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TVS Apache RTR 200 4V 2021, Manual

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TVS Apache RTR 200 4V 2021 Manual Download Page 69

WSS cable clamps - (front) 

I 

I 

I 

I 

I 

I 

– 

Fix new clamp, if missing

WSS / toner ring 

 

I & C 

I & C 

I & C 

I & C 

I & C 

I & C 

– 

Replace if damage

   

Service 

1st 

2nd 

3rd 

4th 

5th 

 

Remarks

Every 

Every

   

km 

500-750  2500-3000  5000-6000  8500-9000 11500-12000 

3000 km  6000 km

Brake effectiveness 

 

I 

I 

I 

I 

I 

I 

–

Brake pedal shaft 

 

L 

L 

L 

L 

L 

L 

– 

Lubricate using TRU4 oil

  Period from the date of sale  1 month  3 months  6 months  9 months  12 months

Brake fluid 

 

I & T 

I & T 

I & T 

I & T 

I & T 

I & T 

– 

Replace every 21000 km

Item 

 

 

 

 

Service

Brake pad wear 

 

I 

I 

I 

I 

I 

I 

– 

Replace if necessary

WSS cable 

 

I 

I 

I 

I 

I 

I 

– 

Replace if damage

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

Master cylinder cups 

 

– 

– 

– 

– 

– 

– 

– 

Replace every 21000 km   

Wheel freeness 

 

I 

I 

I 

I 

I 

I 

–

Engine idling RPM 

 

I & S 

I & S 

I & S 

I & S 

I & S 

I & S 

–

Brake hose / bundy tubes 

I 

I 

I 

I 

I 

I 

– 

Replace every 30000 km

Evaporative emission control 

I 

I 

I 

I 

I 

I 

– 

Check for intactness of 

system 

 

 

 

 

 

 

 

 

hoses and canister

Ball joint gear shift lever 

– 

– 

L 

– 

L 

– 

L 

Lubricate using grease

Tyre pressure at cold condition 

I & S 

I & S 

I & S 

I & S 

I & S 

I & S 

– 

Toner rings teeth damage 

I 

I 

I 

I 

I 

I 

– 

Replace if necessary

7

Idling CO%  

 

I & S 

– 

– 

– 

– 

– 

– 

I & S every 12000 km

63

MAINTENANCE

7  

  Idling CO% should be set with the help of exhaust gas analyser and tachometer only.

   

Contd...                               

Summary of Contents for Apache RTR 200 4V 2021

Page 1: ......

Page 2: ...pache RTR 2004V takes that connection to another level with TVS SmartXonnect a Bluetooth based connection between your smartphone and race machine that provides call and SMS notifications turn by turn navigation and comprehensive racing statistics to give you a winning edge As a proud owner of the TVS Apache RTR 200 4V you are now part of the 3 5 million strong TVS Racing families This manual expl...

Page 3: ...ill experience riding your new vehicle Ensure that anyone else riding your TVS Apache RTR 200 4V does the same 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 w...

Page 4: ...ty information in following form in this manual These words carry the following connotations Operating this vehicle safely is an important responsibility of the rider To help you make decisions on safety we have provided necessary 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 ...

Page 5: ... Riding your TVS Apache RTR 200 4V 54 Running in information 01 Safe riding tips 06 Know your TVS Apache RTR 200 4V 10 Service record sheet 81 Maintenance 60 Technical specifications 84 Antilock braking system 02 ...

Page 6: ......

Page 7: ...e 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 service will ensure optimum service life and performance from the engine The first 1000 km is a crucial part of your motorcycle Proper running in operation during this period helps in ensuring a maximum life and...

Page 8: ...tion the ABS works similar to a normal brake but functions only when the wheel tends to lock up The speed sensors fitted on front wheel measures the rotational speed of the wheel when the wheel speed reduces rapidly i e wheel tends to lock the HECU modulates the pressure in the brake circuit and thereby prevents the wheel from locking The slipping wheels on a riding surface results in losing contr...

Page 9: ...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 As soon as the actual circumstances arises the system reacts instantly and adjusts braking force accordingly to achieve optimum braking Only the front brake of you...

Page 10: ...e speed is less than 6 km h indicating that the ABS is working fine If the warning lamp is continuously ON even after the vehicle crossing speed then ABS has an error 6 km h and your bike should be taken to any of your nearest TVS Motor Company Authorised Distributors or Dealers Authorised Service Centers DO S AND DON T S t Apply both front and rear brake for better performance t Carefully remove ...

Page 11: ...thod t Do not use non genuine spares like pads discs tyres etc t Do not use non standard tyres Never open HECU on your own it is a very sensitive part of ABS and needs to be handled only by the trained personnel Contact your nearestTVS Motor Company Authorised Distributors or Dealers Authorised Service Centers This motorcycle is equipped with ABS and Tubeless tyres For repair or replacement please...

Page 12: ...able and unsafe when riding a two wheeler Choose good quality two wheeler riding apparel Know your limits 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 Familiarise yourself with new TVS Apache RTR 200 4V Riding skill and your mechanical knowledge forms the foundation of safe riding practices W...

Page 13: ...ce Avoid abrupt application of brake or sudden steering by all means Posture 1 Keep your elbows relaxed and flexible 4 Keep the knees close to the fuel tank 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 3 Look widely instead of gazing at one point ...

Page 14: ...e 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 irregula...

Page 15: ... 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 Distributor or Dealer Authorised Service Center 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 the motorcycle in good condition by getting ...

Page 16: ...dering parts or referring to special information Please fill the above boxes now for future reference Frame number Engine number Control key number 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 KNOW YOUR TVS APACHE RTR 200 ...

Page 17: ...witch 10 Horn switch 11 Turn signal lamp switch 12 High low beam switch 14 Rear view mirror L 3 Master cylinder front 5 Rear view mirror R 1 Connected instrument cluster 2 Ignition cum steering lock 4 Engine cut off switch 6 Front brake lever 11 KNOW YOUR TVS APACHE RTR 200 4V 2 1 3 5 4 8 11 16 15 14 7 9 10 12 13 6 ...

Page 18: ...DE 7 Centre stand 3 Rear wheel axle 10 Cover frame L 5 Rider foot rest L 1 Wheel hugger rear 2 Saree guard 4 Pillion foot rest L 6 Side stand 9 Front wheel axle 8 Gear shift lever KNOW YOUR TVS APACHE RTR 200 4V 12 10 3 9 7 6 5 8 4 2 1 ...

Page 19: ...dal 10 Rider foot rest R 13 Disc plate rear 11 Pillion foot rest R 5 Toner ring front 14 Rear wheel axle nut 15 Caliper assembly rear 12 Muffler assembly 16 Cover frame R 2 Cover toner ring 3 Front wheel axle nut 7 Location of spark plug 17 Location of ram air duct 13 KNOW YOUR TVS APACHE RTR 200 4V 1 16 17 2 11 12 13 7 10 9 8 3 4 5 6 14 15 ...

Page 20: ...lamp front L 6 Turn signal lamp front R 5 Position lamps 4 Crash guard REAR 3 Number plate lamp 3 Oil cooler 2 Reflex reflector 2 Head lamp assembly 4 Turn signal lamp rear L 1 Turn signal lamp rear R 5 Tail lamp assembly 14 KNOW YOUR TVS APACHE RTR 200 4V 1 2 3 4 6 5 2 1 3 4 6 5 ...

Page 21: ...once upon activation The engine can be started The key cannot be taken out from the lock Insert the key into the lock and turn it to OFF or ON position to unlock the steering Turn the handlebar to the left or right Press the key in and rotate it to the LOCK position from OFF position All electrical circuits are deactivated and the steering is locked The key can be removed from the lock Your TVS Ap...

Page 22: ...he key out when the vehicle is not in use Always lock the steering while parking for safety Never attempt to move the vehicle when the steering is locked you may lose balance 1 Speedometer Indicates the vehicle speed in kilometer per hour by default whenever the ignition is turn ON This can be changed to mile per hour Change the mode between kilometer per hour and mile per hour using the mode and ...

Page 23: ... self check This lamp goes OFF once the vehicle reaches the speed 6 km h and above If this lamp glows continuously then have your vehicle checked at TVS Motor Company Authorised Distributor or Dealer Authorised Service Center refer page no 04 for more details KNOW YOUR TVS APACHE RTR 200 4V 17 If you leave the ignition key in ON position and vehicle is kept without moving for more than 3 minutes a...

Page 24: ...6 5 liters approx the fuel gauge displays only four bars as shown Low fuel indication serial no 4 starts blinking and one bar will be visible when the fuel reaches to the minimum safe level 1 8 liters approximately Refill the fuel immediately Once the fuel level reaches 1 1 liters approximately no bar will be visible and low fuel indication serial no 4 glows continuously Digital bars indicate the ...

Page 25: ...meter or mile as per the user s preferred setting The digit after the dot mark denotes one tenth of a kilometer or mile Set the meter in ODO mode to know the odometer reading 19 KNOW YOUR TVS APACHE RTR 200 4V 11f 11a 11b 11c 11d 11e 11b Trip meter In ODO mode Press mode button once and twice to enter TRIP 1 and TRIP 2 meters respectively Trip meter indicates the trip distance travelled in kilomet...

Page 26: ...ess the Info switch again to stop the current lap timer and to start a new lap Existing lap timings will be displayed as shown below and continue to get updated whenever a new lap is started and stopped Long press the Info switch for few seconds more than 1 second and less than 3 seconds to stop the lap timer count To start a lap timer again after stopping it by pressing the Info switch the lap ti...

Page 27: ...layed for few seconds as shown KNOW YOUR TVS APACHE RTR 200 4V Whenever the vehicle speed crosses the previous achieved high speed a message ACHIEVED HIGH SPEED will be popped up and a trophy symbol will be flashed to cheer your achievement when the vehicle reaches to a safer low speed These pop ups can be cancelled by pressing the Info switch on the handle bar else it will disappear automatically ...

Page 28: ...ator 22 KNOW YOUR TVS APACHE RTR 200 4V These pop ups can be cancelled by pressing the Info switch on the handle bar else it will disappear automatically Overall best time achieved so far and the last recorded time to reach 60 km h or 40 mph speed will be displayed when the ignition is turned ON and the meter is set in SHORTEST TIME mode Once the speed reached 60 km h or 40 mph then the time will ...

Page 29: ...r Lean angle is calculated from the mobile device when it is connected to the instrument cluster and lean angle mode is set The accuracy of the lean angle information depend on the mobile device used orientation and placement of the mobile device on the vehicle Refer page No 31 for detail procedure connecting the mobile with the instrument cluster For best accuracy it is recommended that the user ...

Page 30: ... and fuel gauge shows only one bar or glows continuously with fuel gauge showing no segment the display automatically switches to the TRIP F indicator after 0 5 km or 0 3 miles as per preferred settings and TRIP F meter starts counting from 0 km in km h mode and 0 miles in mph mode KNOW YOUR TVS APACHE RTR 200 4V 24 If you notice an error message CHECK GEAR SENSOR Contact nearest TVS Motor Company...

Page 31: ... diagnostic cycle when the battery charge is too low Get the battery checked at TVS Motor Company Authorised Distributor or Dealer Authorised Service Center Service remainder and battery low pop up can be cancelled by pressing the Info switch on the handle bar Note A B MODE AND SET BUTTONS The mode A and set B buttons are provided to change between various modes and set the some of the digital dis...

Page 32: ...s 2 Trip 1 3 Trip 2 4 Lap timer 1 ODO 6 Shortest time indicator Above mode changes are possible only when the vehicle is in static condition for safety Note P r e s s M O D E B u t t o n P r e s s M O D E B u t t o n P r e s s M O D E B u t t o n Press MODE Button Press MODE Button 4 LEAN ANGLE MODE RPM MODE 3 SHIFT RPM SETTING 2 CLOCK SETTING MODE 5 BLUETOOTH PARING MODE On long pressing the Mode...

Page 33: ...to desired mode 2 In TRIP 2 meter mode Press the Mode button once to enter lap timer mode On entering the lap timer mode a message and last three laps timing will be displayed in the cluster s display 4 In TRIP 2 meter mode press the Mode button thrice to enter shortest time mode On entering this mode last achieved shortest time and overall best time will be displayed in the cluster s display 3 In...

Page 34: ...itch to KMPH mode by default whenever the ignition is turned OFF and ON Note 6 If the clock is in 24 hours format press the Mode button once again to set the clock to 12 hours format 9 On pressing the Set button again the hours of the clock is set and the minute digit blinks 4 On pressing the Set button if the clock is in 12 hours format the hour format AM or PM blinks Else the clock will be ready...

Page 35: ... mode is exit 2 Release and press the Mode button twice so that the display enters mode Ensure the display is in ODO mode TVS CONNECT 2 Press and hold the Mode button for few seconds till the display enters SET mph MODE or SET kmph MODE based on preferred setting 1 Ensure the display is in ODO mode l Else it will enter to mode 3 Press the Set button to set the LEAN ANGLE MODE or RPM MODE 3 Release...

Page 36: ...to paired with a single instrument cluster at a time If the user need to connect multiple iPhones with the single instrument cluster the previous connected iPhone has to be forgotten by clicking ForgetThis Device from Bluetooth settings in the iPhone If the vehicle battery is reset or fuse is blown then too Forget This Device from Bluetooth settings in the iPhone has to be done Note Note Steps to ...

Page 37: ...described below 3 Release and press the Mode button four times so that the display enters 2 Press and hold the Mode button for few seconds till the display enters SET mph MODE or SET kmph MODE based on preferred setting 1 Ensure the display of the instrument cluster is in ODO mode 4 Now press the Set button to establish the connection with your smart phone 5 On pressing the Set button the connecte...

Page 38: ...airing process there is any occurrence of error the connected instrument cluster should be turned OFF and ON and the application also need to be restarted For the first time pairing the connected instrument cluster should be in BLUETOOTH PAIRING MODE If the phone enters battery saver mode auto pairing might not happen It takes maximum of five minutes for auto pairing and it can happen in vehicle run...

Page 39: ...hones if the Bluetooth is ON and if the app is already paired with the cluster the app opens automatically and connects with the cluster once the user takes his phone to near by the vehicle and turns ON the ignition if the auto launch setting of your smart phone is turned ON This feature can be disabled if required If the application unfortunately stops due to unfrossen circumstances Close and reo...

Page 40: ...al strength displayed in connected instrument cluster might vary from the display in smart phone as the former is referred from telephonic standards Incase multiple SIM cards are used in smart phone by default SIM 1 s network provider s signal strength is shown in the display of connected instrument cluster Note The connected instrument cluster will display the incoming calls alerts from the smart...

Page 41: ...ming calls missed calls and SMS alerts can be cancelled by pressing the Info switch on the handle bar in IOS pressing the switch only clears the notification but the call will not be cancelled in the phone Please remember that the Navigation License has to be renewed after 5 years of vehicle purchase and renewal can be done by contacting near by Distributor or Dealer end Note Note Navigation window...

Page 42: ... the app sends a fuel assist message to the instrument cluster You can either accept or reject the assist request Low fuel assist Nearest location alert You can either accept the request and navigate to the nearest fuel station or reject the request using Info switch on the handle bar The customer also can chose to reject the request by pressing the Info switch on the handle bar for about 1 sec In...

Page 43: ...is recommended that the user mounts the phone to a rigid part of the bike The G force is measured based on the vehicle speed andnot with an on board measurement unit So there might be a variation between the actual and the measured values The G force value displayed is only an estimate of the actual value Note Note Whenever the app is connected to the connected instrument cluster the clock of inst...

Page 44: ... your Android smart phones and iPhones To access the features of your TVS Apache RTR 200 4V s connected instrument cluster like 6 Do Not Disturb mode during the ride applicable only for Android smart phones 10 To know the signal strength of your mobile network in connected instrument cluster 11 To generate and store Ride reports 12 To sync the connected instrument cluster clock with smart phone cl...

Page 45: ...with various login options opens up as shown You can login using your social media logins like FACEBOOK and GOOGLE or using your mobile number which has been registered already Using your social media logins you can create new login else press the CREATE AN ACCOUNT tab If you are a new user then press the sign up tab where you will find various options for registering using your social media login...

Page 46: ...a screen opens with one time password OTP entry Enter the OTP which is received from TVS Motor Company Limited sent to the registered email id and submit After successful verification the Home screen of the app opens Please remember that the Navigation License has to be renewed after 5 years of vehicle purchase and renewal can be done by contacting near by Dealer end Note ...

Page 47: ...hen press the add vehicle tab COOLING SYSTEM The oil cooler is mounted in front of the engine which improves the engine durability and provides better heat management without any compromising the engine performance TVS Apache RTR 200 4V is designed with an external oil cooler with stone guard arrangement for optimal engine cooling 41 ...

Page 48: ...aintains its temperature in optimum level Which in turn results in better heat management without any compromise on the engine performance and improves the engine s durability RAM AIR DUCT KNOW YOUR TVS APACHE RTR 200 4V TVS Apache RTR 200 4V comes with a LED head lamp which glows automatically once the ignition is turned ON Only the head lamp beam high low can be controlled by pressing the high l...

Page 49: ...te direction while overtaking other vehicles during day HANDLE BAR LEFT SIDE 1 Info switch Info switch is used to cancel certain functions and to start anad stop the LAP etc Press the switch for particular action Press the switch to blow horn It is used to attract the attention of other road users in case of danger 2 Horn switch 3 Turn signal lamp switch When the turn signal switch is moved to lef...

Page 50: ...igh beam and bottom end for Low beam KNOW YOUR TVS APACHE RTR 200 4V Note Note Ensure to turn ON the engine cut off switch before starting the vehicle Release the electric starter switch immediately after pressing Once the engine is started the head lamp glows automatically Only head lamp beam high low can be controlled using beam control switch It is strongly recommended to ride thevehicle in low...

Page 51: ...peed Rotate the throttle grip in counter clockwise from its idle position to increase the engine speed and vice versa to reduce 3 Front brake lever 2 1 Flush type fuel tank cap 1 is provided in TVS Apache RTR 200 4V To open the fuel tank cap lift the protection lid 2 insert the control key into the lock and turn it in clockwise and lift the cap Press the cap back to close Rotate the key anti clock...

Page 52: ...ling Do not use cell phones while refueling Avoid spilling of fuel on the hot engine Refill petrol in well ventilated area Switch off the engine while refueling as petrol is highly inflammable After refilling close the cap properly Warning Do not clean the vehicle by laying down on floor to avoid fuel entry into EVAP system Never fill fuel beyond the fuel tank inlet 1 Filling above the inlet may r...

Page 53: ...at the carburettor assembly itself Gently pull the choke lever upward for operation During cold start apply the choke and start the vehicle without opening with less opening of throttle Choke lever should be turned back to its original position when the engine idle rpm is stable CHOKE LEVER 47 KNOW YOUR TVS APACHE RTR 200 4V RES OFF ON Leaving the fuel cock in ON or RESERVE position when the vehic...

Page 54: ...TR 200 4V Always use choke for starting the cold engine Never open the throttle fully when the choke is applied It may lead to flooding of engine and difficulty in starting If the choke knob remains ON it will lead to erratic running of engine and high fuel consumption Caution Gear shift lever position can be set to your convenience Contact your TVS Motor Company Authorised Distributor or Dealer A...

Page 55: ...r jerk while shifting the gears Remember to return to neutral position before restarting the engine Caution Rear brake pedal position can be set to your convenience Contact your TVS Motor Company Authorised Distributor or Dealer Authorised Service Center for setting the brake pedal position Independent use of rear or front brake reduces the overall braking efficiency In extreme conditions braking ...

Page 56: ...hicle 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 50 KNOW YOUR TVS APACHE RTR 200 4V 2 1 1a Park the motorcycle safely on a solid ground On slopes engage the first gear and park the vehicle in such a way that the front wheel faces uphill Always release the side stand to its full up position before movi...

Page 57: ...om rear end slide it backward to remove 1 2 3 A Make sure that the seat is locked securely in position Caution Utility box is located under the passenger seat to store some important items and it provides security to things placed inside SEAT The seat lock is located between the rider and the passenger seat assembly Rear seat passenger seat To remove the rear seat 1 insert the ignition key into th...

Page 58: ... page no 51 1 Grip driver 2 Bit 3 12 x 14 open end spanner 4 Tool bag Tool kit consists of one number each of the following 52 KNOW YOUR TVS APACHE RTR 200 4V 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 Distributor or Dealer Authorised Service Center Caution Warning Do not remove the tool kit from t...

Page 59: ...ate the lugs of the cover frame at the holes provided on the frame and install the mounting screws 1 2 and 3 Re install 1 Remove the seats as explained in Page no 51 2 Remove the mounting screws 1 2 3 and take out the cover frame 53 KNOW YOUR TVS APACHE RTR 200 4V Caution Make sure that the cover frame is locked securely in position after installation 2 3 1 ...

Page 60: ...amps horn and pass by switch Low battery indication Battery charge page no 65 Steering Smooth movement No play or looseness Throttle Correct free play of cable Smooth operation Speedometer Performing self check Proper working of ABS warning lamp page no 17 Clutch Correct free play of cable page no 69 Smooth and progressive action Wheels Free rotation Drive chain Slackness and lubrication of chain ...

Page 61: ...e turned back to its original position when the engine has started running stable when the engine is warm hot do not use choke STARTING THE ENGINE As you turn the ignition switch to the ON position the instrument cluster and the warning lights will go through the self diagnostic cycle During this phase make sure that all the warning lights on the cluster comes on q Apply the choke and start the ve...

Page 62: ...ver and open the throttle smoothly Select the required gears in a similar manner Riding on hills gradients 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 sure to park the vehicle in a place where pedestrians or children are not likely to touch the hot s...

Page 63: ...park plug Use fuel additives in petrol as recommended by the respective manufacturer for low carbon deposition Regular checks CHECKS AND TIPS FOR IMPROVING FUEL ECONOMY Regular maintenance checks will save fuel ensuring trouble free enjoyable and safe riding besides keeping the environment clean Carry out the periodic maintenance checks as specified in this manual refer page no 61 Spark plug A dir...

Page 64: ...d fuel economy Further more handling may be affected adversely Engine cum transmission oil 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 Check and arrest fuel leak if any from tank carburettor and fuel lines Loss ...

Page 65: ... potentially dangerous traffic situation Fuel is wasted whenever the rider suddenly accelerate or apply brake Fast starting from rest wastes fuel Chain slackness Avoid unnecessary idling Anticipate corners and slopes as well as the traffic conditions Unnecessary and frequent braking reduces the fuel economy Avoid frequent braking 59 RIDING YOUR TVS APACHE RTR 200 4V Please note that the on road mi...

Page 66: ...otor Company Limited strongly recommends that the jobs as per the maintenance schedule be performed by your TVS Motor Company Authorised Distributor or Dealer Authorised Service Center MAINTENANCE SCHEDULE Periodic inspections may reveal one or more parts that may need replacement Whenever replacing parts on TVS Apache RTR 200 4V it is recommended that you use only the TVS Motor Company Genuine pa...

Page 67: ...ngine breather hose I I I I I I Replace every 21000 km if required 1 Clutch and throttle cable play I A L I A L I A L I A L I A L I A L Carburetor rubber ducts I I I I I Replace every 21000 km required every 15000 km Hose fuel I I I I I I Replace every three years if required Clutch plates Inspect replace if Fuel cock sediment bowl C C C C C C required every 21000 km Tappet clearance I A I A I A I...

Page 68: ...ion I I I I I I 3 Head lamp beam I A I A I A I A I A I A premium grade 3 grease 6 Battery voltage I I I I I I 4 Retainer oil seal I I I R I I Replace every 9000 km 62 6 Recharge if necessary 4 5 Inspect at every service Replace if found damaged However the retainer oil seal the chain guide bottom need to be replaced every 9000 km Contd 3 Inspect for smooth and proper function of front and rear sus...

Page 69: ... I I I I Replace if damage 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 Master cylinder cups Replace every 21000 km Wheel freeness I I I I I I Engine idling RPM I S I S I S I S I S I S Brake hose bundy tubes I I I I I I Replace every 30000 km Evaporative emission control I I I I I I Check for intactness of system ...

Page 70: ...d pivot L L L L L L Lubricate using TRU4 oil Swing arm bearings C L with fresh Bechem premium grade 3 grease every two years R Replace I Inspect T Top up C Clean A Adjust L Lubricate TI Tighten S Set Disk brake fluid TVS Girling DOT 3 DOT 4 1400 ml during engine overhaul SAE 10W30 API SL JASO MA2 Fuel additives As recommended IFTEX Chain lubricant TVS Motor Company TRU SPRAY Engine cum transmissio...

Page 71: ...istributor or Dealer Authorised Service Center The inversion of the battery wires can damage the battery and the recharging system If the motorcycle is to remain unused for a long time a month or longer it is advisable to disconnect the battery cables or have the battery removed by skilled personnel Never check the battery charge by shorting the terminals Always connect the positive terminal first...

Page 72: ... wiring and may result in fire Never replace a fuse with a rating other than that prescribed in order to avoid damage to the electrical equipment Non working of electrical systems may be due to safety fuse failure Short circuit or overload in the electrical system are the main causes for fuse failure FUSE REPLACEMENT Follow the procedure given below for inspecting and replacing the fuse 1 Turn OFF...

Page 73: ...o be more than the limit replace the spark plug with a new one After cleaning and inspecting the gap reinstall the spark plug and tighten by hand to avoid cross threading Finally tighten using the spanner Do not over tight or cross thread the spark plug 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...

Page 74: ...le with insufficient without engine cum transmission oil as it will cause serious damage to the engine components Excessive oil filling will cause oil leak and other malfunctions Always use TVS TRU4 FULLY SYNTHETIC oil only SAE 10W 30 API SL JASO MA2 Correctly recycle or dispose the used engine oil in order to avoid environmental pollution 1 The check must be performed when engine is in cold condi...

Page 75: ...the free play is not within the specified limit Clutch lever free play is one of the most important adjustment which you may need to check in between services for better life of the clutch plates The free play of the clutch lever should be 8 15 mm as measured at the clutch lever end at handle bar 1 Ensure that the engine is cold engine oil at room temperature Too much or too less clutch lever free...

Page 76: ...ly compressed gas Do not try to open or disassemble it in any way After adjusting free play properly if there is a clutch slip or there is difficulty in shifting gear visit your TVS Motor Company Authorised Distributor or Dealer Authorised Service Center for rectification REAR SHOCK ABSORBER TVS Apache RTR 200 4V is provided with dual rated 7 step adjustable gas filled rear shock absorber to meet ...

Page 77: ...sc 4 and a toner ring along with a cover 5 fitted on the front wheel 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 Distributor or Dealer Authorised Service Center for topping up the brake fluid air bleeding and other brake related inspections 2 Brake fluid level always s...

Page 78: ...n the right side rider foot rest a reservoir 2 below the cover frame R a caliper assembly 3 fitted on the rear wheel axle a disc 4 to the rear wheel and a high pressure hose 5 connecting the master cylinder and the caliper assembly 2 Check the brake fluid level in the reservoir It should be between maximum and minimum level 1 Remove the cover frame R refer page no 53 for removal procedure Rear bra...

Page 79: ...or 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 Brake pad wear indicator Replace the brake pads as a set if the wear indicator shows beyond the wear limit Caution MAINTENANCE Lack of maintenance of the brake system increases the risk of accident If you notice any malfunction in brake system contact nearest TVS...

Page 80: ...oval fitment machine If at all tyre levers need to be used the levers should be free from sharp edges and care should be taken not to damage the rim and tyre Tyre puncture TVS Apache RTR 200 4V is fitted with a tubeless tyre on both front and rear wheel lncase of any puncture tyre damage it is advised to visit nearest tyre manufacturer Dealer or the tyre repair shops who know the repairing methods...

Page 81: ...ter chain life and smooth vehicle running 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 5 If the slackness is found within the limit clean the chain with a dry cloth and lubricate using TRU SPRAY TRU4 oil 3 The slackness of the drive chain should not exceed the limit 20 25 mm 4 If t...

Page 82: ...le from falling and lift the vehicle up 5 Reverse the procedure for reassembling 1 Remove the axle nut 1 along with a washer 4 Carefully dislocate the disc from the caliper assembly and slide the wheel out 2 Pull out the axle 2 along with a washer and remove a spacer from both the sides of the wheel Warning 1 2 Lubricate the drive chain after the motorcycle is washed with water or riding in rainy ...

Page 83: ... it along with the disc 7 Re assemble the other parts in the reverse order of removal MAINTENANCE 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 that whenever the wheel is removed axle nut is properly re tightened to the specified torque and chain play is re checked and adjusted i...

Page 84: ...light and freezing temperatures 8 Cover up the vehicle completely with a clean tarpaulin or any other suitable cover Store the vehicle inside a garage or similar area to avoid damage due to dust and rain Make sure that the storage area is well ventilated and free from any source of flame or spark 7 Place a suitable support at the bottom of the frame so that both the tyres are off the ground This w...

Page 85: ...ttle and clutch cables one number each 1 Tightness of all bolts and nuts with correct torque value 1 Take the vehicle out of the garage and clean it thoroughly 2 Remount the battery after bench charging if required 4 Lubricate the parts as instructed in the maintenance schedule 5 Fill up fresh petrol in the fuel tank 7 Check and correct the points mentioned in page no 54 3 Fill the engine cum tran...

Page 86: ...ediment cup filter cleanliness 12 Spark plug cleanliness and condition of spark plug 16 Intactness of EVAP system hoses and canister 8 Slackness and lubrication of chain page no 75 13 Air filter element cleanliness 17 Any other job as necessary 9 Front rear brake functioning and rear brake lamp switch adjustment 14 Correct idling speed 18 Have your vehicle checked at any TVS Motor Company Authoris...

Page 87: ...curs earlier b 3 months from the date of purchase reading stamp and sign b 6 months from the date of purchase b 9 months from the date of purchase 4 4th service between a 5000 6000 km or whichever of the two occurs earlier 1 1st service 2 2nd service b 1 month from the date of purchase between a 8500 9000 km or whichever of the two occurs earlier SERVICE RECORD SERVICE RECORD SHEET 81 ...

Page 88: ...ce whichever of the two occurs earlier b 21 months from the date of purchase reading stamp and sign S No Description Odometer Job card no Date Servicing Dealer s 5 5th service b 15 months from the date of purchase between a 11500 12000 km or between a 20500 21000 km or whichever of the two occurs earlier whichever of the two occurs earlier 7 7th service SERVICE RECORD SERVICE RECORD SHEET 82 ...

Page 89: ...ichever of the two occurs earlier b 27 months from the date of purchase between a 23500 24000 km or whichever of the two occurs earlier b 24 months from the date of purchase 11 11th service b 30 months from the date of purchase 10 10th service between a 26500 27000 km or whichever of the two occurs earlier between a 29500 30000 km or 83 ...

Page 90: ... and micronic paper filter Lubrication system Forced wet sump Maximum power in kW 15 09 20 5 PS 8500 rpm Maximum torque in Nm 18 1 Nm 7000 rpm Engine idling rpm 1500 100 rpm Starting system Electric starter Maximum speed 128 km h TRANSMISSION Clutch Wet multiplate type Gear shift pattern 1 down and 4 up Primary transmission Helical gears Secondary transmission Chain and sprockets II gear 1 857 Pri...

Page 91: ...BS Overall length 2050 mm Kerb weight with toolkit 148 kg incase of without ABS Trail length 95 5 mm Front suspension Telescopic oil damped CHASSIS 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 Rear 130 70 x 17 Tubeless Tyre size TYRE Front 90 90 x 17 Tubeless BRAKES Spark plug BOSCH UR4KE Position lamp LED lamp 12V 3W x 2 Head lamp 12V LED Headlamp ...

Page 92: ...es including reserve oil grade SAE 10W30 API SL JASO MA2 oil and capacity 1400ml during engine overhaul Front fork oil grade KYB G10 oil Front fork oil capacity 325 2 cc leg Brake fluid TVS Girling DOT 3 DOT 4 The fuel tank 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 overloadi...

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