TVS MOTOR COMPANY,
Marketing (Service),
Post Box No.4, Harita,
Hosur - 635 109,
Tamilnadu.
Tel : 04344 - 276780 - 84 ( 5 Lines )
Fax : 04344 - 276878, 277311
Page 1: ...SER INF MAN APACHE RTR Revision 3...
Page 2: ...on available at the time of printing TVS MOTOR COMPANY LIMITED reserves the right to mak changes at any time without prior notice and without incurring any obligation whatsoever No part of this public...
Page 3: ...NTENANCE TUNE UP PROCEDURE 5 3 5 SERVICING OF ENGINE 4 FUEL LUBRICATION AND EXHAUST SYSTEM 6 5 ELECTRICAL SYSTEM 6 6 CHASSIS 7 to 9 7 SERVICE INFORMATION 10 8 FREE PAY SERVCES WARRANTY 10 9 PRE DELIVE...
Page 4: ...kl can remove the flap rear fender mud flap rear from the rear fender assembly The flap rear fender can be assembled back during rains or whenever required The Flap rear fender will be sent separately...
Page 5: ...lter element Oil filter Wire mesh and micronic paper filter Lubrication system Forced wet sump Compression ratio 9 5 1 Maximum power in kW 12 52 17 bhp 8500 rpm Maximum torque 15 5 Nm 6500 rpm Maximum...
Page 6: ...DC twin electrode Battery type 12V 9 Ah Body earthing Negative Generator Fly wheel magneto 12V 100W Head lamp Halogen HS 12V 35 35W Position lamp 12V 4W x 2 Tail lamp Brake lamp LED indicators 0 5W 3...
Page 7: ...rial no manufacturer Y ar code identifier identifier ENGINE NUMBER 1 The Engine serial number is engraved on the left side cran case near cylinder block Location same as Apache RTR 2 Eng ne type code...
Page 8: ...procedures and instructions on the following refer Apache Service Manual SER MAN APACHE 01 Revision 0 August 2006 Page No 1 8 to 1 10 1 Running in p riod 2 Fuel and oil recommendations 3 Precautions a...
Page 9: ...eding from brake system and brake fluid replacement Inspection of hose complete brake 12 Wheel assembly front rear 13 Inspection and adjustment of chain 14 Inspection of tyres and tyre pressure 15 Ins...
Page 10: ...SAI 2 3 Part Numbers of Exclusive Child parts of carburettor Carburettor assembly N9041400 Ring jet needle N9322960 Jet needle N9322870 Piston valve N9322880 Mixture control screw MCS N9322940 Needle...
Page 11: ...6...
Page 12: ...Servicing of tubeless tyre 3 Removal and re assembly of Flap rear fender PUNCTURE REPAIRING PROCEDURE TUBELESS TYRES Unlike the normal tyre tube vehicles to repair a puncture in a Tubeless tyre the t...
Page 13: ...ig 4 Insert the reaming tool and carefully ream the Puncture hole location at the marked area Ref fig 3 Step 4 Take the cold mending strip and insert it in the slot provided in the Strip inserting too...
Page 14: ...moval of tubeless tyre is necessary using a tyre demounting machine to remove the tyre from the wheel rim Re assembly of the tyre also must be done in similar way using the tyre de mounting machine In...
Page 15: ...8...
Page 16: ...Step 1 Loosen and remove 1 no of reflector mounting nut A from the flap rear fender using 8 mm spanner Step 2 Loosen and remove 1 no of CRR pan head screw B from flap D rear fender bottom mounding usi...
Page 17: ...losed end gap 2 nd 0 350 0500 0 7 Top 0 015 0 045 0 12 6 Ring groove clearance 2 nd 0 015 0 045 0 10 Top 0 8005 0 820 __ 7 Ring piston groove width 2 nd 0 8005 0 820 __ Top 0 775 0 790 __ 8 Ring thick...
Page 18: ...s 2 2 Rider Pillion footrest rubber 2 3 Any other items 3 Fasteners Tightness 3 1 Front Axle Nut 3 2 Rear Axle Nut 3 3 Rear shock absorber mou ti g uts 3 4 Swing Arm Nut 3 5 Engine mounting bolts 3 6...
Page 19: ...Fuel leak if any 5 7 Any abnormal Noise 6 Electrical check Engine running 6 1 Head lamp Parking lamp ON OFF 6 2 High beam Low beam Focus 6 3 Rear combination lamp Brake Tail LED 6 4 Speedo panel bulbs...
Page 20: ...part available at dealership under old part number must be used only for RTR 160 cc Do not use the old Part in RTR 180 cc 7 Only new part will be serviced in spares MUFFLER COMPLETE 1 Muffler complet...
Page 21: ...dentified by USHA 50 engraved on the top surface of both the rings CAR URETTOR ASSEMBLY Red in 1 Carburettor Assembly N9041400 colour 2 New Part to match increased engine capacity 180 cc 3 Not interch...
Page 22: ...LY 1 Oil pump assembly N9080240 Step 2 New part 3 Oil pump capacity incr as d by 1 2 Litre per minute for better lubrication 3 Oil pump alone without the driven gear is not interchangeable with existi...
Page 23: ...c vehicles CHASSIS HANDLE AR ASSEMBLY 1 Ha dlebar complete LH N9151400 Ha dlebar complete RH N9151390 2 Ha dle bar complete LH RH finish changed to black colour 3 Can be interchanged with existing RTR...
Page 24: ...pip provid d the lower bracket complete 5 The modified part can be interchangeable with existing Apache RTR 160 vehicles 6 Only mod f ed part will be serviced in spares LEG ASSEM LY FRONT FORK 1 Leg...
Page 25: ...vicing Cleaning lubrication the O Ring chain if necessary 4 Not interchangeable with existing RTR 160 vehicles CHAIN COVER 1 Chain cover N9091700 2 Chain cover is modified with releif cut to suit modi...
Page 26: ...uminator N9222020 2 New part to suit new rear fender 3 Not interchangeable with existing RTR 160 vehicles WHEEL ASSEMBLY FRONT TUBELESS 1 Wheel assembly front N9112890 Alloy wheel front N9112860 Tyre...
Page 27: ...mbly an be used 6 Valve Tubeless tyre will be servi ed under this part No N9112880 SAREE GUARD COMPLETE 1 Saree guard compl te N9221710 2 No Change in Part No 3 Saree guard is modified to new styling...
Page 28: ...TVS MOTOR COMPANY Marketing Service Post Box No 4 Harita Hosur 635 109 Tamilnadu Tel 04344 276780 84 5 Lines Fax 04344 276878 277311...
