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TVS Apache RTR 160 BS-VI, Owner'S Manual

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TVS Apache RTR 160 BS-VI Owner'S Manual Download Page 75

62

6.   For locating and reassembling the rear wheel 

easily, engage the gear. This will arrest the free 

movement of the drum sprocket.

7.  Reverse the procedure for reassembly.

Once the split pins are removed, replace them with new 

ones.

REAR WHEEL REMOVAL AND REASSEMBLY - 
DRUM TYPE

1.  Remove the rear brake adjuster nut (1) and 

disconnect the brake rod. 

2.  Remove the split pin (2) and the nut (3) from the 

torque link mounting with the brake panel and 

disconnect the torque link.

3.  Remove the axle nut (4).
4.  Pull out the axle (5) and take out the spacer bush 

from the rear wheel assembly.

5.  Tilt the vehicle to the left and take out the wheel 

assembly along with brake panel. Separate the 

brake panel from the wheel.

5

1

4

2

3

Summary of Contents for Apache RTR 160 BS-VI

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Page 3: ...over for addresses Or Toll Free Number 1800 258 7111 Email customercare tvsmotor com Disclaimer TVS Motor Company or any of its officials Authorized Main dealer Authorized Dealer do not ask customers for bank card wallet details authentication In case you face any such claim please report to the relevant local authorities immediately ...

Page 4: ...o 2 MC Nichols Road Chetpet Chennai 600 031 Phone 044 28361651 28361654 Email AO Chennai tvsmotor com AO Madurai tvsmotor com TAMILNADU 2 2 TVS Motor Company Limited No 10 2nd floor Shree Shanmugapriya Towers Kannuswamy Street Behind Hotel Annapoorna R S Puram Coimbatore 641 002 Phone 0422 4350060 2541035 Email AO Coimbatore tvsmotor com KERALA 3 TVS Motor Company Limited Ambady Towers Second Floo...

Page 5: ...ity Near Brindhavan Dhaba Hosangabad Road Bhopal 462 026 Phone 0755 2499406 2499306 Email AO Bhopal tvsmotor com AO Indore tvsmotor com RAJASTHAN 1 2 10 TVS Motor Company Limited Plot No 17 18 2nd Floor of National Motors Building Jhotwara Industrial Area Jaipur 302 012 Phone 0141 5150901 5150902 Email AO Jaipur tvsmotor com AO Udaipur tvsmotor com DELHI HARYANA 11 TVS Motor Company Limited D 3 D ...

Page 6: ...ve Plaza Rasulgarh Bhubaneshwar 751 010 Phone 0674 2580019 Email AO Bhubaneshwar tvsmotor com NORTH EAST STATES 18 TVS Motor Company Limited 147 Udayan Ganesh Guri Opp Punjab National Bank R G B Road Guwahati 781 005 Phone 0361 2202030 2202031 Email AO Guwahati tvsmotor com ...

Page 7: ... of any sport bike we have ever made It is the lightest fastest stopping quickest lapping TVS bike in history For the first time TVS Racing s Dirt and Road racing technology have been combined to create a racing bike that is Street Legal but just barely The results are stunning DESIGNED BYTHE RACETRACK The look and stance of the RTR 160 were designed by the combination of race track technology tra...

Page 8: ... year round Breakfast ride Overnight ride Marquee ride Chapter ride Apache Racing Experience If you have the mettle we have the track Apache Racing Experience ARE a flagship property of TVS Racing Apache is the embodiment of our philosophy the bikes we race are the bikes we sell Hone your racing skills and techniques with the INMRC Champion riders from TVS Racing and test the limits of your machin...

Page 9: ...formance Gear an entire range of riding gear designed to offer you the ultimate riding experience With utmost safety and extreme comfort it lets you take on every terrain and any weather With the range of urban wear you can wear your passion even off track And the racing DNA woven in is all you need to get your podium look on https accessories tvsmotor com performance gear aspx To know more log on...

Page 10: ...hed It started a revolution in racing and continues to dominate with 90 of race wins and multiple national championships TVS Racing wins their 18th Championship title TVS Racing won SLADA and Sri Lanka National Championship in 2011 2016 and 2017 First factory team in India to sign a woman rider and launch a dedicated road racing cup for women Won 12 national championships Supercross Motocross and ...

Page 11: ...r 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 fo...

Page 12: ...associated with operating or maintaining the vehicle you must use your own judgement You will find important safety information in following form in the owner s manual as well as the service handbook These words carry the following connotations Disregarding this message might result in injury to the rider or deadly accidents This message indicates special procedures or precautions to be followed t...

Page 13: ...YSTEM 02 SAFE RIDING TIPS 07 KNOW YOUR TVS APACHE RTR 160 11 RIDING YOUR TVS APACHE RTR 160 34 MAINTENANCE 40 WARRANTY AND SERVICES 66 SERVICE INFORMATION 70 EXPRESS SERVICE 71 EXPERT ON WHEELS 72 PICKUP AND DROP 73 TECHNICAL SPECIFICATIONS 74 GENERAL INFORMATION 77 ...

Page 14: ...ee 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 RUNNING IN INFORMATION Replacing the engine cum transmissio...

Page 15: ... riders who drift Preventing the wheels from slipping due to excessive braking force compensates losing control and help the rider to maneuver the vehicle and to avoid accidents So what the ABS does is actually limiting the braking force exerted by the rider by either squeezing the lever and keep the wheel spinning Once the imminence of the locking and therefore skidding is avoided the system re a...

Page 16: ...umstances arises the system reacts instantly and adjusts braking force accordingly to achieve optimum braking Why does brake lever pulsate during brake application Vehicles fitted with ABS uses the conventional brake system during normal operation But during hard stop the brake lever feels different i e a rapid pulsation in the brake lever This is absolutely normal HECU HECU Wheel speed sensor Whe...

Page 17: ...aches 7 km h speed and above and the ABS warning lamp blinks whenever the bike speed is less than 7 km h speed indicating that the ABS is working fine If the warning lamp glows continuously even after the bike crossing 7 km h speed or if the ABS lamp is not blinking or glowing at all then the ABS has an error and your bike should be taken to any of our nearest TVS Motor Company Authorised Main dea...

Page 18: ...Do not test the ABS on road but use ABS it is already tested Do not use non genuine spares like pads discs tyres etc Do not try to service HECU or open to separate parts Do not disengage the ABS by removing the ABS coupler Incase of ABS failure the braking system will work like a non ABS braking system and provides normal stopping distance This motorcycle is equipped with ABS on front wheel and tu...

Page 19: ...ride at a suitable speed while taking care of conditions and road surface ABS will not compensate for errors in the judgement or improper brake use in the various situation ABS never eliminates the danger of falling while turning Hard braking during sharp cornering on slippery surface may lead to vehicle instability Under such circumstances gradual braking is recommended ...

Page 20: ...ing can be uncomfortable and unsafe when riding a two wheeler Choose good quality two wheeler riding apparel Know your limits Ride within the boundaries of your own skill at all times Knowing these limits and staying within them will help you avoid accidents Two wheeler safety starts with wearing a good quality helmet One of the most serious injuries that can happen is a head injury Always wear an...

Page 21: ...e open area to thoroughly familiarise with the operation of the vehicle 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 the radius of the corner During cornering reduce speed so as to reduce the effects of centrifugal force Avoid abrupt application of brake or sudd...

Page 22: ...her 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 3 Approximately 60 braking effect is from front brake Non usage of front brake causes poor braking ACCESSORY INSTALLATION AND SAFETYTIPS Use extreme caution while selecting and installing the accessories for your motorcycle The addition of unsuitable ac...

Page 23: ...nkcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the fuel system Evaporative Emission Control System The TVS Apache RTR 160 is equipped with an evaporative emission control system which consists of a canister and associated piping This system prevents the escape of fuel vapors from the fuel ta...

Page 24: ... for ordering parts or referring to special information KNOWYOURTVS APACHE RTR 160 Frame serial number is engraved on the right side of the steering head tube as shown in the above figure Engine serial number is engraved on the left side crankcase assembly near cylinder block as shown in the above figure Frame number Engine number Control key number Please fill the above boxes now for future refer...

Page 25: ...ylinder front 4 Engine cut off switch 5 Rear view mirror R 6 Front brake lever 7 Throttle grip 8 Electric starter switch 9 Fuel tank cap 10 Horn switch 11 Turn signal lamp switch 12 High low beam switch 13 Clutch lever 14 Rear view mirror L 15 Pass by switch 2 1 3 5 4 8 11 15 14 7 9 10 12 13 6 ...

Page 26: ... LEFT SIDE 1 Saree guard 2 Rear wheel axle 3 Rear shockabsorber L 4 Pillion foot rest L 5 Rider foot rest L 6 Side stand 7 Center stand 8 Gear shift lever 9 Front wheel axle 10 Cover frame L 11 Pillion handle 10 11 2 9 7 6 5 8 3 4 1 ...

Page 27: ...nsor front 5 Toner ring front 6 Caliper assembly front 7 Location of spark plug 8 Gauge oil level 9 Rear brake pedal 10 Rider foot rest R 11 Pillion foot rest R 12 Rear shockabsorber R 13 Disc plate rear 14 Muffler assembly 15 Cover frame R 1 15 2 11 12 13 7 10 9 8 3 4 5 6 14 Applicable only for rear disc brake model ...

Page 28: ...mp assembly 3 Crash guard 4 Position lamps 5 Turn signal lamp front R REAR 1 Turn signal lamp rear R 2 Reflex reflector 3 Number plate lamp 4 Turn signal lamp rear L 5 Tail lamp assembly 6 Pillion handle License plates are mandatory accessory will be charged extra 1 2 3 4 6 5 2 1 3 5 4 ...

Page 29: ... can be started Control key cannot be taken out from the lock 3 LOCK position Your TVS Apache RTR 160 steering can be locked in both left and right directions Turn the handlebar to the left or right Press the key IN and rotate it to the LOCK position from OFF position All the electrical circuits are deactivated and the steering is locked The control key can be removed from the lock Insert the cont...

Page 30: ...amps tail lamp and number plate lamp glow automatically once the ignition is turned ON without activating any other switch When the ignition is turned ON the instrument cluster performs self diagnostic cycle count down starts Wait till the messgae GO appears on the insturment cluster s dial Never attempt to move the vehicle when the steering is locked you may lose balance Leaving the ignition cum ...

Page 31: ... indicator glows when the battery charge is too low Get the battery checked at TVS Motor Company Authorised Main Dealer Authorised Dealer 5 ABS warning lamp ABS warning lamp blinks when the ignition key is turned ON and speedometer performing self check This lamp goes OFF once the vehicle reaches 7 km h speed and above If this lamp glows continuously then have your vehicle checked at TVS Motor Com...

Page 32: ...l no 2 starts glowing continuously If all the fuel level bars in the cluster are blinking contact nearest TVS Motor Company Authorised Main Dealer Authorised Dealer If the battery is disconnected and reconnected during service You may need to reset the time as explained in page No 23 8 Turn signal indicator Flashes when the left or right side turn signal indication is activated 9 Digital clock Dig...

Page 33: ...O segments are blinking while the vehicle is in move Contact nearest TVS Motor Company Authorised Main Dealer for rectification 12b Trip meter A B In ODO mode press the mode button once and twice to enter TRIP A and TRIP B meters respectively Trip meter indicates the trip distance travelled in kilometer The digit after the dot mark denotes the one tenth of a kilometer Provision to measure two diff...

Page 34: ...splay will go off automatically once the vehicle starts moving 1 km h and it will continue the normal operation Max speed recorded will be stored until manual reset If the high speed is reset the speed value will be shown as 0 12d Shortest time indicator Shortest time indicator records the minimum time taken so far to reach 60 km h speed You can reset and record new time if required Set the meter ...

Page 35: ...meters respectively To reset any of the trip meter while ensuring the display is in TRIP A or TRIP B press and hold the Set switch B for a few seconds 2 Press the Mode switch till the display appears to set the HIGH SPEED indicator mode To reset the high speed recorded keep the display in mode and press hold the Set switch for a few seconds 3 Press the Mode switch till the display changes to to se...

Page 36: ...s while hours digits are blinking 5 To access the minutes press the Set switch again for a few seconds 6 Press the Mode switch to increase the minutes while minutes digits are blinking 7 Press the Set switch to exit the setting HANDLE BAR LEFT SIDE 1 Horn switch Press the switch to blow horn It is used to attract the attention of other road users in case of danger 2 Turn signal lamp switch When th...

Page 37: ...eady glowing in High beam the pass by system will not work 5 Head lamp high low beam switch The head lamp glows automatically once the engine is started Only the head lamp beam high low can be controlled with the beam control switch Press the top end of switch for High beam and bottom end for Low beam Once the engine is started the head lamp glows automatically Only head lamp beam high low can be ...

Page 38: ... is applied by pressing the front brake lever gently towards the grip The brake lamp glows on application of front brake 4 Throttle grip It controls the fuel air mixture supplied to the engine which regulates the engine speed Rotate the throttle grip in counter clockwise from its idle position to increase the engine speed and vice versa to reduce 3 2 4 1 Ensure to turn ON the engine cut off switch...

Page 39: ...l tank cap 1 is provided inTVS Apache RTR 160 To open the fuel tank cap lift the protection lid 2 insert the control key into the lock turn it in clockwise direction and take out the tank cap along with the key To close the cap press the cap gently in its position by keeping the front end towards the handles Take out the key while ensuring the proper locking of the cap and close the protection lid...

Page 40: ...he hose Never fill fuel beyond the fuel tank inlet 1 Filling above the inlet may result in improper breathing of fuel tank which leads to difficulty in starting as well as improper running of the vehicle Whenever refueling the bike fill only the recommended quantity of fuel 12 liters including reserve Do not clean the vehicle by laying down on floor to avoid fuel entry into EVAP system This vehicl...

Page 41: ...er up Lifting the lever up repeatedly engages all the gears in succession up to the fifth gear 1 1 N N 2 2 3 3 4 4 5 5 Never shift gears without disengaging the clutch and releasing the throttle Failure to comply this will lead to rough shift or jerk while shifting the gears Remember to return to neutral position before restarting the engine Gear shift lever position can be set to your convenience...

Page 42: ...odification in the vehicle remove the air duct or block the air duct passage Else it will lead to over heating of engine and muffler Ensure not touch or bring any flammable objects near the muffler which may lead to severe burns CATALYTIC CONVERTER The Apache RTR 160 has a dual catalytic converter to reduce and to meet the emission norms Muffler temperature near the catalytic converter can go very...

Page 43: ...ition Incase of rear drum brake model after setting the brake pedal position adjust the rear brake paly as explained in page No 55 Independent use of rear or front brake reduces the overall braking efficiency In extreme conditions braking with only rear or front brake may lock the wheel which would result in skidding or toppling of vehicle Braking performance is affected adversely with wet surface...

Page 44: ...round before placing the vehicle on the stand Side stand can be operated by sitting on the vehicle with your left foot by pushing it away from the vehicle to its extreme end Do not sit on the vehicle when it is parked on the side stand centre stand as your full weight would rest on the vehicle s only support Park the motorcycle safely on a solid ground On slopes engage the first gear and park the ...

Page 45: ...over frame by gently pulling out at front 2 and rear 3 end of the cover frame 1 2 3 To assemble the cover frame back 1 Locate the lugs of the cover frame at 2 3 to the holes provided in the fuel tank assembly and the frame while ensuring the availability of the cushion in the holes 2 Gently press the cover frame lugs into the holes 3 Now lock the cover frame by turning the key in anti clockwise di...

Page 46: ...rgency only It is always advisable to take your vehicle to TVS Motor Company Authorised Main Dealer Authorised Dealer Do not remove the tool kit and first aid kit from the vehicle Always ensure to keep them along with the vehicle Ensure the first aid equipments are changed periodically based on the date of expiry To access the tool kit first aid kit open the cover frame R as explained in the previ...

Page 47: ...ks or cuts Battery Proper working of all lamps horn and pass by switch Low battery indication and battery charge page No 46 Instrument cluster Performing self check Proper working of ABS warning lamp page No 18 Malfunction indicator Turned OFF after starting the engine page No 17 Steering Smooth movement No play or looseness Throttle Correct free play of cable Smooth operation Clutch Correct free ...

Page 48: ...hrottle when the vehicle is parked It leads to overheating of engine and damage to the internal components SETTINGTHE VEHICLE IN MOTION Press the clutch lever and engage first gear by pressing the gearshift lever down Open the throttle slowly and simultaneously release the clutch lever gently and gradually The vehicle starts moving forward As the vehicle picks up speed shift to the next higher gea...

Page 49: ...er pressed disengaged as the road speed decreases Bring the engine to neutral position just before the vehicle stops 3 Turn the ignition OFF 4 Park the vehicle on a firm flat surface 5 Lock the steering Reduce speed to a safe limit before turning cornering Do not apply brake while turning cornering Do not disengage clutch before braking Since the engine and exhaust system becomes very hot make sur...

Page 50: ...e fuel ensuring trouble free enjoyable and safe riding besides keeping the environment clean Spark plug A dirty or defective spark plug leads to wastage of fuel due to incomplete combustion Inspect and clean the spark plug if necessary Visually inspect the spark plug gap If the gap is found more replace the plug with a new one However the spark plug need to be replaced every 12000 kms or 1 year wh...

Page 51: ... between various parts of the engine and reduces the engine life thereby increases fuel consumption Regularly inspect the engine cum transmission oil for correct level and top up if necessary Get it replaced at regular intervals as per the maintenance schedule Always use TVS TRU4 FULLY SYNTHETIC oil only SAE 10W 30 API SL JASO MA2 Fuel leak If any fuel leak from tank is suspected tow the vehicle t...

Page 52: ...also creates a potentially dangerous traffic situation Fuel is wasted whenever the rider suddenly accelerate or apply brake Avoid unnecessary idling While waiting for someone or stopping in signals for long time if the engine is kept running at idle speed it causes unnecessary wastage of fuel Avoid frequent braking Anticipate corners and slopes as well as the traffic conditions Unnecessary and fre...

Page 53: ...items and require very special and careful servicing TVS Motor Company Limited strongly recommends that the jobs as per the maintenance schedule be performed by your TVS Motor Company Authorised Main Dealer Authorised Dealer Periodic inspections may reveal one or more parts that may need replacement Whenever replacing parts on TVS Apache RTR 160 it is recommended that you use only the TVS Motor Co...

Page 54: ... A I A I A I A Adjust if required Clutch plates Inspect replace if required every 21000 km Engine breather hose I I I I I I Replace every 21000 km if required Throttle body rubber ducts I I I I I Replace every 21000 km if required Fuel filter I I I I I I Hose fuel with respective clamps I I I I I I Replace every two years or 21000 km Clutch and throttle cable play2 I A L I A L I A L I A L I A L I ...

Page 55: ...nd switches I I I I I I Inspect for proper functioning Head lamp beam I A I A I A I A I A I A Battery voltage5 I I I I I I Brake effectiveness I I I I I I Brake pedal shaft L L L L L L Lubricate using TRU4 oil 3 Inspect for smooth steering rotation steering shake noise Adjust the steering if necessary 4 Inspect for smooth and proper function of front and rear suspension Also inspect for any visual...

Page 56: ...I I Replace if damage Brake hose bundy tubes I I I I I I Replace every 30000 km Bundy tube mounting all joints I TI I TI I TI I TI I TI I TI Inspect for leak HECU mounting cushions I I I Replace every 30000 km Toner rings teeth damage I I I I I I Replace if necessary Malfunction codes MIL check I I I I I I Master cylinder cups Replace every 21000 km Wheel freeness I I I I I I Tyre pressure at cold...

Page 57: ...months 6 months 9 months 12 months Evaporative emission control I I I I I I Check for intactness of system hoses and canister Fuel tank assembly I C I C I C I C I C I C Check for abnormal vehicle jerk noise while opening the cap leak If found any contact TVS Motor Company Authorised Main Dealer or Authorised Dealer R Replace I Inspect T Top up C Clean A Adjust DR Drain L Lubricate TI Tighten S Set...

Page 58: ...RU4 FULLY SYNTHETIC oil 1100 ml after disassembly SAE 10W30 API SL JASO MA2 Front fork oil 140 2 ml leg Gabriel make IOC Castrol Teleshockab oil 152 2 ml leg Top make Disc brake fluid TVS Girling DOT 3 DOT 4 Grease Bharat petroleum MP Grease no 3 IOC Servo Gem no 3 Bechem Bechem premium grade 3 Chain lubricant TVS Motor Company TRU SPRAY ...

Page 59: ...any Authorised Main Dealer Authorised Dealer 3 Apply petroleum gelly to the terminals to avoid corrosion 4 Do not add additional electrical accessories Never check the battery charge by shorting the terminals Always connect the positive terminal first red wire and then negative black wire to avoid sparking The inversion of the battery wires can damage the battery and the recharging system If the m...

Page 60: ...use box contains two 10A fuses one 15A fuse and one 5A fuse Out of this one 10A fuse is used for ABS system while the other one is used for EMS system 15A fuse used for DC loads and the 5A fuse is used for ABS system again Use the fuse puller A placed near the fuse box to pull out the blown fuse 5 Replace the blown fuse with a new one with same rating extra fuses are provided inside the fuse case ...

Page 61: ...system lncase if the fuse fails again consult the nearest TVS Motor Company Authorised Main Dealer Authorised Dealer SPARK PLUG 1 Wipe and clean the dust and mud around the spark plug mounting to avoid their entry inside the cylinder 2 Pullout the suppressor cap from spark plug Remove the spark plug using a plug spanner A spark plug with heavy carbon deposits will not produce strong sparks Hence o...

Page 62: ...er placing the motorcycle in center stand with front wheel touching the ground Always use only recommended make and type of spark plug Replace spark plug every 12000 km or 1 year whichever is earlier Cover the spark plug hole with a cloth when the plug is removed to prevent entry of dust water It is advisable to tighten the new spark plug by hand till the end using plug spanner tighten by 1 4 turn...

Page 63: ...f the oil level is below the minimum level top up with TVS TRU4 FULLY SYNTHETIC oil SAE 10W 30 API SL JASO MA2 upto the maximum level mark Do not overfill 9 Wipe out the oil traces with a clean cloth to prevent dust accumulation and re fix the gauge CLUTCH ADJUSTMENT Clutch lever free play is one of the most important adjustment which you may need to check in between services for better life of th...

Page 64: ...hile holding the clutch cable adjusting nut 1 3 Adjust the clutch cable adjusting nut 1 in or out to give sufficient play in the clutch lever 4 After adjusting the play hold the adjuster nut in the same position tighten the lock nut 1 2 Too much or too less clutch lever free play will damage the clutch plates thereby affecting the performance of the vehicle Adjust the clutch lever free play only w...

Page 65: ... gas filled rear shock absorbers to meet different road and load There are 5 notches for adjusting spring load If the spring is adjusted to the minimum notch then the shock absorber will be softer which is good for light loads If the spring is adjusted to maximum notch then it will be stiffer which is good for heavy loads Adjust the spring pre load by shifting the adjuster to the required notch ac...

Page 66: ...sembly 1 Check the master cylinder brake fluid level through the view piece glass A 2 Brake fluid level always should be above the LOWER mark B on the master cylinder when the master cylinder is parallel to the ground 3 If the brake fluid level is below the mark or while applying brake if you feel the brake is more spongy or ineffective due to air entry contact TVS Motor Company Authorised Main De...

Page 67: ... No 32 for removal procedure 2 Check the brake fluid level in the reservoir It should be between maximum and minimum level 3 If the brake fluid level is below minimum or while applying brake if you feel the brake is more spongy or ineffective due to air entry contact TVS Motor Company Authorised Main Dealer Authorised Dealer for topping up the brake fluid air bleeding and other brake related inspe...

Page 68: ...asure the free play of the rear brake pedal at the pedal end as shown in the figure 1 The free play of the brake pedal before the engagement of brake should be between 15 20 mm Brake pad wear indicator Visually check the brake pads for wear If the wear is found beyond the wear indicator groove as shown in the figure then replace the brake pads as a set with a new one Check the brake pedal play per...

Page 69: ...orrect play 3 Turn the adjuster nut clockwise to reduce the free play or turn it in anti clockwise direction to increase the free play Brake shoe wear indicator When the brake is applied the wear index mark A on the cam brake should be within the range of wear limit indicator B on the rear brake panel assembly In case of the mark going beyond the wear limit index the lever to next slot with the he...

Page 70: ... inflated tyres decreases the tyre contact with the ground which can lead to skidding and loss of control Be sure that the tyre pressure is within the specified limits at all times Solo Pillion Front 1 75 kg cm 25 psi 1 75 kg cm 25 psi Rear 2 00 kg cm 28 psi 2 25 kg cm 32 psi The tyre inflation pressure in cold condition and the tyre thread condition are extremely important for the performance and...

Page 71: ... of any puncture tyre damage it is advised to visit nearest tyre manufacturer Dealer or the tyre repair shops who know the repairing methods of tubeless tyre It is not necessary to remove the tyre from wheel rim always to attend the puncture Even though if there is a need of tyre removal it is strongly recommended to use a tyre removal fitment machine If at all tyre levers need to be used the leve...

Page 72: ...ubricate and adjust the drive chain in the following manner 1 Place the vehicle on centre stand with the transmission in neutral 2 Inspect the drive chain slackness vertical movement using the finger as shown in the figure 3 The slackness of the drive chain should not exceed the limit 20 25 mm 4 If the slackness is found more contactTVS Motor Company Authorised Main Dealer Authorised Dealer for ad...

Page 73: ...evere conditions like dusty muddy wet high speed or frequent starting stopping Ensure proper seating of disc in the caliper assembly while reassembling the wheel Ensure to re fix the spacer and toner ring cover at the respective sides of the wheel Keep the toner ring upwards whenever the wheel is removed in order to avoid damages to the toner ring Damaged toner ring affects ABS function 4 Place a ...

Page 74: ...ssembly by gently tapping it along with the disc 5 For locating and easy reassembly of the wheel enage the gear This will arrest the free movement of the drum sprocket 2 1 6 Re assemble the other parts in the reverse order of removal While assembling the caliper assembly ensure that the slot provided in the caliper is properly located to the lug provided in the swing arm assembly Always make sure ...

Page 75: ...D REASSEMBLY DRUMTYPE 1 Remove the rear brake adjuster nut 1 and disconnect the brake rod 2 Remove the split pin 2 and the nut 3 from the torque link mounting with the brake panel and disconnect the torque link 3 Remove the axle nut 4 4 Pull out the axle 5 and take out the spacer bush from the rear wheel assembly 5 Tilt the vehicle to the left and take out the wheel assembly along with brake panel...

Page 76: ...e spark plug 5 Remove the battery store it away from direct sunlight and freezing temperatures Do not park the vehicle on a slope or soft ground or else it may fall During storage the battery must be recharged on a constant current battery charger at recommended amperage atleast once in a month 6 Place a suitable support at the bottom of the frame so that both the tyres are off the ground This wil...

Page 77: ...ON position Start the engine and allow it to idle for a few minutes and ride out RECOMMENDED TIPS WHEN TAKING A LONG TRIP OF MORETHAN 500 KM A Please keep the following items for use in case of emergency 1 Complete tool kit first aid kit 2 Recommended spark plug one number 3 Head lamp bulb and turn signal lamp bulb each one number 4 Throttle and clutch cables one number each B Precautions to be ta...

Page 78: ...cleanliness 12 Correct idling speed 13 Lubrication of all items mentioned in the periodic maintenance schedule 14 Intactness of EVAP system hoses and canister 15 Any other job as necessary 16 Have your vehicle checked at any TVS Motor Company Authorised Main Dealer Authorised Dealer Long journey are to be taken only after the running in period of 1000 km Ensure the first aid equipments are changed...

Page 79: ... cases the Company s decision either to repair or replace the affected parts will be final In the event of replacement of parts the Company also reserves the right to use parts of the same brand as the affected parts or any other brand which is used by the Company in the course of manufacture All parts replaced under this warranty will become the property of the Company and must be returned to the...

Page 80: ... same and assess the cause for the reported problems produces to such Authorised Main Dealer Authorised Dealer the Service Handbook for the concerned vehicle for verification of relevant details 8 This is the only warranty given by the Company for the TVS Apache RTR 160 No employee Dealer or other person is authorised to extend or enlarge this warranty Modifications to this vehicle not approved by...

Page 81: ...ubber rexine plastic items All hoses pipes and plastic aesthetics Proprietary Items Battery tyres and tubes the warranty terms are subject to our agreement with proprietary OEM Parts of the vehicle getting affected due to atmospheric effect environmental factors rusting paint peel off etc However depending on the vehicle usage condition warranty would be accepted up to 2 years from the date of pur...

Page 82: ...ervice including scheduled paid service is not availed when it falls due at TVS Motor Company Authorised Main Dealer Authorised Dealer Vehicles sold or transferred by original retail purchaser Vehicles used for racing or any competition or used otherwise than for ordinary personal transportation Vehicles attached with side cars etc Vehicles which have been taken out of India Vehicles affected by n...

Page 83: ...ervice record sheet of Service Handbook for your record and reference Periodic maintenance always helps good performance of an automobile and our services are planned to keep your TVS Apache RTR 160 performing good Please note that carrying out the service for your vehicle at scheduled intervals at any of the TVS Motor Company Authorised Main Dealer Authorised Dealer is necessary for availing of w...

Page 84: ...71 71 Facility available at selected Dealerships only Terms and conditions apply Get your vehicle serviced in 1 hour at no additional cost Contact your nearest Dealership for details EXPRESS SERVICE ...

Page 85: ...ns apply Busy Life Easy Servicing Now service your bike anywhere anytime Service the vehicle at your door step Available for regular maintenance or breakdown service only Offered at nominal convenience charges Contact your nearest Dealership for details EXPERT ON WHEELS ...

Page 86: ...Service the vehicle at your door step Available for regular maintenance or breakdown service only Offered at nominal convenience charges Contact your nearest Dealership for details Facility available at selected Dealerships only Terms and conditions apply PICKUP AND DROP ...

Page 87: ...d micronic paper filter Lubrication system Forced wet sump Maximum power in kW 11 42 8400 rpm Maximum torque in Nm 13 9 7000 rpm Maximum speed Around 107 km h Engine idling rpm 1500 200 rpm Starting system Electric starter Emission norms BS VI TRANSMISSION Clutch Wet multiplate type Gear shift pattern 1 down and 4 up Primary transmission Helical gears Secondary transmission Chain and sprockets GEA...

Page 88: ...suspension Telescopic oil damped Rear suspension Monotue inverted gas filled 5 step adjustable shocks with rectangular swing arm Trail length 81 3 mm TYRE Tyre size Front 90 90 17 49P Tubeless Rear 110 80 17 57P Tubeless Tyre pressure Front 1 75 kg cm 25 psi Rear solo 2 00 kg cm 28 psi Rear dual 2 25 kg cm 32 psi BRAKES Front Hand operated 270 mm petal disc Rear Foot operated 200 mm petal disc Dis...

Page 89: ...is not a measuring instrument and the capacity of fuel tank may slightly vary from the indicated capacity Using the bulb other than the specified rating can result in overloading of the electrical system or premature failure of the bulb Specifications are subject to change without notice CAPACITIES Fuel tank capacity 12 l including reserve Fuel BS VI Unleaded Petrol with minimum RON 91 Engine cum ...

Page 90: ...blic place without a valid policy of insurance issued by an authorised insurer Driving a motor vehicle without any such insurance is an offense under Motor Vehicles Act To assist our Customers on their insurance requirements such as the prompt issue and renewal of policies as well as expeditious settlement of claims if any our preferred insurers are ...

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