TVS TVS StaR HLX 150 User manual

Dear Friend,
Thank you for choosing the TVS StaR HLX 150, strongest
and most reliable motorcycle.
As a proud owner of TVS StaR HLX 150, you are now part of a
family of millions of satisfied TVS customers.
TVS StaR HLX 150 is designed to deliver superior durability,
best in class power and host of other features. It also comes
with refreshing looks.
This manual explains the features and operations of your
TVS StaR HLX 150. Please read it carefully and follow the
instructions to enjoy years of safe riding.
To ensure reliable performance, we urge you to get your
TVS StaR HLX 150 serviced only at TVS Motor Company
Authorised Dealers / Authorised Service Centers at specified
regular intervals.
Happy Riding!
TVS MOTOR COMPANY LIMITED
All information, illustrations, photographs and
specifications contained in this owner‘s manual are based
on the latest product information available at the time of
this publication. TVS Motor Company Limited may, however
incorporate modifications or improvements on its vehicles
at any time without notice and therefore, in such events it is
possible that the relevant part of the owner‘s manual does
not apply to your vehicle.
Prior permission of TVS Motor Company Limited is required
for quoting, copying or reproducing any part of this owner‘s
manual.
Partnumber:- Revision 0, April 2017 N6210970
Accessories shown in the picture may not be part of the
standard equipment.
FOREWORD - NOTICE
1
FOREWORD - NOTICE
NOTICE
FOREWORD
NOTE

CONTENTS
Information 03
Safe Riding Tips 04
Know your TVS StaR HLX 150 07
Riding your TVS StaR HLX 150 21
Maintenance 26
Services Record Sheet 40
Technical Specifications 42
CONTENTS
CONTENTS
2

RUNNING-IN INFORMATION
The first 1000 km is a crucial part for the life of your TVS StaR
HLX 150. Proper running-in operation during this period
helps in ensuring a maximum life and smooth performance
of your motorcycle.
The reliability and performance of your TVS StaR HLX 150
depends on the special care and restraint exercised during
the running-in period. It is especially important that you
avoid operating the engine in a manner, which could expose
the engine parts to excessive stress. Maximum
recommended speed during the running-In is:
Maximum 50 kmph speed upto 1000 km (vary the
engine speed for better mating of parts).
The first free service at 500 ~ 750 km is most important.
During running-in period all the engine components and
other parts will have set in. All adjustments to be restored, all
fasteners to be tightened. Engine cum transmission oil to be
replaced. Timely performance of the first free service will
ensure optimum service life and performance from the
engine.
WARNING
CAUTION
Operating this vehicle safely is an important responsibility
of the rider. To help you make decisions about safety, we
have provided operating procedure and other information
in this manual. This information alerts you on potential
hazards that could hurt you or others. Since it is not possible
to warn you about all hazards associated with operating or
maintaining the vehicle, you must use your own judgement.
You will find important safety information in following form
with corresponding connotations in this manual:
Disregarding this message might result in injury to the rider.
This message indicates special procedures or precautions to be
followed to avoid damage to the vehicle.
This message provides further clarification for clearer
understanding of any particular information.
SAFETY INFORMATION
INFORMATION
3
INFORMATION
NOTE

WARNING
SAFE RIDING RECOMMENDATIONS
Any two wheeler riding requires some precautions to
be taken to ensure the safety of the rider, pillion rider
and other road users. These precautions are:
Riding apparel
Loose, fancy clothing can be uncomfortable and
unsafe when riding a two-wheeler. Choose good
quality two wheeler riding apparel.
Familiarise yourself with new TVS StaR HLX 150
Riding skill and your mechanical knowledge form the
foundation of safe riding practices. We suggest you
to practice riding in a low-traffic condition until you
are thoroughly familiar with your vehicle and its
controls. Remember perfect practice makes you
perfect.
Two wheeler safety equipment starts with a safety helmet of
good quality. One of the most serious injuries that can
happen is a head injury. Always wear good quality helmet.
You should also have good suitable eye protection.
Know your limits
Ride within the boundaries of your own skill at all times.
Knowing these limits and staying within them will help you
to avoid accidents.
Posture
Proper vehicle riding starts with proper posture.
1. Keep your elbows inside close to the body and kept
flexible.
2. Hold your arms at an angle of about 120°.
3. Hips should be in a position so that arms and shoulders
are relaxed.
4. Look widely instead of gazing at one point.
5. Relax to guard against a sudden impact.
6. Hold the tank tightly with knees.
7. Point the toes straight ahead.
Cornering
When cornering, centrifugal force works in a direction
perpendicular to the direction in which the vehicle is
moving.
Centrifugal force increases in proportion with speed and
shorter the radius of the corner, the greater it becomes.
During cornering, reduce speeds so as to lessen the effects
SAFE RIDING TIPS
SAFE RIDING TIPS
4

of centrifugal force. By all means, avoid abrupt application
of brakes or sudden steering.
Braking
For safe riding, it is very important to master the braking
techniques.
1. Close / release the throttle.
2. Hold the vehicle upright as you apply the brake.
3. Progressive application of brakes is safer.
4. Never depress the clutch lever while braking at higher
speeds.
5. Apply both the brakes.
WARNING
One-hand riding is dangerous. Keep both hands firmly on the
handle bar and both feet securely on the foot rest. Under no
circumstances should both the hands be removed from the handle
bar, as it is very dangerous.
Avoid use of mobile phones while riding as it could lead to fatal
accident.
Do not downshift the gears in the midst of cornering. Slow down to a
safe speed before negotiating a corner. If this is the first time that
you are riding a vehicle of this type, we suggest that you practice on
a safe, open area to become thoroughly familiar with the operation
of the vehicle.
6. Riding down hills and while cornering, close throttle
and down shift the gear to take advantage of gearbox
and engine which acts as an additional brake. This will
avoid the loss of control over the vehicle due to over
speed.
Causes for poor braking
1. If the brake shoes or drum are worn out or if there is
water or oil on them, sufficient friction does not
develop and brakes do not work well.
2. Even when the brake works normally, if the road
surface is wet or the tyre surface is worn-out, tyres do
not take a firm hold on the surface, prolonging the
stopping distance.
3. Approximately 60% braking effect is from front
brake.Non-usage of front brake causes poor braking.
As the vehicle speed increases, the stopping distance also increases
progressively. Be sure that, you have sufficient distance between
you and the vehicle or obstruction ahead of you.
Using only the front or rear brake is dangerous and can cause
skidding and loss of control. Apply both the brakes together and
with great care on a wet road or other slippery surfaces. Any abrupt
braking on slippery or irregular roads can cause loss of rider
control.
WARNING
SAFE RIDING TIPS
3
SAFE RIDING TIPS

ACCESSORY INSTALLATION AND SAFETY TIPS
Use extreme caution while selecting and installing the
accessories for your TVS StaR HLX 150.
The addition of unsuitable accessories can lead to unsafe
operating conditions. Your friendly dealer will assist you in
selecting quality accessories and installing them correctly.
While selecting the accessories, make sure the accessories
should not obstruct lighting, steerability and suspension
level.
Additional electrical equipments and controls should not
exceed the specified electrical system load of the vehicle.
EMISSION CONTROL
All the TVS motorcycles are tested in the factory for
optimum fuel efficiency and lowest possible CO levels.
Kindly do not disturb the Carburettor settings as this may
lead to higher fuel consumption and also higher CO
levels.
If the vehicle needs any adjustments, please consult nearest
TVS Motor Company Authorised Dealer or Authorised
Service Centre.
While adequate care is exercised at the factory to ensure
that the emissions are within the limits, it is essential for the
owner to always maintain TVS StaR HLX 150 motorcycle in
good condition by getting it periodically serviced and
checked by TVS Motor Company Authorised Dealer or
Authorised Service Centre so that the emission and fuel
consumption levels are maintained as per norms.
SAFE RIDING TIPS
SAFE RIDING TIPS
6

VEHICLE IDENTIFICATION NUMBER
Serial numbers of both frame and engine are required for vehicle identification. They are also required to assist your dealer for
operating parts or referring to special information.
Frame number
The frame serial number is stamped on the left side of the
steering head tube. The engine serial number is stamped on the top surface of
left hand side crank case near the cylinder block
mounting.
Please fill the above box now for future reference
Control key number
Engine number
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LOCATION OF PARTS - HANDLE BAR
1. Choke lever
2. Horn switch
3. Turn signal lamp switch
4. Clutch lever
5. Pass by switch
6. Rear view mirror L
7. High / low beam switch
8. Speedometer assembly
9. USB Charger
10. Ignition switch cum steering lock
11. Hazard switch
12. Rear view mirror R
13. Front brake lever
14. Throttle grip
15. Headlamp switch
16. Electric starter switch
17. Fuel tank cap
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8
3
6 7 11 12
13
1
2
4
5
8910
14
14
15
16
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LOCATION OF PARTS
1. Pillion foot rest L
2. Rear shock absorber L
3. Chain inspection window
4. Gear shift lever
5. Fuel cock
6. Speedometer cable
7. Front brake cable
8. Lock cover frame L
9. Handle pillion
1. Spark plug
2. Gauge oil level
3. Rear brake pedal
4. Kick starter lever
5. Cover frame R screw
6. Rear shock absorber R
7. Pillion foot rest R
8. Muffler assembly
VEHICLE LEFT SIDE VEHICLE RIGHT SIDE
765 4
89
3 8 76543 2 1
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12

LOCATION OF PARTS
VEHICLE FRONT SIDE
1. Front turn signal lamp L
2. Head lamp assembly
3. Crash guard
4. Rider foot rest
5. Front turn signal lamp R
6. Housing head lamp front visor
VEHICLE REAR SIDE
1. Tail / brake lamp assembly
2. Rear turn signal lamp R
3. Rear number plate
4. Reflex reflector
5. Rear turn signal lamp L
2
1
3
4
5
6
1
4
52
3
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CONTROL KEY
TVS StaR HLX 150 comes with a pair of identical control keys.
These keys are to operate ignition switch cum steering lock,
fuel tank cap and cover frame L.
IGNITION SWITCH CUM STEERING LOCK
The ignition switch cum steering lock has three positions:
1. ‘OFF’ position
All the electrical circuits are turned ‘OFF‘ in this position. Key
can be taken out.
2. ‘ON’ position
In this position you can start the engine and operate turn
signal lamp, gear position indicators and horn. Key cannot
be removed in this position.
3. ‘LOCK’ position
TVS StaR steering can be locked in both left and right
directions.
To lock the steering, turn the handle bar all the way to the
left or right. Insert the key into the lock, push in, hold and
turn it to ‘LOCK’ position. Take out the key once the steering
is locked.
Turning the key to ‘OFF’ or ’ON’ position unlocks the
steering.
Leaving the key in ‘ON’ position will drain the battery when vehicle
is not in use . So “Switch off” and take the key out when the vehicle
is not in use.
CAUTION
Never attempt to move the vehicle when the steering is locked, you
may lose the balance.
WARNING
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KNOW YOUR TVS StaR HLX 150

SPEEDOMETER ASSEMBLY
1. Speedometer
Indicates the road speed in kilometers per hour.
2. Odometer
Registers the total distance covered by the vehicle in
kilometers.
Last digit of the odometer denotes one tenth of a kilometer.
3. High beam indicator
When the head lamp high beam is ‘ON’, a blue indicator
( ) glows.
4. Turn signal indicator left
When the turn signal lamp switch knob is operated to the
left side ( ), the left side turn signal indicator lamp flashes.
5. Gear position indicators
Indicates the gear position. When the gear position
becomes neutral, a green colour neutral indicator ( N )
st nd rd th
glows. All other gear positions (ie. 1, 2, 3 and 4) are
indicated with the number and glows in amber colour.
6. Turn signal indicator right
When the turn signal lamp switch knob is operated to the
right side ( ), the right side turn signal indicator lamp
flashes.
7. Fuel gauge
Fuel gauge indicates the approximate quantity of fuel
available in the fuel tank.
1
2
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5
6
7
34

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KNOW YOUR TVS StaR HLX 150
HANDLE BAR LEFT SIDE
1. Choke lever
Choke is required for starting a cold engine.
Choke lever is provided on the left side of handle bar. Pull
the lever to switch ‘ON’ the choke. Once the vehicle is
started and engine is running at stable speed, release the
lever to its original position.
2. Horn button
Press the knob ‘ ’ to operate the horn.
3. Turn signal lamp switch
When the turn signal lamp switch knob is pushed to the left
side ( ) or right side ( ), the turn signal lamps flashes
along with the indicator.
4. Clutch lever
Use clutch lever to disengage the drive to the rear wheel
while shifting the gears. Pressing the lever disengages the
drive.
1
CAUTION
WARNING
2
3
5 6
Always use choke for cold starting.
Never open the throttle when the choke is applied, it may lead to
flooding of engine and difficulty in starting.
5. Pass by switch
The head lamp high beam glows when the pass by switch
knob ( PASS ) is pressed.
Press the knob intermittently while overtaking another
vehicle during day time to give signal to the opposite
vehicles.
Always use the appropriate turn signal lamps when you intend to
change lanes or take turns. Be sure to switch ‘OFF’ the lamps after
negotiating the lanes or turns.
4

6. Head lamp high/low beam switch
Press the knob towards ‘ ’ to operate the head lamp high
beam.
Press the knob towards ‘ ’ to operate the head lamp low
beam.
HANDLE BAR RIGHT SIDE
1.Electric Starter Switch
Press the switch ‘ ‘ to start the engine electrically even
when the vehicle is in any gear.
2. Head lamp switch
Head lamp switch has two positions ‘ ’and ‘ ’ to control
head lamp.
Off : Head lamp, speedometer lamps and tail lamp
are ‘OFF’ when the knob is positioned at ‘ ’.
On: Head lamp, speedometer lamps and tail lamp
glows when the knob is positioned at ‘ ’ and
engine is running.
3. Throttle grip
Engine speed is controlled by the rotation of the throttle
grip. Twist it towards you to increase the engine speed. Twist
it away from you or release it to decrease the engine speed.
4. Front brake lever
The front brake is applied by pressing the front brake lever
gently towards the throttle grip. Brake lamp also glows on
application of brake.
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14
Use appropriate head lamp high/low beam as per the traffic and
road conditions for your safety and to avoid inconvenience to the
riders.
WARNING
4
123
5

5.Hazard switch
Hazard switch is provided to use whenever you find it
necessary to park the motorcycle in a hazardous location
due to emergency situation. Pressing this switch away from
you with the ignition ‘ON’ condition makes all the turn
signal lamps to flash simultaneously to make other road
users aware of the presence of the vehicle.
FUEL TANK CAP
To open the fuel tank cap, move away the lid from its
position, insert the control key into the key hole, turn it
clockwise and lift the cap. Press the cap back to its original
position for closing. Take out the and move the lid back to
its original position.
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WARNING
Avoid spilling of fuel on the hot engine. Never refill fuel near open
flame. Do not smoke while refueling. Do not use cell phones while
refueling.
CAUTION
Whenever refueling the bike, fill upto the bottom of neck portion of
the fuel tank. Filling above the neck may result in improper
breathing of fuel tank.
FUEL COCK
Fuel cock has the following three positions:
ON: Fuel flows in this position when the fuel is above the
reserve level in the tank.
RES: Switch over the fuel cock lever to this position when
the fuel stops flowing in ‘ON’ position.
OFF: Fuel flow cuts off from the tank to carburettor.

KICKSTARTER LEVER
The kickstarter lever is located on the right side of the
engine. The engine can be started by kicking the lever while
the ignition key in ‘ON’ position and keeping the
transmission in neutral.
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ON
RES
CAUTION
Do not position the fuel cock lever between ‘ON’ and ‘OFF’ position
as this may drain off entire fuel while riding the vehicle.
It is good practice to turn the fuel cock lever “OFF” position, when
the engine is not running.
NOTE
While riding with fuel cock lever in ‘ON’ position and if the
fuel in the tank reaches reserve level, you may experience
engine sluggishness and jerky feeling. Take the vehicle to
the left side of the road while taking care of traffic and
change the fuel cock lever position to ‘RES’.
WARNING
It is recommended always to start the vehicle keeping the gear in
neutral position.

4
3
2
1
N
N
1
2
3
4Higher gears
Lower gears
GEAR SHIFT LEVER
Gear shift lever is located on the left side of the vehicle.
Shifting into the higher gears from neutral position is
accomplished by depressing the clutch lever and pressing
the front end of shifting lever by toe and down shifting to
lower gears by pressing the rear end of the lever by heel
once for each gear.
REAR BRAKE PEDAL
Rear brake pedal is located on the right side of the vehicle.
Press the rear brake pedal with your right foot to apply the
rear brake. The brake lamp glows on application of brake.
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KNOW YOUR TVS StaR HLX 150
Brakes are items of personal safety and should always be
maintained in proper condition.
WARNING

23
1
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18
Never sit on the vehicle when it is supported by side stand. Always
park the vehicle on a flat, firm surface.
CAUTION
WARNING
Always release side stand to its full up position before putting the
vehicle in motion.
2
1
1A
CENTRE STAND AND SIDE STAND
TVS StaR HLX 150 is equipped with centre and side stand.
To place the vehicle on the centre stand (1), hold the handle
bar left grip with left hand and pillion handle with right
hand. Place your foot firmly on the centre stand extension
(1a) and press down with adequate effort. Ensure both the
legs of centre stand are touching ground before placing the
vehicle on the stand.
Side stand (2) can be operated with your foot by pushing it
away from the vehicle till it stops.
COVER FRAME L
TVS StaR HLX 150 is provided with lockable cover frame on
the left side. Open the cover frame to access tool kit and
battery assembly.

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KNOW YOUR TVS StaR HLX 150
While reassembling the cover frames, see that the rubber cushions
provided for the cover lugs are in place.
CAUTION
1. Insert the key in the cover frame at lock (1) and rotate it
in clockwise direction.
2. Pull out the cover frame gently at (2), slide it forward at
(3) and take out.
Reassembly
1. Assemble the cover frame by carefully sliding the rear
portion (3) on to the hook on the frame while ensuring
the availability of rubber cushion on the hook.
2. Locate its lug (2) on the hole provided in the fuel tank
while ensuring the availability of rubber cushion on the
hole, gently press and lock with the key by rotating in
anti-clockwise direction.
COVER FRAME R
Cover frame R can be removed by removing the mounting
screw (A). Follow the procedure of cover frame L removal
and reassembly.
TOOL KIT
To assist you in performing certain aspects of maintenance
and emergency repairs, a tool kit is supplied along with the
vehicle and is located below the cover frame L.
Remove the cover frame as explained earlier.
The tool kit consists one number each of the following:
1. 16 mm box spanner
2. 14x17 mm open end spanner
3. 10x12 mm open end spanner
4. Combination screw driver bit
5. Screw driver handle
6. Tool bag
A

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SMART PHONE CHARGERS
An all new smart phone charging port has been provided
above the speedometer assembly of your vehicle.
Please follow the guidelines provided for using it properly:
DO'S
1. Ensure that no water enters into the unit, by closing
the USB flap properly.
2. Use only mobile phone company's authorized USB
cable for mobile charging.
3. Ensure the flap is not damaged while opening/ inserting
the USB cable.
DON'T'S
1. Do not leave the USB charging flap open/partially
closed when not in use.
2. Do not attempt to use/charge any other device, other
than one mobile phone at a given time.
3. Do not try to force the USB connector in, check if it is
inserted in the appropriate direction, to prevent
damage.
It is recommended to use the tool kit in case of any emergency only.
It is always advisable to take your vehicle to TVS Motor Company
Authorised Dealer/Authorised Service Centre.
CAUTION
4. Do not charge your mobile when engine is off.
5. Do not use other device, this port is for charging mobile
phones only.
The charging time of the mobile may vary, depending on
the mobile battery’s state of charge.
The flap in the unit has been designed to prevent water
entry and is not replaceable.
TVS is not responsible for any damage to mobile phones in the event
of fall while charging during vehicle moving.
CAUTION