TVS Racing Apache RTR 160 Manual Download

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RECOMMENDED LUBRICANTS

APPLICATION

QTY MANUFACTURER BRAND

Engine cum transmission oil

1000 ml (after draining)

TVS Motor Company

TVS TRU4 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 cleaner

TVS Motor Company

TRU SPRAY chain cleaner

Chain lubricant

–

TVS Motor Company

TRU SPRAY

Summary of Contents for Racing Apache RTR 160

Page 1: ...Fully Digital Speedometer New LED Head Lamp Ride Modes THE ALL NEW RACER S CHOICE...

Page 2: ...particular product will be sent to your registered with company mobile number Open the link for downloading relevant owner s manual copy of your vehicle while ensuring your mobile Internet connection...

Page 3: ...I I 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 4: ...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 5: ...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...

Page 6: ...T 1 FOREWORD 5 SAFETY INFORMATION 9 NOTICE 10 RUNNING IN INFORMATION 11 ANTI LOCK BRAKING SYSTEM 12 SAFE RIDING TIPS 17 KNOW YOUR TVS APACHE RTR 160 21 RIDING YOUR TVS APACHE RTR 160 66 MAINTENANCE 72...

Page 7: ...s Area Offices flip 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 d...

Page 8: ...C 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 Tow...

Page 9: ...ne 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...

Page 10: ...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 Gu...

Page 11: ...d tank and engine cowls slice through the air While the race inspired graphics add flair to the performance With this Apache you unlock the door to the Apache World Prepare to be part of some of the m...

Page 12: ...ar 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...

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Page 14: ...1982 1992 93 1998 1988 89 1993 94 2000 2005 2005 Till date 2011 2016 2017 2015 2007 2017 2018 2019 2020...

Page 15: ...ith 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...

Page 16: ...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 rele...

Page 17: ...ervice 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 trans...

Page 18: ...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 19: ...as the actual circumstances arises the system reacts instantly and adjusts braking force accordingly to achieve optimum braking Why does brake lever pulsate during brake application Vehicles fitted w...

Page 20: ...ches 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...

Page 21: ...t use different toner ring Do not insert any metallic parts near wheel speed sensor 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...

Page 22: ...braking during sharp cornering on slippery surface may lead to vehicle instability Under such circumstances gradual braking is recommended Warning This motorcycle is equipped with ABS on front wheel...

Page 23: ...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...

Page 24: ...a corner If this is the first time that you are riding a vehicle of this type we suggest that you practice on a safe open area to thoroughly familiarise with the operation of the vehicle Warning 5 Alt...

Page 25: ...king on slippery or irregular roads can cause loss of rider control Warning 2 Even when the brake works normally if the road surface is wet or the tyre surface is worn out tyres do not take a firm hol...

Page 26: ...kcase 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...

Page 27: ...ype They are also required to assist your Dealer for ordering parts or referring to special information KNOWYOURTVS APACHE RTR 160 Frame serial number is engraved on the right side of the steering hea...

Page 28: ...ode switch 5 Engine cut off switch 6 Rear view mirror R 7 Front brake lever 8 Throttle grip 9 Electric starter switch 10 Fuel tank cap 11 Horn switch 12 Turn signal lamp switch 13 High low beam switch...

Page 29: ...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...

Page 30: ...wheel axle nut 4 Wheel speed sensor front 5 Caliper assembly front 6 Location of spark plug 7 Gauge oil level 8 Rear brake pedal 9 Rider foot rest R 10 Pillion foot rest R 11 Rear shockabsorber R 12...

Page 31: ...assembly 3 Crash guard 4 Front 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...

Page 32: ...n 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 Pres...

Page 33: ...er switch When the ignition switch is turned ON the instrument cluster performs self diagnostic cycle Wait till the display becomes static Note Never attempt to move the vehicle when the steering is l...

Page 34: ...e head lamp High beam also glows along with the Low beam Pass by system will not work if the head lamp is glowing in High beam Note Use appropriate head lamp beam high low as per the traffic and road...

Page 35: ...HT SIDE 1 Ride mode switch Press the ride mode switch to switch between Urban Rain and Sport modes refer page no 37 for further details 2 Electric starter switch Ensure that the transmission is in neu...

Page 36: ...t cluster with lots of features and various modes AB 1 3 4 5 6 7 8 9 10 12 2 11 The connected instrument cluster also has a mobile app for Smart Phones and navigation assist etc additionally along wit...

Page 37: ...sage CHECK SPEED SENSOR while the vehicle is in move Contact nearest TVS Motor Company Authorised Main Dealer Authorised Dealer for rectification Note In geared condition if the side stand is deployed...

Page 38: ...n is turned ON till the engine is started It will go OFF once the engine is started If the battery is disconnected and reconnected during service you may need to reset the time as explained in page no...

Page 39: ...le and low fuel indication serial no 5 glows continuously Before turning the ignition key to ON position ensure the availability of adequate fuel in the tank That is LOW FUEL INDICATION shall not come...

Page 40: ...Trip meter indicates the trip distance travelled in kilometer or mile as per the preferred settings The digit after the dot mark denotes the one tenth of a kilometer or mile Provision to measure two d...

Page 41: ...be started again until the timer is reset Only last three lap s timing will be displayed in the cluster on entering the lap timer mode Note 13d Notification area This is a general purpose notificatio...

Page 42: ...If the high speed is reset the speed value will be shown as 0 Note 13f Shortest time indicator Shortest time indicator records the minimum time taken so far to reach 60 km h or 40 mph speed according...

Page 43: ...s 9 9 secs Overall best time recorded cannot be reset manually It will be replaced automatically by next overall best time Once the speed reached 60 km h or 40 mph then the time will stop at the exact...

Page 44: ...n Sport mode the engine and ABS braking system is modified to suit highway riding condition The vehicle s max speed in sport mode is 107 km h and the ABS braking will be aggressive with late ABS inter...

Page 45: ...fault is detected with respect to the ride mode change in the EMS or ABS system then your motorcycle will operate only in the Urban mode after ignition key reset Caution 15 Shift RPM indicator 16 Tach...

Page 46: ...e level TRIP F meter cannot be activated or deactivated manually It will be enabled automatically until fuel level raises above minimum safe level 2 5 L Gear shifting suggestion changes in accordance...

Page 47: ...cator The following message will be popped up after the speedometer s self diagnostic cycle when the battery charge is too low Get the battery checked at TVS Motor Company Authorised Main Dealer Autho...

Page 48: ...detail below A B 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 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 TRIP A TRIP B Short press the Mode button to...

Page 49: ...will be displayed during next ignition ON If any other modes other than the above were set while turning the ignition OFF then ODO meter will be displayed by default during next ignition ON 1 In ODO m...

Page 50: ...ord will be reset and best time display will remain same until new best time is achieved 5 Press the Mode button once to change the display to ODO mode again MPH and Km h setting 1 Ensure the display...

Page 51: ...n pressing the Set button again the hours of the clock is set and the minute digit blinks 10 Now press the Mode button to increase the minutes while minute digits are blinking 11 Press the Set button...

Page 52: ...ted iPhone has to be forgotten by clicking Forget This 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...

Page 53: ...below 1 Ensure the display of the instrument cluster is in ODO mode 2 Press and hold the Mode button for few seconds till the display enters SET mph MODE or SET km h MODE based on preferred setting 3...

Page 54: ...cluster should be in BLUETOOTH PAIRING MODE During the course of pairing process there is any occurrence of error the connected instrument cluster should be turned OFF and ON and the application also...

Page 55: ...gadgets like smart watch health band or helmet the auto pairing works with your TVS Apache RTR 160 motorcycle s connected instrument cluster Note In Android and IOS smart phones if the Bluetooth is ON...

Page 56: ...rds are used in smart phone by default SIM 1 s network provider s signal strength is shown in the display of connected instrument cluster Signal strength displayed in connected instrument cluster migh...

Page 57: ...ng 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 ph...

Page 58: ...he request by pressing the Info switch on the handle bar for about 1 sec In that case the previous display will remain in the cluster Clock auto sync Whenever the app is connected to the connected ins...

Page 59: ...alled in your Android smart phones and iPhones To access the features of your TVS Apache RTR 160 s connected instrument cluster like 1 Incoming call alerts in connected instrument cluster 2 Incoming S...

Page 60: ...d to disablement of few functions on some of the operating system Note 7 To send navigational assist instructions inputs to the connected instrument cluster from your smart phone 8 To save the last tr...

Page 61: ...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 If you are a new user then press the...

Page 62: ...is received from TVS Motor Company Limited and submit On submitting the OTP another screen opens where you have to enter your vehicle s chassis number for verification After successful verification o...

Page 63: ...iew of the frame number and also you can get help by chatting with us or by E mailing to us or by calling us LED HEAD LAMP TVS Apache RTR 160 comes with a LED head lamp which glows automatically when...

Page 64: ...ose the protection lid 2 1 The fuel tank is not a measuring instrument and the capacity of the fuel tank may slightly vary from the indicated capacity To avoid accumulation of water in the fuel tank a...

Page 65: ...report to the TVS Motor Company Authorised Main Dealer Authorised Dealer Never fill fuel beyond the fuel tank inlet 1 Filling above the inlet may result in improper breathing of fuel tank which leads...

Page 66: ...ter To shift the transmission from neutral to first gear push the gear shift lever down Never shift gears without disengaging the clutch and releasing the throttle Failure to comply this will lead to...

Page 67: ...on in the vehicle remove the air duct or block the air duct passage Else it will lead to over heating of engine and muffler Caution Ensure not touch or bring any flammable objects near the muffler whi...

Page 68: ...case of rear drum brake model after setting the brake pedal position adjust the rear brake play as explained in page no 88 Note Independent use of rear or front brake reduces the overall braking effic...

Page 69: ...cle 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...

Page 70: ...2 Take out the cover frame by gently pulling out at front 2 and rear 3 end of the cover frame To assemble the cover frame back 1 Locate the lugs of the cover frame at 2 3 to the holes provided in the...

Page 71: ...only It is always advisable to take your vehicle to TVS Motor Company Authorised Main Dealer Authorised Dealer Caution Do not remove the tool kit and first aid kit from the vehicle Always ensure to k...

Page 72: ...racks or cuts Battery Proper working of all lamps horn and pass by switch Low battery indication and battery charge page no 78 Instrument cluster Performing self check Proper working of ABS warning la...

Page 73: ...open excessive throttle when the vehicle is parked It leads to overheating of engine and damage to the internal components Caution SETTINGTHE VEHICLE IN MOTION Press the clutch lever and engage first...

Page 74: ...d 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...

Page 75: ...rmalities observed due to use of ethanol blended fuels customers are advised to use a different fuel station brand for standard E10 fuel or contact authorised service centers CHECKS AND TIPS FOR IMPRO...

Page 76: ...ransmission oil Dirty or less engine cum transmission oil increases the friction between various parts of the engine and reduces the engine life thereby increases fuel consumption Regularly inspect th...

Page 77: ...start from rest at full throttle will waste fuel and damage the engine It also creates a potentially dangerous traffic situation Fuel is wasted whenever the rider suddenly accelerate or apply brake No...

Page 78: ...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 Deale...

Page 79: ...um transmission oil R I T R I T R I T R Oil filter strainer C C C C Oil filter paper filter R R R R Spark plug1 I R Inspect Clean and adjust if required Replace every 12000 km Air cleaner element I R...

Page 80: ...sprocket and chain together Contd Item Service km Period from the date of sale In free service After free service Remarks 1st 500 750 1 month 2nd 2500 3000 3 months 3rd 5000 6000 6 months 4th 8500 90...

Page 81: ...T I T WSS toner ring I C I C I C I C I C I C Replace if damaged WSS cable clamps I I I I I I Fix new clamp if found missing WSS cable I I I I I I Replace if damage Brake hose bundy tubes I I I I I I R...

Page 82: ...te of sale In free service After free service Remarks 1st 500 750 1 month 2nd 2500 3000 3 months 3rd 5000 6000 6 months 4th 8500 9000 9 months 5th 11500 12000 12 months Every 3000 km 3 months Every 60...

Page 83: ...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 petrole...

Page 84: ...e 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 dam...

Page 85: ...ore during and after long storage of battery 1 Before Storage a Store the battery only after fully charging it b Battery fuse to be disconnected and stored safely This will reduce the sleep mode curre...

Page 86: ...ged battery as it may damage electrical components Do not push start the vehicle use a good battery to start the vehicle Battery develop explosive gases Keep it away from heat sources If charging is r...

Page 87: ...se 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...

Page 88: ...BS 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 a...

Page 89: ...acing 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...

Page 90: ...re 8 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...

Page 91: ...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 92: ...d 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 wh...

Page 93: ...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 grou...

Page 94: ...r 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 br...

Page 95: ...y Insufficient air pressure in the tyres not only hasten tyre wear but also seriously affects the stability of the vehicle Under inflated tyres make smooth cornering difficult and over inflated tyres...

Page 96: ...stability and can lead to loss of control It is recommended to replace the tyre when the tyre wears off to the tyre wear indicator level indicated by TWI on the tyre Tyre rotation direction While reas...

Page 97: ...h the ground for more than week time Inflation pressure should check on cold condition maximum travel time should not exceed more than 1 km Weekly basis inflation pressure check helps to improve 10 of...

Page 98: ...icle running Check clean and lubricate the drive chain in the following manner 1 Place the vehicle on centre stand with the transmission in neutral 2 Clean the chain in the as explained below Turn OFF...

Page 99: ...ler Authorised Dealer for adjustment Lubricate the drive chain after the motorcycle is washed with water or riding in rainy wet condition The chain must be serviced more frequently when the vehicle is...

Page 100: ...erse 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 that wheneve...

Page 101: ...d above we recommend to carry out the following steps 1 Clean the vehicle thoroughly Park the vehicle on centre stand 2 Warm up the engine and drain engine cum transmission oil Store the oil if new in...

Page 102: ...D 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...

Page 103: ...ness 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 Long journey are t...

Page 104: ...ill 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...

Page 105: ...or 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...

Page 106: ...are subject to our agreement with proprietary OEM Battery warranty for MF type Maintenance Free is applicable for a period of 21 months from the date of charging or 18 months from the date of sale or...

Page 107: ...rs Factors Vehicles on which any warranty service including scheduled paid service is not availed when it falls due at TVS Motor Company Authorised Main Dealer Authorised Dealer Vehicles sold or trans...

Page 108: ...An OTP would be sent to customer s registered mobile number The same to be shared with the servicing Dealer on or before vehicle delivery Periodic maintenance always helps good performance of an auto...

Page 109: ...7 7th service 17500 18000 18 months 8 8th service 20500 21000 21 months 9 9th service 23500 24000 24 months 10 10th service 26500 27000 27 months 11 11th service 29500 30000 30 months 12 12th service...

Page 110: ...charges Charges for the pay service should be borne by the customer Cost of engine oil periodic maintenance parts filter brake fluids all types of greases petroleum jelly distilled water chain cleane...

Page 111: ...er Viscous Paper filter Oil filter Wire mesh and micronic paper filter Lubrication system Forced wet sump Maximum power in kW In Sport Mode 11 80 kW 8750 rpm In Urban and Rain Mode 9 80 kW 8000 rpm Ma...

Page 112: ...smission Helical gears Secondary transmission Chain and sprockets GEAR RATIO I gear 2 917 II gear 1 857 III gear 1 333 IV gear 1 050 V gear 0 880 Primary reduction 3 095 Final reduction 3 385 CHASSIS...

Page 113: ...n weight 268 kg Steering angle 36 both sides Caster angle 26 Frame Double Cradle Synchro STIFF Front suspension Telescopic oil damped Rear suspension Monotube inverted gas filled 5 step adjustable sho...

Page 114: ...ICAL Type AC generator Ignition system ECU 3D Ignition timing map Spark plug BOSCH UR6DE Spark plug gap 0 6 0 1 mm Battery type VRLA or Flooded Battery capacity 12V 6 Ah MF Generator Fly wheel magneto...

Page 115: ...signal lamp 12V 10W x 4 Number plate lamp 12V 5W x 1 Instrument panel LCD LED indicators Horn 12V DC x 2 Fuse Main 12V 25A x 1 ABS 12V 15A x 1 Load 12V 15A x 1 EMS 12V 10A x 1 Using the bulb other tha...

Page 116: ...ITIES Fuel tank capacity 12 l Fuel BS VI petrol with minimum RON 91 containing upto 10 of ethanol by volume Engine cum transmission oil grade TVS TRU4 FULLY SYNTHETIC OIL SAE 10W30 API SL JASO MA2 Eng...

Page 117: ...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 thei...

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