RTR 160 Service Manual

PRODUCT TRAI TRAI NI NG CENTRE





PRODUCT TRAI NI NG CENTRE





Exclusive features of Apache RTR 160 All New Racing Graphics Racing Throttle Response Engine (RTR) Digital Speedo…with Service indicator system Split Type sporty Handle bar Bull horn pillion Handle Adjustable Link type gear shift mechanism 270mm Front Disc brake 16 LED Tail Lamp


RTR… Feature: •RTR : Racing Throttle Response •15.2 bhp engine Benefit: • Quick Response to the throttle. • Feel of a race bike.


IDI System Feature: TCI : Transistor controlled ignition

Benefit: Long and high intensity Spark for better combustion of Fuel mixture. Help in cold start & Cold Recovery


CDI Vs IDI

CAPACITOR


Gas Filled Shock Absorber Feature Gas filled 5 step adjustable shock absorber with Bottle designed Canister

Benefit Comfortable ride even on bad roads


Sporty Silencer Feature • Stainless steel, sporty silencer with catalytic converter and exhaust resonator. • Narrow snout designed muffler. Benefit • Sporty looks • Resonator helps to achieve good power & Torque • Rust Free • Catalytic converter reduces pollution


Stylish Contoured Fuel Tank Feature • Sporty and Stylish • 16 liters (including Reserve – 2.5 ltr) capacity with flushed petrol tank cap Benefit • Higher capacity Petrol Tank for long distance ride.


Halogen HL Bulb with Twin City Lamps Feature • Halogen HL bulb with Twin city lamps Benefit • Brighter light • Safer to ride in city traffic condition


RCF Technology Feature • Roller Cam Follower • Auto De-Compression Valve Benefit Friction free engine – Low maintenance Longer engine life Smoother engine No back kick during kick starting


Racing Response Engine… Feature • Powerful Engine Power 15.2 BHP@8500 rpm Torque13.1 Nm@6000 rpm • Engine with Charcoal Grey colour is added look. Benefit • Excellent Initial pickup • Better top speed


270mm Disc Brakes… Feature • Disc brakes with Sprocket design disc Benefit • Sporty looks • Effective braking • Better stability


Any Gear Electric Start… Feature • Any Gear Self Starting • Constant mesh self starter • SM-6 Motor Benefit • Positive engagement • Effortless Starting • Soft button start


Digital Speedo… Feature • Vehicle speed, clock, odometer, Trip meter on LCD screen.

Benefit • Guides the customer in time • More accurate


IE SURGE… Feature • IE SURGE - Intake Exhaust Resonator Surge •Induction resonator on air filter • Exhaust Resonator on Silencer Benefit • Intake Resonator accelerates the air fuel mixture flow during sudden throttling and helps in quicker power response to zoom the bike. • Exhaust Resonator helps in clearing exhaust gas quickly out of the silencer during sudden throttling which results in high torque. PRODUCT TRAI NI NG CENTRE

5 – Speed Transmission… Feature • 5 Speed gear box • Link type Adjustable shifting system • Carbo-nitrating Gears Benefit • High speed • Racing bike gear shifting system. • Improved life of gears



Dimensions SPECIFICATIONS

TVS Apache RTR 160

TVS Apache

Overall Length

2020 mm

1976 mm

Overall Width

730 mm

743 mm

Overall Height

1050 mm

1100 mm

Ground Clearance

180 mm

165 mm

Wheel Base

1300 mm

1260 mm

Kerb Weight

136 kg

136 kg

Pay Load

130 kg

130 kg

Gross Vehicle W eight

266 kg

266 kg


Engine SPECIFICATIONS Type

TVS Apache RTR 160

TVS Apache

4 stroke ,air cooled, single cylinder OHC

Bore

62 mm

57 mm

Stroke

52.9 mm

57.8 mm

Piston Displacement

159.7cc

147.5 cc

Carburettor Type

Ucal mikuni BS - 26

Ucal mikuni BS - 26

Air Filter

Double polyurethene foam filter element

Starting System

Kick start / Electric start

Lubrication System

Forced wet pump

Compression Ratio

9.5:1

Compression Pressure

10 - 13 kg/cm

2

Maximum Horse Power

11.19 KW (15.2 bhp) @ 8500 rpm

9.95 Kw(13.5 BHP)@8500 rpm

Maximum Torque

13.1 Nm @ 6000 rpm

12.3 Nm@6000 rpm

Valve Clearance (Cold)

Inlet 0.08 / Exhaust 0.11 mm

Inlet 0.07 / Exhaust 0.12 mm

Maximum Speed

118 kmph

108 kmph

Engine Idling Speed

1400±100


Transmission SPECIFICATIONS

TVS Apache RTR 160

TVS Apache

Clutch

Wet Multiplate type

Transmission

Constant mesh 5 speed gearbox

Gear Shift Pattern

All down heel - toe shift

Primary Reduction

65/21

Final Reduction

44/13

First Gear

35/12

Second Gear

26/14

Third Gear

24/18

Fourth Gear

21/20

Fifth Gear

22/25


Chassis SPECIFICATIONS

TVS Apache RTR 160

TVS Apache

Frame

Double Cradle SynchroSTIFF

Double cradle tubular type

Front Suspension and Travel

lescopic Forks, 105mm Stroke

Telescope oil damped 105mm

Rear Suspension

Monotube Inverted Gas filled shox (MIG) with spring aid

Gas filled 5 step adjustable with canester

Steering Angle

41' °

Caster Angle

25.5

Trail Length

81.3 mm

90mm

Br akes: Front

270 mm Petal Disc

130/240 mm dia Drum/Disc

Brakes: Rear

130 mm Drum

130 mm foot operated

Tyre Size Front

90/90 x 17”

90/90 x 17 - 6 ply

Tyre Size Rear

100/80 x 18”

100/80x 18


25.5'

Electrical SPECIFICATIONS

TVS Apache RTR 160

TVS Apache

Ignition System

IDI -dual mode digital ignition - DC

Sparkplug

Bosch Super UR 5 DDC

Sparkplug Gap Battery Type

0.6 mm 12V 9 Ah

Body Earthing

Negative terminal

Generator

12V, 100W

Head Light Tail Light/Brake Light Turn Signal Light

35/35W Halogen HS1, Clear lens with MFR

12V, 35/35 W HS 1 halogen

0.5 W. LED-Twin triangle with prism on lens 12V,10W

High Beam Indicator Light

12V,2W

Neutral Indicator Light

12V,3.4W

Speedometer Light

12V,3.4W

Economy & power mode lamp

12V,2W

Turn Signal Indicator Light

12V,2W PRODUCT TRAI NI NG CENTRE

12 V, 5W / 21W

Capacity SPECIFICATIONS

TVS Apache RTR 160

TVS Apache

Fuel Tank Including Reserve

16 Lts

Reserve

2.5 lts

Front Fork Oil

125 ± 2.5 ml ea ch

Transmission cum Engine Oil (Grade) Transmission cum Engine Oil (Qty)

4T Oil 1000ml(Overhauling)


Carburettor Specifications Discription Carburettor Type Main Jet

TVS APACHE RTR 160

TVS APACHE

BS26 CV Ucal Mikuni

BS26 - X21 CV Ucal Mikuni

105

102.5

Needle Jet

P2

Jet Needle

QK

E - ring position Pilot Jet Pilot air jet (1)

2 nd from top 15

12.5

1.45

1.45

Pilot air jet (2) Piston valve

NA CA - 3.9(2 vacuum sensing holes)

Throttle Valve MCS screw - No of turns

120 2±1(1 ~ 3 turns out)

Idling RPM Idling CO%(with SAI) Idling CO%(without SAI)

CA - 3.9(1 vacuum sensing hole)

1400±50 0.8 ~ 1.2%

0.6 ± 0.4% 3.5 ~ 4.5%



Cylinder Head

Combustion Chamber diameter increased. bigger Inlet & Exhaust valve seats provided. Painted with Charcoal grey colour.


Cylinder Bl ock

Bore Dia. increased to 62 mm Auto Chain Tensioner mounting design is changed. 159.7 cm3 embossed for identification. Painted with Charcoal grey colour.


P iston Assy.

Piston Dia. increased to 62 mm Piston Rings dia increased to match the new piston. Piston Pin and locks also modified


Crankshaft A ssy.

160cc

Crankshaft web weight increased. Connecting rod modified. Chamfer on Crank web are bigger.

150cc


Clutch Cover

New Part Rod comp. Clutch release is modified. Charcoal grey painting is provided


Auto C hain Tensioner

New Part Strip coil type tensioner


Crankcase R H

New Part Guide bush

Guide bush provided for Cam gear shift shaft. Painted with charcoal grey colour.


Crankcase LH

New Part Painted with Charcoal grey colour.


Clutch Assy. New Part Clutch plate Drive and plate driven are modified. Clutch spring are changed. Clutch plate serrations reduced to 45( Apache 150 – 48 serrations). Plain surface provided for pressure plates (Apache 150 – dotted surface)


Cover M agneto

New Part Charcoal grey colour.


Stator coil assy.

New Part Charging and lighting coils increased to 8(Apache 150 – 7 coils) Since Source coil is not available here, that location is used for one additional lighting /charging coil.


CV Carb uretor New Part Fuel Jets and Tuning specifications changed Main Jet – 105 Pilot Jet – 15 Piston Valve CA-3.9(1 vacuum hole) CO (with SAI) – 0.8 ~ 1.2% Since change in By pass pitch , RTR 160 have new carburetor body Can not interchange with Apache 150cc PRODUCT TRAI NI NG CENTRE

Inlet & Exhaust Valve RTR

150cc

New Parts Valve face diameter increased Inlet tappet clearance – 0.07 mm Exhaust tappet clearance – 0.11 mm

Exhaust Inlet


Sil encer Assy.

New Part. Narrow snout Muffler Assy. design is to suit the new styling. Mounting bracket point is changed. Exhaust resonator position shifted to bottom side vehicle.


Lever Kick Starter

New Part. Design is changed to suit the new styling.


Suppres ser Cap

New part. Suppressor cap design is changed to avoid the water entry.


Lever Gear Shifting New Part. Link type design provided to give racing bike feel during gear shift. Cam gear shift design changed to match the changes in Crankcase RH for smoother gear shifting. Transmission gears are same as Apache 150cc.


Rear Brake Pedal

New part. To suit the new styling.


W iring Harness Ha rness New Part. New couplers to connect the LED tail lamp. Water proof cou coupler pler provided for avoiding the water entry. Special coupler provided to connect the digital speedometer.


Relay pass by

New part Relay unit provided for Pass by operation. Pass by will work in both DC and AC.


TCI Unit

New part.

160cc

Ignition timing curves are changed in TCI of RTR. For identification IDI in grey colour.

150cc


Handle Bar New part. Split type handle bar to suit the new styling. Handle bars can be adjusted to two positions as per the requirement. Upper bracket cover added for styling.


Bracket Pill ion Foot Rest New part. diecasted pillion foot rest holder. Charcoal Grey colour to match the look of the bike.


Bracket Side S tand

New Part. To improve the Part lift.


Chain Case

New part both Chain case upper and Lower are modified to match the new swing arm fitments. Dimple profile provided at inner side of case to avoid wheel fouling during the ride.


Rear Fender

New part. Rear fender design is changed to suit the new styling.


Num ber Plate Lamp

Design is changed. Rear Reflector is fitted to lamp body.


Digital Speedo Hub Driv e

New Part. Connected to digital Speedo meter through the wires. Speedo cable is not provided.


Front Fork R H

New Part. Outer Tube design is changed Disk Mounting point is changed.


Vibration Dampers & Handle Grip

New Part. Handle grip is modified Vibration damper is modified. Chrome plating is provided for Clutch lever and Front Brake lever.


Engine Guard

New Part. To provide a sporty look to the bike.


Gas filled Rear shock A bsorbers

New Part. Canister Design modified. Filled with Nitrogen Gas. Lower mounting bracket length increased.

150cc

160cc PRODUCT TRAI NI NG CENTRE

Front W heel Assy.

New Part. Disc mounting positions changed to mount the 270 mm disc.


APACHE - IGN ITION CIRCUIT Charging Coil WR

B

RW

BW

RR Unit 10A Fuse

BW

R

Ignition Switch

BW

Battery

Or B

W

B BlR

DC TCI

Br

BW PULSER COIL

SELF STARTER SWITCH

B

BW

Or

DC CIRCUIT

ENGINE KILL SWITCH

R

Or

Digital SPEEDOMETER

Bl

HT COIL

GW BlW TCS

HT Cord

Spark Plug


THROTTLE CONTROL SWITCH

A P AC HE – I D I C I R C U I T

10A Fuse BW

R BW

Battery

Ignition Switch

SELF STARTER

B RELAY UNIT

BW

Or

DC CIRCUIT

ENGINE KILL SWITCH

R

Or B

W Br

B BlR

DC IDI BW

Or

Digital SPEEDOMETER

Bl

PULSER COIL

HT COIL

GW BlW

HT Cord

Spark Plug


TCS THROTTLE CONTROL SWITCH

APACHE - CHARGIN G CIRCUIT Charging Coil WR

B

RW

BW

BW

DC TCI ENGINE KILL SWITCH

RR Unit 10A Fuse

BW

R

B

SELF STARTER SWITCH

B

R BW

Battery

Ignition Switch Or

Or

Or

F r. Br S wi tch

W

Or

R r. Br. S wi tch

Or

Y Or

DC TCI

Horn(2) Flasher Unit

RELAY PASS BY Y

W

Or

GB

TSL Switch L R

Fr. TSL

G Horn Switch

High/Low Beam switch

lbl

Fr. TSL V

Rr. TSL

lG

Rr. TSL

BW Brake Light

YBl BW

HEAD.LAMP

TSL Indy PASS BY SWITCH

Lighting Switch


TSL Indy

APACHE – SELF START CIRCUIT

ENGINE KILL SWITCH

DC TCI B

10A Fuse R

B

R

BW

BW

Battery

Ignition Switch

TO DC Circuit

Gr

B

BW

Clutch Switch

BlW

Starter Button

Or BlW Neutral Lamp Bl Bl

Starter Relay S TARTER MOTOR


Neutral Switch

APACHE - LIGHTIN G CIRCUIT Lighting Coil B W

Y

PASS BY SWITCH

BW

GB

YR

OR

RR Unit

RELAY PASS BY

YW

Lighting Switch Yor

Y

Gr YB Gr

Gr

Gr

Gr SPEEDOMETER

BW

Number plate lamp BW

Tail Lamp

Headlamp

Gr

City lamp

BW BW

City lamp

H

BW

L

WR

Headlamp Switch PRODUCT TRAI NI NG CENTRE

BW

A P A CH E - C O I L T E S T I N G Lighting Coil Resistance:0.25 - 1.0 ohm Lighting coil Y Ohms

+ -

B

Pulser Coil

Charging Coil

Resista nce: 125 - 150 Oh ms

Resista nce: 0.4 - 1.0 Ohm s Charging coil

Pulse r coil

Br 2000

Ohms

+ -

BW

R

200

R

WR

W

200

Ohms

B

R

+ -

BW

B

IGNITION COIL TE ST ING Secondary Coil

Primary Coil

Resista nce: 11.0 - 13.0 KOhms

Resistance: 2.0 - 4.0 Ohm Ignition coil

Ignition coil

Or 20 0 Ohms

HT CO RD

Bl

HT CORD

+ -

20 K

Ohms

+ -

To Spark Plug


From C DI Unit

P DI 01.CHECK FOR PAINT SCRATCHES/DAMAGES 02.MISSING ITEMS 03.ALIGNMENTS/GAP 04.STANDARD CHECKS 05.FASTENER TIGHTNESS CHECKS 06.GENERAL CHECKS (AFTER STARTING THE ENGINE) 07.ELECTRICAL FUNCTION CHECKS 08.ROAD TRIAL 09.POST TRIAL (ON STAND)


Custom er In stallation Basic Check points before starting the Vehicle •All controls operations(clutch,brake,throttle,gear shifting) •Explain all settings on Digital Speedometer • Tank capacity : 16lit Res: 2.5lit •Tyre pressure •Battery condition – Proper functioning of horn,brake lights,turn signal indicators,electrolyte level •Tool kit •First aid kit •Engine oil level •Lighting

Service schedule •Explain Service schedule of Apache RTR 160 as per owners manual

Warranty •Warranty period, Parts not covered under warranty, Limitations of warranty.

•Tips for achieving best performance from vehicle •Proper tyre pressure •Battery condition checking •Usage of IFTEX for petrol(2ml/ltr) •Running in period •Riding tips


Service Schedule Se rvice

Kms

Month

I

500 - 750

II

2500 - 3000

3 Months

III

5500 - 6000

6 Months

IV

8500 - 9000

9 Months

V

11500 - 12000

12 Months

VI

14500 - 15000

15 Months

VII

17500 - 18000

18 Months

VIII

20500 - 21000

21 Months

IX

23500 - 24000

24 Months

X

26500 - 27000

27 Months

XI

29500 - 30000

30 Months

Fre e/Pay

1 month

Warranty Period: 30000kms/24 months


e e r F

y a P

Periodic M aintenance








RTR 160 Service Manual

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