Sugarcane (Saccharum officinarium L.) varieties CP-43/33 and L-118 susceptible, BF -162 and SPSG- 26 resistant while CP-72/2086 as intermediate were screened for studies on top borer, Scirpophaga nivella Fabricus (Pyralidae: Lepidoptera). Morpho-physio chemical plant factors as well as quality of sugar were examined to elucidate the relationship between pest infestations. The observations on leaf thickness $0.735^{ast}$ and moisture contents $0.771^{ast}$ showed positive and significant correlation with the pest infestation at tillering stage. Total minerals, manganese and copper contents did not show significant correlation with the pest infestation, whereas nitrogen, potassium, calcium, magnesium and ferrous contents manifested positive and significant correlation with the pest infestation. Phosphorous, carbohydrates, fats and zinc produced significant and adverse effect on the pest infestation at tillering stage. Zinc contents with contrasting behaviors appeared to be the most important character with co-efficient value of 0.764 followed by ferrous with positive sign. The effect of borer infestation was significantly negative on pol (sucrose), Brix contents (total soluble solids), and CCS (commercial cane sugar). The coefficient of determination value was 0.821, obtained by computing fiber content, pol, Brix and CCS factors together for multivariate regression models. Application of trash mulching at the time of sowing proved to be the most effective treatment with minimum infestation $(3.91\%)$ of borer and maximum protection level $(62.87\%)$ followed by Furadan, removal of dead hearts+ spike thrust, hand collection of egg masses, and cutting of shoots at 15 days interval.