GENERAL INFORMATION

TVS APACHE RTR160 SINGLE DISC

1

Fig. 1.1

TVS APACHE RTR160 DUAL DISC

E
AG
IM
IS
TH
CE
LA
P
RE
SE
EA
PL

Fig. 1.1

General information 1-1

 GENERAL INFORMATION

TVS APACHE RTR180 DUAL DISC

E
AG
IM
IS
TH
CE
PLA
RE
SE
EA
PL

Fig. 1.3

VEHICLE IDENTIFICATION NUMBERS

LOCATIONS
MD
634

FRAME NUMBER
KE42
92H

l The frame serial number is engraved on the frame

090
96

of right side of the steering head pipe. (Fig. 1.4)

Fig. 1.4
ENGINE NUMBER

l The engine serial number is engraved on the left

side crankcase near cylinder block. (Fig. 1.5)

95
92 213 0
OE4H

Fig. 1.5

General information 1-2

 SYSTEM FOLLOWING IN FRAME NO. IDENTIFICATION
PT TVS MOTOR COMPANY INDONESIA

Z - PT TVS MOTOR COMPANY INDONESIA

6 - TVS MOTOR COMPANY INDIA Year code

D - India Engine type Plant code

K - Indonesia
GENERAL INFORMATION

M - Asia Month code

M D 6 3 4 K E 4 2 9 2 H 0 9 0 9 6

Frame type

Check digit Manufacturer serial no.

Vehicle type

Variant identifier

General information 1-3

1
 SYSTEM FOLLOWING IN ENGINE NO. IDENTIFICATION
PT TVS MOTOR COMPANY INDONESIA

General information 1-4

Engine type

FILLER Plant code

GENERAL INFORMATION

0 E 4 H 9 2 2 1 3 0 9 5

Month code

Year code Manufacturer serial no.

GENERAL INFORMATION

1
TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
DIMENSIONS AND WEIGHT
Overall length 2020 mm 2085 mm
Overall width 730 mm
Overall height 1050 mm 1105 mm
Seat height 790 mm
Ground clearance 180 mm 165 mm
Wheel base 1300 mm 1326mm
Kerb weight (with toolkit and 90% of fuel) 136 kg 139 kg 137 kg
Pay load 130 kg
Maximum laden weight 266 kg 269 kg 267 kg

ENGINE
Type 4 stroke, air cooled, single cylinder OHC
Bore 62 mm 62.5 mm
Stroke 52.9 mm 57.8 mm
Piston displacement 159.7 cc 177.4 cc
Carburettor type (Ucal Mikuni) BS26 X39Z1 BS29
Air filter Double polyurethane foam filter element
Oil filter Wire mesh and micronic paper filter
Lubrication system Forced wet sump
Compression ratio 9.5 : 1
Maximum power @ 8500 rpm 11.19 kW(15.2 BHP) 12.52kW(17BHP)
Maximum torque @ 6000 rpm 13.1 Nm 15.5 Nm
Maximum speed 118 km / hr 124 km / hr
Engine idling rpm 1400 ± 100 rpm
Starting system Kick starter & Electric starter

TRANSMISSION
Clutch Wet, multi-plate type - Manual over ride
Transmission 5 speed constant mesh
Gear shift pattern 1 down and 4 up, toe shift
Primary reduction (Helical gears) 3.095 (65/21)
Final reduction (Chain and Sprocket) 3.384 (44/13) 3.286 (46/14)
Overall reduction (at top gear) 9.22 8.95

General information 1-5

 GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
GEAR RATIO
First gear 2.917 (35/12)
Second gear 1.857 (26/14)
Third gear 1.333 (24/18)
Fourth gear 1.050 (21/20)
Fifth gear (top gear) 0.880 (22/25)

CHASSIS
Frame Double cradle synchro - stiff
Front suspension and travel Telescopic, oil damped 105 mm travel
Rear suspension and travel Monotube inverted gas filled 5 step adjustable
hydraulic shocks with rectangular swing arm.
Steering angle 82°
Caster angle 25.5°
Trail length 81.3 mm 84.3 mm
Turning radius 2010 mm 2150 mm
Brakes - Front (Hand operated) 270 mm dia petal disc
- Rear (Foot operated) 130 mm (Drum) 200 mm dia petal disc
Tyre size - Front 90/90 x 17“ 90/90 x 17“ (Tube Less)
- Rear 100/80 x 18“ 100/80 x 17“ (Tube Less)
Tyre pressure - Solo (Front) 1.75 kg / cm2 (25 PSI)
(Rear) 2.00 kg / cm2 (28 PSI)
- Dual (Front) 1.75 kg / cm2 (25 PSI)
(Rear) 2.25 Kg / cm2 (32 PSI)

ELECTRICAL
Type AC generator
Ignition system IDI - Dual mode digital ignition
Ignition timing (At coinciding mark) 5.0º ± 2º at 1500 rpm
(Full advance) 34.0º ± 2º at 10000 rpm
Spark plug (BOSCH) UR5DDC - Twin electrode
Battery type 12 V, 9.0 Ah
Body earthing Negative terminal

General information 1-6

GENERAL INFORMATION

1
TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
ELECTRICAL
Generator 12 V, 100 W
Head lamp 12 V, 35/35 W HS1 (Halogen)
Position lamp 12 V, 4 W x 2 Nos
Tail lamp 12 V, 0.5 W (LED)
Brake lamp 12 V, 3.5 W (LED)
Turn signal lamp 12 V, 10 W x 4 Nos
Number plate lamp 12V, 4 W
Instrument panel lamp LCD / LED indicators
Horn type 12 V, DC x 2Nos
Fuse 12V, 10 A

CAPACITIES
Fuel tank (including reserve) 16.0 litres
Reserve 2.5 litres
Front fork oil (grade) Teleshockab oil
Front fork oil (qty) GIL 140 ± 2.0 ml per leg 140 ± 2.0 ml per leg
TOP 152 ± 2.5 ml per leg
Engine cum transmission oil (grade) 4T oil
Engine cum transmission oil (quantity) 1000 ml (During service)
1100 ml (During overhaul)
Disc brake fluid DOT 3 / DOT 4

Note:
Specifications are subject to change on account of continuous improvements in
the product.

General information 1-7

 GENERAL INFORMATION

RUNNING - IN PERIOD

The first 1000 kms is a crucial part. Proper running-in operation during this time helps in ensuring a longer life and smooth
performance of TVS Apache RTR.

The reliability and performance of TVS Apache RTR depends on special care and restraint exercised during running-in
period. It is especially important that you avoid operating the engine in a manner, which could expose the engine parts to
excessive heat. Maximum recommended speed during running-in is 50 kmph.

Do not ride at constant low speed for a longer time during any portion of the running-in period. Keep varying the engine
speed for better mating of parts.

PRECAUTIONS AND GENERAL INSTRUCTIONS

Observe the following precautions without fail when dismantling and reassembling.

l Do not run the engine indoors with little or no ventilation.

l Be sure to replace gaskets, O-rings, circlips and cotter pins with new ones, for safety.
l When tightening nuts and bolts, start first with the larger or centre ones. Tighten these to the specified torque following a
crisscross pattern.
l Use specified special and common tools only.
l Avoid any dent or damage to fork inner tube through contact of internal objects.
l When engine and final drive components are disassembled and inspected, coat the mating surfaces with a lubricant to
prevent corrosion.
l When assembling components, use recommended lubricants.
l After assembling, check every part for proper installation, movement and operation.
l Always ensure mutual safety when working with the partners.
l Use only TVS Motor Company genuine parts and recommended lubricants.

General information 1-8

 GENERAL INFORMATION

LIST OF HAND TOOLS REQUIRED

1. Flat head spanners:

1
7 mm, 8 mm, 10 mm, 12 mm and 14 mm.

2. Ring spanners:
8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm , 17 mm, 22 mm, 27 mm, and 32 mm.

3. Tubular spanners:
8 mm, 10 mm, 12 mm, 14 mm, 16 mm and 17 mm.

4. Socket spanners:
8 mm, 10 mm, 12 mm, 13 mm, 14 mm, 17 mm, 22 mm, 27 mm and 32 mm.

5. Allen keys:
4 mm, 6 mm, 8 mm, 10 mm and 12 mm.

6. Screw drivers:
Flat screw driver-small, flat screw driver, phillips head screw driver no.1, phillips head screw driver no. 2 and phillips head
screw driver no. 3.

7. Hammers:
Nylon hammer, rubber mallet and metal hammer.

8. Pliers:
Straight nose plier, combination plier, water pump plier, external circlip plier-6 inch and external circlip plier-7 inch.

9. Others:
Drift, chisel, plug spanner, compression gauge, special adopter, micrometer, vernier calliper, dial gauge, battery charger,
feeler gauge, pocket tester, impact driver set, tachometer, hydrometer and hot plate.

LIST OF SPECIAL TOOLS REQUIRED

Sl. no. Part no. Description

1 0312401 Universal oil seal remover

2 1313501 Front fork oil seal installer
3 2310300 Assembly tool steering cups
4 M1310010 Holder assembly magneto
5 M1310020 Puller assembly magneto
6 M1310070 Tappet adjuster
7 M1310110 Puller assembly crankcase
8 M1310160 Holder front fork cylinder
9 N2310010 Clutch holding tool
10 N2310020 Clutch nut tightening tool
11 N2310070 Mandrel gear shaft oil seal
12 N2310080 Mandrel drive shaft R side bearing
13 S1310020 Extractor assembly inlet and exhaust valve
14 S1311110 Extractor main bearing

General information 1-9

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APPLICATION OF SPECIAL TOOLS .....................................................................................................................................................................................................
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1. Un versa o sea remover - 0312401 .....................................................................................................................................................................................................
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l Used o remove o sea rom he ron ork ou er .....................................................................................................................................................................................................
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ube and crankcase F g 1 7 .....................................................................................................................................................................................................
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2. Front fork o sea nsta er - 1313501 .....................................................................................................................................................................................................
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l To ns a ron ork o sea and dus cap F g 1 8 .....................................................................................................................................................................................................
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Fg 1 8
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3. Assemb y too steer ng cups - 231030000 .....................................................................................................................................................................................................
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l To ns a cup bo om and cup op n he rame .....................................................................................................................................................................................................
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s eer ng s em Fg1 9 .....................................................................................................................................................................................................
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4. Ho der assemb y magneto - M1310010 .....................................................................................................................................................................................................
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l To ho d magne o ro or wh e oosen ng or .....................................................................................................................................................................................................
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gh en ng he nu magne o F g 1 10 .....................................................................................................................................................................................................
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General information 1-10
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GENERAL INFORMATION .....................................................................................................................................................................................................
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1
5. Pu er assemb y magneto - M1310020 .....................................................................................................................................................................................................
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l To remove magne o ro or rom he cranksha .....................................................................................................................................................................................................
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assemb y F g 1 11 .....................................................................................................................................................................................................
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6. Tappet ad uster - M1310070 .....................................................................................................................................................................................................
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l Used o oosen and gh en he appe ad us ng .....................................................................................................................................................................................................
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screw F g 1 12 .....................................................................................................................................................................................................
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7. Pu er assemb y crankcase - M1310110 .....................................................................................................................................................................................................
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l To separa e crankcase Land R F g 1 13 .....................................................................................................................................................................................................
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8. Ho der front fork cy nder - M1310160 .....................................................................................................................................................................................................
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l To ho d he ron ork p s on wh e remov ng or .....................................................................................................................................................................................................
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assemb ng p s on bo n G L make eg assy .....................................................................................................................................................................................................
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General information 1-11
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9. C utch ho d ng too - N2310010 .....................................................................................................................................................................................................
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l To ho d d sc c u ch pressure wh e oosen ng and .....................................................................................................................................................................................................
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gh en ng he nu c u ch sha F g 1 15 .....................................................................................................................................................................................................
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F g 1 15
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10. C utch nut t ghten ng too - N2310020 .....................................................................................................................................................................................................
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l Used o oosen and gh en he nu c u ch sha .....................................................................................................................................................................................................
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F g 1 16 .....................................................................................................................................................................................................
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F g 1 16
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11. Mandre gear shaft o sea - N2310070 .....................................................................................................................................................................................................
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es
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l To ns a o sea n gear sh sha F g 1 17 .....................................................................................................................................................................................................
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a g
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im
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se
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e
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h
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t
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d
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d
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ea
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as
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Ple
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F g 1 17
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12.Mandre dr ve shaft R s de bear ng - .....................................................................................................................................................................................................
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N2310080 .....................................................................................................................................................................................................
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s
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ge
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l To ns a o sea n k ck s ar er sha F g 1 18 a
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im
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se
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t he
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dd
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a
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se
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le a
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P
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F g 1 18
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General information 1-12
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GENERAL INFORMATION .....................................................................................................................................................................................................
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1
13.Extractor assemb y n et and exhaust va ve - .....................................................................................................................................................................................................
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S1310020 .....................................................................................................................................................................................................
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l To remove and ns a he n e & exhaus va ve .....................................................................................................................................................................................................
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co er va ves F g 1 19 .....................................................................................................................................................................................................
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F g 1 19
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14.Extractor ma n bear ng - S1311110 .....................................................................................................................................................................................................
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l To remove ma n bear ng rom cranksha .....................................................................................................................................................................................................
s
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ge
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F g 1 20 .....................................................................................................................................................................................................
a
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im
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se
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t e
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h
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d
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ad
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as
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Ple
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F g 1 20
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General information 1-13