Page 1: ......
Page 2: ......
Page 3: ...r 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...
Page 4: ...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...
Page 5: ...City 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 Fl...
Page 6: ...e 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 G...
Page 7: ...he 6 consecutive Indian National Motorsport Racing Championship winning race machine As a proud owner of the TVS Apache RTR 160 4V you are now a part of over two and a half million strong TVS Racing f...
Page 8: ...ear 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 Apach...
Page 9: ...Performance 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 r...
Page 10: ...ed It started a rev olution 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 Lank...
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...
Page 12: ...sociated 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 Th...
Page 13: ...ING SYSTEM 02 SAFE RIDING TIPS 07 KNOW YOUR TVS Apache RTR 160 4V 11 RIDING YOUR TVS Apache RTR 160 4V 38 MAINTENANCE 44 WARRANTY AND SERVICES 70 EXPRESS SERVICE 75 EXPERT ON WHEELS 76 PICKUP AND DROP...
Page 14: ...e 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 tr...
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...
Page 16: ...mstances 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 con...
Page 17: ...p goes OFF once the bike reaches 6 km h speed and above and the ABS warning lamp blinks whenever the bike speed is less than 6 km h speed indicating that the ABS is working fine If the warning lamp gl...
Page 18: ...o 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 rem...
Page 19: ...ide 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 dan...
Page 20: ...othing 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...
Page 21: ...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 Cen...
Page 22: ...er 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...
Page 23: ...ankcase system to prevent dischargingcrankcaseemissionsintotheatmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the fuel system Evaporative Emission Control Syst...
Page 24: ...r ordering parts or referring to special information KNOWYOURTVS Apache RTR 160 4V Frame serial number is engraved on the right side of the steering head tube as shown in the above figure Engine seria...
Page 25: ...er cylinder 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...
Page 26: ...RTS VEHICLE LEFT SIDE 1 Wheel hugger rear 2 Saree guard 3 Rear wheel axle 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 1...
Page 27: ...t 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 Muffler assembly 13 Rear wheel axle nut 14 Di...
Page 28: ...bly 3 Oil cooler 4 Crash guard 5 Position lamps 6 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 Pillio...
Page 29: ...be started Control key cannot be taken out from the lock 3 LOCK position Your TVS Apache RTR 160 4V steering can be locked in both left and right directions Turn the handlebar to the left or right Pre...
Page 30: ...Leaving the ignition cum steering lock in ON position for a prolonged time will drain the battery when the vehicle is not in use Switch OFF and take the control key out when the vehicle is not in use...
Page 31: ...x Low fuel indication serial No 4 starts blinking when the fuel reaches to the minimum safe level 2 5 liters approximately Refill the fuel immediately Once the fuel level reaches 1 8 liters approximat...
Page 32: ...check This lamp goes OFF once the vehicle reaches 6 km h speed and above If this lamp glows continuously then have your vehicle checked at TVS Motor Company Authorised Main Dealer Authorised Dealer r...
Page 33: ...de to know the time taken by a rider to reach the specific speed from starting LAST RECORD Minimum time taken recorded so far to reach 60 km h speed will be displayed when the ignition is turned ON an...
Page 34: ...stance TRIP 1 or TRIP 2 is provided for the users to use as per their convenience 11d High speed indicator High speed indicator records the maximum speed top speed achieved by the rider so far You can...
Page 35: ...ndicator does not work when the vehicle is in neutral 0 1 2 3 4 5 6 7 8 9 10 11 12 12 13 15 14 14 Low battery indicator An icon with battery symbol glows when the battery charge is too low Get the bat...
Page 36: ...keep track and follow the service schedule MODE AND SET BUTTONS The Mode A and Set B buttons are provided to change between various modes and to set the some of the digital display functions of the i...
Page 37: ...et button for a few seconds 4 Press the Mode button till the display changes to to set the SHORTEST TIME indicator To reset the LAST RECORD of the shortest time press and hold the Set button for few a...
Page 38: ...25 25 7 Now press the Mode button to change the hour format AM or PM 8 Press the Set button once again to set hour format and to come out from clock setting...
Page 39: ...k plug cools the plug and maintains 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 durabili...
Page 40: ...ch 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 the turn signal switch is m...
Page 41: ...ch while shifting the gears 4 Pass by switch Press the switch to flash the head lamp It is used to give signal to the vehicles coming from the opposite direction while overtaking other vehicles during...
Page 42: ...d and vice versa to reduce 3 Front brake lever It controls a hydraulic circuit ABS that operates the front brake system The front brake is applied by pressing the front brake lever gently towards the...
Page 43: ...the key anti clockwise take out the key and close the lid To avoid accumulation of water in the fuel tank a small drain hole and a pipe is provided in the fuel tank lid cavity so that the water enter...
Page 44: ...lt 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 10 liter i...
Page 45: ...h lever without the throttle operation This is a convenient feature while riding in heavy traffic The requirement of the synchronization of the clutch lever and throttle grip is eliminated engine stal...
Page 46: ...he throttle completely and gradually press the brake pedal downwards Independent use of rear or front brake reduces the overall braking efficiency In extreme conditions braking with only rear or front...
Page 47: ...ound 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 2 1 1a Do not sit on the ve...
Page 48: ...lamp assembly Seat removal To remove the seat assembly insert the ignition key into the seat lock and turn it in clockwise direction Pull and take out the seat assembly by lifting it from the rear en...
Page 49: ...ove the seat assembly as explained in page No 35 Tool kit consists of one number each of the following 1 Grip driver 2 Bit 3 12 x 14 open end spanner 4 Tool bag It is recommended to use the tool kit i...
Page 50: ...disc brake master cylinder This cover can be opened in the following manner 1 Remove the seat assembly as explained in page No 35 2 Remove the mounting screws 1 2 3 and take out the cover frame Re in...
Page 51: ...s or cuts Battery Proper working of all lamps horn and pass by switch Low battery indication Battery charge page No 50 Digital instrument cluster Performing self check Proper working of ABS warning la...
Page 52: ...parked It leads to overheating of engine and damage to the internal components SETTINGTHE VEHICLE IN MOTION 1 Press the clutch lever and engage first gear by pressing the gearshift lever down 2 Open...
Page 53: ...ver 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 steer...
Page 54: ...esides 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...
Page 55: ...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 re...
Page 56: ...lso 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...
Page 57: ...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 Aut...
Page 58: ...SAI hose connections I Tappet clearance I A I A I A I A Adjust if required Oil cooler fins I C I C I C I C Oil cooler pipes I I I I I Inspect replace if required every 15000 km Clutch plates Inspect r...
Page 59: ...ry Drive chain C L A C L A C L A C L A C L A C L A Adjust if necessary All bulbs horn and 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 2 Inspect for prope...
Page 60: ...cable clamps I I I I I I Fix new clamp front rear if found missing WSS cable I I I I 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...
Page 61: ...g6 I 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 6 It is advisable to balance the wheels every 1 year or 12000...
Page 62: ...TVS Motor Company TVS TRU4 FULLY SYNTHETIC oil 1400 ml after disassembly SAE 10W30 API SL JASO MA2 Front fork oil 242 2 5 cc leg TRU Fork oil Disc brake fluid TVS Girling DOT 3 DOT 4 Grease Bharat pet...
Page 63: ...ny 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 te...
Page 64: ...page No 35 3 Open the fuse box lid 4 The fuse box contains two 15A fuses and one 10A fuse One 15A fuse is used for ABS system while the other one is used for DC loads 10A fuse is used for EMS system U...
Page 65: ...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 avoi...
Page 66: ...uching 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 remov...
Page 67: ...If 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...
Page 68: ...ile 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 sam...
Page 69: ...ness can be set to your convenience Contact your TVS Motor Company Authorised Main Dealer Authorised Dealer for setting the rear shock absorber load REAR SHOCK ABSORBER TVS Apache RTR 160 4V is provid...
Page 70: ...embly 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 parall...
Page 71: ...No 37 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 fee...
Page 72: ...asure the free play of the rear brake pedal at the pedal end as shown in the figure 2 The free play of the brake pedal before the engagement of brake should be between 15 20 mm Brake pad wear indicato...
Page 73: ...rrect play 4 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...
Page 74: ...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...
Page 75: ...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 t...
Page 76: ...bricate 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 a...
Page 77: ...itions 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 right spacers at both the s...
Page 78: ...engage the drum sprocket with the wheel along with the drive chain and then assemble the wheel into swing arm 7 Re assemble the other parts in the reverse order of removal While assembling the caliper...
Page 79: ...Y DRUMTYPE 1 Remove the wheel hugger rear 2 Remove the rear brake adjuster nut 1 and disconnect the brake rod 3 Remove the split pin 2 and the nut 3 from the torque link mounting with the brake panel...
Page 80: ...park 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 rec...
Page 81: ...gnition switch to 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...
Page 82: ...r filter element cleanliness 13 Correct idling speed 14 Lubrication of all items mentioned in the periodic maintenance schedule 15 Intactness of EVAP system hoses and canister 16 Any other job as nece...
Page 83: ...h 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 t...
Page 84: ...ame 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...
Page 85: ...bber 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 get...
Page 86: ...rvice 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...
Page 87: ...or pay service 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...
Page 88: ...75 75 Facility available at selected Dealerships only Terms and conditions apply EXPRESS SERVICE Get your vehicle serviced in 1 hour at no additional cost Contact your nearest Dealership for details...
Page 89: ...s 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...
Page 90: ...ervice 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 a...
Page 91: ...aper filter Lubrication system Forced wet sump Maximum power in kW 12 97 9250 rpm Maximum torque in Nm 14 73 7250 rpm Maximum speed Around 114 km h Engine idling rpm 1600 200 rpm Starting system Elect...
Page 92: ...oil damped Rear suspension Gas charged Mono shock absorber 7 step adjustable with rectangular swing arm Trail length 95 8 mm TYRE Tyre size Front 90 90 17 49P Tubeless Rear 130 70 17 M C 62P Tubeless...
Page 93: ...ot 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...
Page 94: ...lic 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...
Page 95: ......
Page 96: ......
