE INTAKE 500 1
P6010220 VALVE EXHAUST 500 1
M1010620 SEAL VALVE STEM OIL 2
N2010350 SPRING VALVE OUTER 2
CYLINDER HEAD ASSY. KIT XL100 K3010680 SEAT VALVE SPRING 2
1 P6010110
S1010320 COTTER VALVE 4
N2011040 RETAINER VALVE SPRING 2
K6010200 ARM COMP ROCKER - PEP+ 2
T4010760 SHAFT ROCKER ARM 2
K3011090 STOPPER ROCKER SHAFT 1
N3011780 SPARK PLUG 1
P6010060 STOPPER CAMSHAFT 1
N8200090 REC CSK SCREW M5x15 1
S1080409 PIPE INLET OIL PUMP 1
2 P6030030 CRANKCASE KIT LH
XL100 P6030020 CRANKCASE MACHINING L 1
P6030050 CRANKCASE MACHINING R 1
3 P6030150 CRANKCASE KIT RH XL100 420602000 BALL BEARING 12x32x10 - 6201 1
N2080920 PIPE BREATHER 1
B5020060 PISTON STD 1
XL100 P010680 PISTON PIN 1
4 B5020100 PISTON & RING KIT STD
N5320440 RING SET PISTON STD 5PC 1
N2200340 CIRCLIP PISTON PIN 2
N5010520 RING PISTON Ist 1
5 N5320440 RING SET PISTON STD XL100 N8020700 PISTON RING 2ND 51.00 CHROME PLATED 1
N5010540 RING OIL PISTON 1
P6320210 PISTON DIA I OS 1
P010680 PISTON PIN 1
N5320030 RING PISTON Ist I OS 1
6 P6320070 Piston & Ring kit I OS XL 100
N8324240 PISTON RING 2ND I OS 1
N5320070 RING OIL PISTON I OS 1
B5020140 CIRCLIP PISTON PIN 2
37
NEW CHILD
PART NO REMARKS MODEL DESCRIPTION Qty
S NO. PART NO
P6320200 PISTON II OS 1
P010680 PISTON PIN 1
N5320040 RING PISTON Ist II OS 1
7 P6320080 Piston & Ring kit II OS XL 100
N8324250 PISTON RING 2ND II OS 1
N5320080 RING OIL PISTON II OS 1
B5020140 CIRCLIP PISTON PIN 2
8 N5320030 RING PISTON 1ST I O/S - 0.25 1
N8324660 N8324240 RING PISTON BOTTOM I O/S 1
RING SET PISTON 51.00 DIA I OS & N5320070 OIL RING SET PISTON I O/S 1
XL 100
II OS N5320040 RING SET PISTON 11 O/S (TOP) 1
9 N8324670 N8324250 RING PISTON BOTTOM II O/S 1
N5320080 OIL RING SET PISTON II O/S (TOP) 1
T4080540 OILSEAL 17296 TYPE-A 2
10 P6320120 KIT OIL SEAL XL 100 K3200640 OILSEAL 17x26x6 MAGNETO - PEP 1
N2200550 OIL SEAL CRANKSHAFT R 1
P6010040 CYLINDER BLOCK 1
P6010120 GASKET CYLINDER HEAD 1
11 P6320110 KIT CYLINDER XL 100
P6010130 GASKET CYLINDER 1
B5020100 PISTON ASSY.DIA 1
P6010160 GASKET TENSIONER ADJ 1
P6010120 GASKET CYL HEAD 1
P6010130 GASKET CYLINDER 1
P6030070 GASKET CLUTCH COVER 1
12 P6320130 KIT MAJOR GASKET ENGINE XL 100 R1020310 GASKET COVER CENTRIFUGAL FILTER 1
P6030060 GASKET CRANKCASE 1
P6040040 GASKET PIPE INTAKE 1
T4050180 GASKET PIPE EXHAUST 1
N3140120 GASKET OIL LEVEL PLUG 2
P6080090 SPROCKET ENGINE 1
P6110160 CHAIN ASSY 104 1
13 P6320140 KIT CHAIN & SPROCKET XL 100 P6110170 SPROCKET RR WHEEL 42 52 68 N 1
N3080250 LOCK PLATE SPROCKET 1
N3110470 WASHER REAR SPROCKET 2
38
NEW CHILD
PART NO REMARKS MODEL DESCRIPTION Qty
S NO. PART NO
N5081330 RATCHET KICK STARTER 1
P6080260 LIFTER RATCHET 1
N5081370 SPRING KICK STARTER 1
14 P6320180 KIT KICK STARTER XL 100 P6080119 SHAFT KICK STARTER 1
N5081280 GUIDE KICK STARTER SPRING 1
P6080130 SPRING KICKSTARTER RATCHET 1
K3200880 SHIM 17x24x0.5 1
15 P6320380 Swing arm with 2 silent blocks XL 100 SWINGARM COMP with Bush 1
P6010210 VALVE INTAKE 500 1
16 P6320160 KIT VALVE XL 100 P6010220 VALVE EXHAUST 500 1
M1010620 SEAL VALVE STEM OIL 2
R1020539 CONNECTING ROD MACHINED 1
17 P6320170 KIT CONNECTING ROD XL 100 N2200010 NEEDLE CAGE STAR CITY 110CC 1
N3020120 CRANK PIN 26.00 42.00 H 1
P6040020 PIPE INTAKE COMP 1
K3040180 O-RING PIPE INTAKE 1
18 P6320190 KIT PIPE INTAKE XL 100 P080700 SPECIAL HEX NUT 2
M1200900 HEX FLANGE NUT M6 2
P6040040 GASKET PIPE INTAKE 1
P6010160 GASKET TENSIONER ADJ 1
19 P6320150 KIT MINOR GASKET XL 100 P6010120 GASKET CYL HEAD 1
P6010130 GASKET CYLINDER 1
T4050180 GASKET PIPE EXHAUST 1
N8320500 Float 1
N8320490 Pin float 1
20 P6320370 Kit Carburettor Float XL 100
P6320320 Petrol stop needle 1
N8320440 Gasket- Float Chamber 1
P6320230 Main Jet 1
P6320270 Slow Jet 1
21 P6320360 CARBURETTOR MINOR XL 100
P6320280 Needle Jet Holder 1
N8320440 Gasket- Float Chamber 1
39
NEW CHILD
PART NO REMARKS MODEL DESCRIPTION Qty
S NO. PART NO
P1320600 Retainer Disc 1
P1320530 Circlip 1
P6320290 Spring Jet needle 1
P6320230 Main Jet 1
P6320270 Slow Jet 1
22 P6320350 CARBURETTOR MAJOR XL 100 P1320560 Valve Controller 1
N8320350 Air adjuster 1
N8320440 Gasket- Float Chamber 1
P1320550 Spring Valve Controller 1
N8320360 Spring Air Adjuster 1
P6320440 Throttle Valve 1
SPOKES & NIPPLE KIT INNER-REAR XL100 P3110050 SPOKE REAR WHEEL INNER27250 18
23 P3320070
(QD WHL) N3110200 NIPPLE DIA3.5 WHEEL SPOKE 18
SPOKES & NIPPLE KIT OUTER-REAR XL100 P3110060 SPOKE REAR WHEEL OUTER 18
24 P3320080
(QD WHL) N3110200 NIPPLE DIA3.5 WHEEL SPOKE 18
P3110060 SPOKE REAR WHEEL OUTER 18
25 P321410 XL100 P3110050 SPOKE REAR WHEEL INNER27250 18
SPOKES & NIPPLE KIT N3110200 NIPPLE DIA3.5 WHEEL SPOKE 36
P150260 DAMPER RUBBER UPPER 4
HANDLE BAR DAMPER KIT ( XL
26 P1320060 XL100 P150280 SPACER BUSH 4
SUPER)
P150270 DAMPER RUBBER LOWER 4
BEARING KIT- FRONT XLS-
27 P321260 420602000 BALL BEARING 12x32x10 - 6201 2
ALL/REAR XLS OLD XL100
P3110230 AXLE OD 12 x 244 1
28 P3320120 REAR AXLE KIT -MAX
XL100 K200570 U NUT 10 X 1.25 F LANGED 1
410013700 CONE TOP PLATED 1
K101430 CUP TOP 1
STEERING CONE KIT(XL,CHAMP,XL XL100 420402000 BALLS DIA 5/32 52
29 P321300
SUP,SPORT 410114700 CUP BOTTOM PLATED 1
410115700 CONE BOTTOM PLATED 1
410073000 TOLERANCE RING 1
40