TVS Apache RTR 200 4V Service Manual
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TVS Apache RTR 200 4V Service Manual

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SERVICE MANUAL
SER.MAN/TVS APACHE RTR 200 4V - REVISION - 0

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Summary of Contents for TVS Apache RTR 200 4V

  • Page 1 SERVICE MANUAL SER.MAN/TVS APACHE RTR 200 4V - REVISION - 0...
  • Page 2 All the illustrations given in this manual may vary from the actual vehicles. TVS MOTOR COMPANY LIMITED reserves the right to make changes at any time without prior notice and without incurring any obligation whatsoever.
  • Page 3 FOREWORD We are happy to provide you the first edition of new TVS APACHE RTR 200 4V motorcycle’s service manual. This manual is prepared to provide the assistance during the process of servicing the new TVS APACHE RTR 200 4V motorcycle. This manual describes about the basic operations of this new product, do‘s and don‘t‘s, service limits of individual components and sub systems while servicing the...
  • Page 4 HOW TO READ THIS MANUAL This service manual is split into seven chapters as “General information“, “Periodic maintenance“, “Servicing of engine”, “Fuel, Lubrication and Exhaust system“, “Electrical system“, “Chassis” and “Service information”. Mostly the pages run through two columns in the inside pages with instructions on left side and the illustrations on the right side.

  • Page 5: Table Of Contents

    GROUP INDEX TVS APACHE RTR 200 SERVICE MANUAL GENERAL INFORMATION Page 1-1 to 1-14 PERIODIC MAINTENANCE Page 2-1 to 2-52 SERVICING OF ENGINE Page 3-1 to 3-58 FUEL, LUBRICATION AND EXHAUST SYSTEM Page 4-1 to 4-19 ELECTRICAL SYSTEM Page 5-1 to 5-28...
  • Page 7 ENGINE TRANSMISSION GEAR RATIO CHASSIS ELECTRICAL CAPACITIES ADVANTAGES AND SPECIAL FEATURES OF TVS APACHE RTR 200 4V WARRANTY TERMS RUNNING- IN PERIOD FUEL AND OIL RECOMMENDATIONS PRECAUTIONS AND GENERAL INSTRUCTIONS LIST OF HAND TOOLS REQUIRED LIST OF SPECIAL TOOLS REQUIRED...

  • Page 9: General Information

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TVS APACHE RTR 200 4V RIGHT SIDE Fig. 1.1 LEFT SIDE Fig. 1.2...

  • Page 10: Vehicle Identification Numbers

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL VEHICLE IDENTIFICATION NUMBERS LOCATIONS FRAME NUMBER The frame serial number is stamped on the right side of the steering head tube. (Fig. 1.3) Fig. 1.3 ENGINE NUMBER The engine serial number is stamped on the left side crankcase assembly near cylinder block.

  • Page 11: Year And Month Codes

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL YEAR AND MONTH CODES CODE FOR THE PRODUCTION YEAR CODE FOR THE PRODUCTION MONTH CODE YEAR CODE MONTH 2001 JANUARY 2002 FEBRUARY 2003 MARCH 2004 APRIL 2005 2006 JUNE 2007 JULY 2008...

  • Page 12: Technical Specifications

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TECHNICAL SPECIFICATIONS DIMENSIONS AND WEIGHT Overall length 2050 mm Overall width 790 mm Overall height 1105 mm Seat height 800 mm Ground clearance 180 mm Wheel base 1353 mm Kerb weight 148 kg...

  • Page 13: Gear Ratio

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TECHNICAL SPECIFICATIONS GEAR RATIO First gear 2.917 Second gear 1.857 Third gear 1.333 Fourth gear 1.050 Fifth gear 0.880 Primary reduction 2.818 Secondary reduction 3.461 CHASSIS Frame Double Cradle Split Synchro STIFF (DCSSS)

  • Page 14: Capacities

    Front fork oil quantity 325 ± 2 cc Brake fluid TVS Griling DOT 3 / DOT 4 Note: Specification are subject to change on account of continuous improvements in the product. * The fuel tank is not a measuring instrument and the capacity of the fuel tank may vary from the...

  • Page 15: Advantages And Special Features Of Tvs Apache Rtr 200 4V

    TVS APACHE RTR 200 4V. The reliability and performance of TVS APACHE RTR 200 4V depends on special care and restrain 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.

  • Page 16: Fuel And Oil Recommendations

    TVS APACHE RTR 200 SERVICE MANUAL FUEL AND OIL RECOMMENDATIONS TVS APACHE RTR 200 4V has a four stroke engine. Do not mix oil with petrol. Be sure to use the following specified fuel and oil. Fuel: Unleaded petrol with octane number between 85 to 95 by research method.

  • Page 17: List Of Hand Tools Required

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL LIST OF HAND TOOLS REQUIRED 1. Flat head spanners: 7 mm, 8 mm, 10 mm, 12 mm, 14 mm and 21 mm 2. Ring spanners: 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm , 17 mm, 22 mm, 24 mm, 27 mm and 32 mm 3.

  • Page 18: Special Tools And Its Application

    GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL SPECIAL TOOLS & ITS APPLICATION 1. Magneto puller - M131 002 0 (Fig. 1.5A) Used to remove the magneto rotor from the crankshaft assembly. (Fig.1.5B) Fig. 1.5A Fig. 1.5B 2. Tappet adjuster - M131 007 0 (Fig.1 .6A) Used to adjust the valve tappet clearance.
  • Page 19 GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL 5. Clutch nut tightening tool - N231 002 0 (Fig.1.9A) Used to remove / reassemble the clutch nut during clutch servicing. (Fig. 1.9B) Fig. 1.9A Fig. 1.9B 6. Front fork oil seal installer - N931 009 0 (Fig.
  • Page 20 GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL 9. Tool cone bottom installer - N931 013 0 (Fig. 1.13A) Used to assemble the cone bottom to the steering stem. (Fig. 1.13B) Fig. 1.13A Fig. 1.13B 10. Tool steering nut - N931 014 0 (Fig. 1.14A) Used to remove / assemble the steering lock nut and arrester steering stem.
  • Page 21 GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL 13. Magneto tool assembly - N931 017 0 (Fig. 1.17A) Used to hold the magne to rotor while removing/assembling the primary drive gear and magneto rotor nuts. (Fig. 1.17B) Fig. 1.17A Fig. 1.17B 14.
  • Page 22 GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL 17. Main bearing extractor - S131 111 0 (Fig. 1.21A) Used to remove the main bearing from the crankshaft. (Fig. 1.21B) Fig. 1.21A Fig. 1.21B 18. Front fork oil level gauge - 031 180 0 (Fig.

  • Page 23: Periodic Maintenance

    CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 2 DESCRIPTION PAGE NO PERIODIC MAINTENANCE SCHEDULE SEAT REMOVAL PROCEDURE COVER FRAME L & R REMOVAL FUEL TANK COMPLETE REMOVAL COVER FUEL TANK REMOVAL TAIL COVER ASSEMBLY REMOVAL PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE...

  • Page 25: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL PERIODIC MAINTENANCE For a trouble free performance of the vehicle and its longer life, the vehicle should be periodically inspected for wear of components, carbon deposits, stretched cables, etc. The worn-out components to be replaced or repaired and necessary adjustment to be made for certain items for better performance of the vehicle as indicated in the table.
  • Page 26 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Item In free service After free service Service Remarks Every Every 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000 km 1 month 3 months 6 months 9 months 12 months Period from the date of sale Retainer oil seal –...
  • Page 27 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL SEAT ASSEMBLIES REMOVAL Rear seat (passenger seat) removal Insert the ignition key into the seat lock (A). Turn it in clockwise, then pull and release the front section of the seat (1) first, followed by the rear section as shown in the figure.

  • Page 28: Cover Frame L & R Removal

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL COVER FRAME R & L REMOVAL Remove the seats as explained earlier. Remove the CRR pan head screw (M6x16 - 3 nos.) from the cover frame R. (Fig. 2.4) Phillips head screw driver Take out the cover frame R by carefully Fig.

  • Page 29: Fuel Tank Complete Removal

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL FUEL TANK COMPLETE REMOVAL Remove the seats and cover frame assembly as explained earlier. Turn fuel cock knob to ‘OFF’ position and disconnect the fuel hose from the carburettor assembly. (Fig. 2.6) Nose plier Fig.
  • Page 30 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL COVER FUEL TANK ASSEMBLY REMOVAL Remove the fuel tank as explained earlier. Remove the CRR flanged pan head tap screw (A) (ST4.2x13 - 2 nos.) from the mounting of deflector. (Fig. 2.9)
  • Page 31 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove hexagonal socket cap screw (M5x30 - 3 nos.) from the mounting of fuel tank cap assembly. (Fig. 2.13) 4 mm allen key Tightening torque 4.5 ± 0.5 Nm Note: Remove only the marked screws (refer Fig.
  • Page 32 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Similarly remove the cover fuel tank inner L from the cover fuel tank assembly. Note: While reassembling, ensure the presence of clips (clip nut ST4) before installing the screws. Remove the CRR flanged pan head tap screw (ST4.2x13 - 3 nos.) from the mounting of cover...
  • Page 33 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY For re-assembly, reverse the procedure removal. Assemble the covers separately and then assemble them as a set into the fuel tank. Refer exploded view for assembly details. (Fig. 2.20) Note: Before assembling the cover fuel tank assembly into the fuel tank. Ensure the availability of cushions at the respective places.

  • Page 34: Tail Cover Assembly Removal

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL TAIL COVER ASSEMBLY REMOVAL Remove the seats and cover frame L & R as explained earlier (refer page nos. 2-3 & 2-4). Remove the hexagonal socket cap screw (M8x25 - 4 nos.) from the mounting of pillion handle and take out the pillion handle.
  • Page 35 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the CRR pan head screw (M6x16) from the tail cover centre rear. (Fig. 2.25) Phillips head screw driver Tightening torque 3 ± 1 Nm Dislocate the tail cover centre rear from tail cover assembly.

  • Page 36: Periodic Maintenance And Tune-Up Procedure

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL PERIODIC MAINTENANCE AND TUNE- UP PROCEDURE ENGINE CUM TRANSMISSION OIL Replacement Replace at initial 500 - 750 km and every 6000 km there after. Inspect and top-up every 3000 km. After long period of use, the engine cum...

  • Page 37: Filter Complete Engine Oil

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Fill TVS TRU4 FULLY SYNTHETIC oil (SAE 10W30 API-SL, JASO MA2). 1200 ml (after draining) Capacity 1400 ml (after disassembly) Note: Before adding the fresh oil, replace the filter complete engine oil without fail.

  • Page 38: Spark Plug

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the filter complete engine oil and ‘O’ ring (A). (Fig. 2.32) Note: Keep an oil bowl while opening the cap oil filter to collect the left over oil. While reassembling, ensure to assemble the ‘O’...
  • Page 39 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Fix the spark plug into the machine as shown in the figure. (Fig. 2.35) Blast the sand (abrasive) by pulling the lever (A) towards sand blasting mode while rotating the spark plug. (Fig. 2.35) Now, blow the air by pushing the lever (A) towards air blasting mode.

  • Page 40: Air Cleaner Element

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Open the air control knob (A) and adjust the air pressure of the tester in such way that the pressure gauge needle is lying either in yellow band or in green band. (Fig. 2.38) Fig.
  • Page 41 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Disconnect the tube inlet from the cover filter element. (Fig. 2.40) Fig. 2.40 Remove the CRR pan head screw (M5x16 - 4 nos.) from the cover filter element. (Fig. 2.41) Phillips head screw driver Tightening torque 2 ±...

  • Page 42: Carburettor Assembly

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Reassemble the parts in the reverse order of removal while ensuring the following: Use only hands to assemble paper filter. Do not use any tool. Ensure that the hands are free from oil and dust.

  • Page 43: Tappet Clearance

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Tuning: Note: Before tuning the carburettor, correct the free play of throttle cable as explained in page no. 26. Turn out the MCS (mixture control screw) to the specified limit from fully-in (tight) position.
  • Page 44 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolt (M6x20 - 2 nos.) mounting the ignition coil assembly with the frame. (Fig. 2.48) 10 mm spanner Tightening torque 5.5 ± 1 Nm Dislocate and take out the ignition coil assembly from the frame.

  • Page 45: Engine Oil Cooler Assembly

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Check the valve clearance when the engine is in cold condition. (Fig. 2.52) Feeler gauge Valve Standard Inlet valve 0.06 mm Exhaust 0.08mm Fig. 2.52 If the clearance measured is not within the specified limit, loosen the nut tappet adjusting.
  • Page 46 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolt (M6x20 - 1 no.) mounting the pipe complete inlet with the crankcase assembly R. (Fig. 2.56A) Remove the hexagonal flange bolts (M6x16 - 2 nos.) mounting the pipe complete inlet with the oil cooler assembly.
  • Page 47 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Oil cooler assembly pipes Inspect at every 3000 km. Replace every 15000 km if required. Visually inspect the cooler assembly inlet and outlet pipes for any crack, leakage, damage or deformation. (Fig. 2.60) If found any replace the oil cooler pipes with a new one.

  • Page 48: Clutch Plates

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL CLUTCH PLATES (Plate clutch drive & driven) Inspect the plate clutch drive and driven at every 21000 km. Replace if required. Normally clutch is serviced for: Lose of power / low pick-up...

  • Page 49: Fuel Cock Sediment Bowl

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL FUEL COCK SEDIMENT BOWL Clean at initial 500 - 750 km and every 3000 km thereafter. Dirty, fuel cock sediment bowl with sediment or water affects the smooth flow of petrol and may cause loss of engine power.

  • Page 50: Cable Assembly Throttle

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Measure the free play at the lever assembly clutch end as shown in the figure, before the 8 ~ 15 mm clutch begins to disengage. (Fig. 2.68) Free play 8 ~ 15 mm Fig.

  • Page 51: Throttle Grip

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL After adjusting, start the vehicle, let the engine run in idle, turn the handle bar to extreme right, left and check whether idling rpm varies. If it varies check the routing of throttle cable and if required correct it.

  • Page 52: Steering Play And Freeness

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Clean the dust and grease from both the cases and grip. Apply fresh grease. Reconnect the throttle cable to the grip and reassemble the parts in the reverse order of removal. Note:...
  • Page 53 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL If any play is found, remove the CRR pan head screw (M6x20 - 2 nos.) housing head lamp front top mounting. (Fig. 2.77) Phillips head screw driver Tightening torque 3 ± 1 Nm Fig.
  • Page 54 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Gently lift the handle bar assembly. Support and hang the handle bar assembly on the vehicle itself. Note: Ensure that the cables are not too much stretched or bent and the surfaces of fuel tank assembly and head lamp assembly not got damaged.

  • Page 55: Front Fork Oil

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL If any play is still found, inspect the following items and replace the affected parts, if necessary (refer chapter “Chassis” page no. 6-23 for removal, checking and reassembly procedures) Wear of the race steering inner and outer Wear of cup bottom and cone bottom.

  • Page 56: All Fasteners

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL ALL FASTENERS (Bolts and nuts) Inspect and tighten at initial 500 - 750 km and every 3000 km there after. All the bolts and nuts must be in good condition, for safety. They must be checked and re-tightened, as necessary to the specified torque (refer chapter “Service...
  • Page 57 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Loosen and adjust the chain adjusting bolts (A and B) ‘in’ or ‘out’ equally by looking at the line mark (C and D) on chain adjusters until the specified play (slackness) is obtained.
  • Page 58 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the CRR pan head screws (M6x20 - 2 nos.) from the cover engine sprocket mounting and take out the cover. Fig. 2.91) Phillips head screw driver Tightening torque 10 ± 2 Nm Fig.
  • Page 59 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal bolts (M6x16 - 4 nos.) from both LH & RH mounting wheel hugger rear mounting. (Fig. 2.95A & B) 10 mm spanner Tightening torque 8 ± 2 Nm Fig. 2.95A Fig.

  • Page 60: Retainer Oil Seal

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Visually inspect the chain assembly drive for the below listed possible malfunctions. Loose pins Damaged rollers Excessive wear If found any defects, the chain assembly drive must be replaced with a new one.

  • Page 61: Chain Guide Bottom

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL CHAIN GUIDE BOTTOM (Drive chain guide) Inspect at initial 500 - 750 km and every 3000 km thereafter. Replace the chain guide bottom at every 9000 km. Remove the hexagonal bolt (M6x20) from the gear shift linkage assembly and dislocate the gear shift linkage from the shaft gear shift.

  • Page 62: All Bulbs, Horn And Switches

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL ALL BULBS, HORN AND SWITCHES Inspect at initial 500 - 750 km and every 3000 km thereafter. Inspect for the proper functioning of all bulbs, horn and switches. Incase found any abnormality, replace them.

  • Page 63: Battery Assembly

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Note: Head lamp focus should be adjusted only when the head lamp in high beam. To adjust the head lamp focus, insert a small phillips head screw driver into the slot provided...

  • Page 64: Brakes

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Add distilled water as necessary, to ensure the Maximum electrolyte is above the minimum level line but not above the maximum level line. (Fig. 2.108) Caution: Do not add tap water or acid for topping up the battery.
  • Page 65 Remove the reservoir cap and take out the plate diaphragm and diaphragm. Fill fresh brake fluid of recommended grade Brake fluid TVS Griling DOT3 / DOT4 Reassemble the parts and apply the front Fig. 2.111 brake to check the effectiveness.
  • Page 66 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Reassemble the parts and apply the rear brake to check the effectiveness. If the brake pedal travel is more or the pedal feels soft or spongy, air bleeding from the brake system to be carried out. Refer chapter “Chassis”...

  • Page 67: Tyres

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL WHEEL FREENESS Inspect at initial 500 - 750 km and every 3000 km thereafter. Slowly rotate both the wheels by hand and observe for any abnormal noise / tightness. (Fig. 2.116) If found any, inspect for the proper functioning of brakes.

  • Page 68: Idling Co

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Tyre rotation direction While reassembling the tyre, after removing from the wheel rim, ensure that the arrow mark (A) provided on the tyre facing the direction of wheel rotation. (Fig. 2.119) Fig. 2.119...

  • Page 69: Ball Joint Gear Shift Lever

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL BALL JOINT GEAR SHIFT LEVER Lubricate every 6000 km using grease Lubricate the ball joint gear shift lever using grease every 6000 km for easy operation of lever and smooth gear shifting. (Fig. 2.121) Fig.
  • Page 70 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Disconnect the spring of stop lamp switch from the rear brake pedal. (Fig. 2.125) Nose plier Note: Ensure to reconnect the spring during reassembly for proper working of brake lamp. Fig. 2.125 Remove the hexagonal socket head cap screw (M10x25 - 1 no.) along with punched washer...
  • Page 71 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL Take out the foot rest assembly RH along with rear master cylinder assembly and brake pedal assembly and hang it carefully. Caution: Care should be taken not to stretch / damage brake hose during the removal foot rest assembly.

  • Page 72: Wheel Balancing

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL WHEEL BALANCING Wheel balancing to be done every 1 year or every 12000 km. In addition, after every tyre puncture repair or tyre replacement, wheel balancing to be done. The Inspection of wheel balance and balancing of...
  • Page 73 PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL 2. Temporarily fix a 10 gram (5 gram each on both the side) balancing weight on the wheel rim near the ‘Q’ marked area, using a temporary adhesive tape (without removing the Angle ‘L’...
  • Page 74 60 g in front wheel and 70 g in rear wheel, irrespective of the procedure used for balancing (manual or automatic). Use genuine TVS-M approved Balancing weights only (refer Table 1). Removal (uninstallation) of balancing weight from wheel rim: As the balancing weight is of “Stick-on”...

  • Page 75: Lubrication Points

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL LUBRICATION POINTS Note: Lubricate the exposed parts which are subject to rust, with either engine oil or grease as mentioned in the schedule or whenever the vehicle has been operated under wet or rainy conditions.

  • Page 76: Service Reminder Resetting Procedure

    PERIODIC MAINTENANCE TVS APACHE RTR 200 SERVICE MANUAL S E R V I C E R E M I N D E R R E S E T T I N G PROCEDURE If the service reminder (R) is glowing, reset it after carrying out periodic services.
  • Page 77 CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 3 DESCRIPTION PAGE NO ENGINE OVERHAUL COMPRESSION PRESSURE CLUTCH - SERVICING REMOVAL INSPECTION REASSEMBLY CYLINDER HEAD ASSEMBLY - SERVICING REMOVAL CYLINDER HEAD ASSEMBLY - DISASSEMBLY DECARBONISING INSPECTION REASSEMBLY CYLINDER HEAD ASSEMBLY - RE-FIXING...

  • Page 79: Engine Overhaul

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL ENGINE OVERHAUL Before beginning engine overhaul, observe engine conditions for the following: Cleanliness Compression pressure Any abnormal noise Oil leak, seepage if any To overhaul the gears, balancer shaft, shaft complete counter, shaft complete drive and crankshaft assembly, the crank cases need to be separated.

  • Page 80: Clutch - Servicing

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL If the compression pressure is low, pour 3 to 5 cc of clean engine oil into the cylinder through the sparkplug hole and re-check the compression pressure. If the compression pressure increases from the previous value, then check the following.
  • Page 81 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Dislocate the cable assembly clutch from the bracket clutch cable. (Fig. 3.4) Place a plastic tray under the engine to collect the remaining oil in the engine while removing the cover clutch.
  • Page 82 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out adopter pin clutch release from the clutch assembly along with a ball (dia. 3/16). (Fig. 3.8) Caution: While reassembling ensure to assemble the ball without fail. Fig. 3.8 Remove the hexagonal flange head bolts (M6x25 - 4 nos.) from the plate clutch release...
  • Page 83 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out the spring disc from clutch shaft. (Fig. 3.12) Note: While reassembling, locate the spring disc in such a way that the concave face diameter of washer faces towards outside.

  • Page 84: Inspection

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL INSPECTION Plate clutch drive Inspect the thickness of plate clutch drive using a vernier caliper. If the thickness is less than the service limit, change the plate clutch drive as a set. (Fig. 3.16)

  • Page 85: Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Gear assembly primary driven (housing clutch) Inspect housing clutch for the indents / cuts created by the plate clutch drive. (Fig. 3.20) Note : Check the primary drive gear play by rotating the gear portion.

  • Page 86: Cylinder Head Assembly - Servicing

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL CYLINDER HEAD ASSEMBLY - SERVICING REMOVAL Remove the cover frame R and L as explained in the chapter “Periodic maintenance“ page no. 2-4. Remove the fuel tank complete as explained in the chapter “Periodical maintenance“...
  • Page 87 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolts (M6x16 - 2 nos.) from the adjuster assembly mounting and take out the adjuster assembly along with a gasket. (Fig. 3.26) 8 mm spanner Tightening torque 10 ±...
  • Page 88 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL In-order to remove the muffler assembly, the engine guard need to be removed. Remove the CRR pan head screw (M6x20 - 1 no.) along with plain washer from the top mounting of engine guard. (Fig. 3.30)
  • Page 89 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange nuts (2 nos.) fastening the cylinder head assembly with the cylinder block. (Fig. 3. 34) 10 mm spanner Tightening torque 7 ± 1 Nm Fig. 3.34 Remove the hexagonal flange bolt (M16x25 - 4 nos.) from the cover cylinder head mounting.
  • Page 90 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Gently pull out the sprocket cam shaft using nose plier and dislocate the cam chain from cam sprocket. (Fig. 3.38) Caution: Care should be taken not to drop the cam chain inside the crankcase assembly while dislocating.

  • Page 91: Cylinder Head Assembly - Disassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove punched washers (3 nos.) and a copper washer (A) from the mounting surface of bolt cylinder head. (Fig. 3.42) Caution: While reassembling the bolt cylinder head at the right hand front side of the cylinder head assembly, always use copper washer to avoid oil leak.
  • Page 92 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove hexagonal flange bolt (A) (M6x25 - 4 nos.) from the mounting of cylinder head assembly. (Fig.3.46) 8 mm spanner Tightening torque 7 ± 1 Nm Fig. 3.46 Remove the REC CSK head screw (M5x15 - 1 no.) from the stopper camshaft and dislocate...
  • Page 93 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the cotter valves (2 nos.) from the valve stem. (Fig. 3.50) Nose plier Loosen and take out the special tool. Remove the cotters of other inlet valve in similar manner.

  • Page 94: Decarbonising

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove seat valve spring. (Fig. 3.54) Nose plier Repeat the same procedure for removing the other side valves. Fig. 3.54 Using M6 nuts, remove stud bolt cylinder head (2 nos.) from cylinder head complete.

  • Page 95: Inspection

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Seat valve Carbon deposition on valve seating will cause valves not to seat properly thereby causing leakage and affects idling, pickup and mileage. Also leads to erratic running and starting trouble.
  • Page 96 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Shaft valve rocker arm Inspect the shaft valve rocker arm for any damage. Measure the outer diameter (OD) of shaft valve rocker arm. If the OD is less than the service limit, replace the shaft. (Fig. 3.60)
  • Page 97 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Measure the cam lobe height. If the lobe height is less than the service limit, replace the camshaft complete with a new one. (Fig. 3.62) Outside micrometer Service limit Inlet 33.35 mm (min) Exhaust 33.20 mm (min)
  • Page 98 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Measure the thickness of valve head. If the thickness is less than the service limit, replace the valve with a new one. (Fig. 3.66) Vernier caliper Service limit Inlet and exhaust 0.500 mm (min)

  • Page 99: Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Cam chain Visually inspect the cam chain for loose pins, twist / seized links etc. If found any replace the cam chain with a new one. Count 21 pins on the cam chain and measure the distance between 20 pitch.
  • Page 100 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Head complete cylinder For reassembly, reverse the disassembly procedure while taking care of the following instructions. Refer exploded view of cylinder head assembly for assembly details. (Fig. 3.71) Note: Use only new ‘O’ rings and oilseals. Do not use old ones.

  • Page 101: Cylinder Head Assembly - Re-Fixing

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL CYLINDER HEAD ASSEMBLY - RE-FIXING Reassemble the parts carefully in the reverse order of removal. Remove plug TDC (A) along with the gasket. (Fig. 3.75) 17 mm spanner Tightening torque 27.5 ± 2.5 Nm Remove plug crankshaft hole (B).

  • Page 102: Cylinder Block, Piston And Rings Piston - Servicing

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Assemble the spark plug and connect the suppressor cap. Reconnect the pipe complete SAI to the cylinder head assembly. Refill the engine cum transmission oil as explained in chapter “Periodic maintenance”...
  • Page 103 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Gently pull out the cylinder block holding the connecting rod by hand to avoid any damage to the piston assembly and crankcase. (Fig. 3.81) Fig. 3.81 Remove the gasket cylinder (A) and tubular dowel (B) (2 nos).

  • Page 104: Inspection

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL INSPECTION Guide cam chain Inspect the guide cam chain for any distortion / damage, cuts or crack. If found any of the above, replace the guide with new one. (Fig. 3.85) Fig.
  • Page 105 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Piston Remove the ring piston top (1st) (A), piston ring 2nd (B) and oil rings (C) along with separator oil ring (D). (Fig. 3.88) Caution: Do not expand the rings more, it may lose it‘s mechanical properties.
  • Page 106 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Check the pin piston bore ID of piston for wear. (Fig. 3.92) Inside micrometer Service limit 15.030 mm (max) Dia. If the ID is more than the service limit, replace the piston with a new.

  • Page 107: Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL To know the service condition of the ring check the free end gap using a vernier caliper. (Fig. 3.95) Vernier caliper Service limit Ring piston top 5.700 (max) Ring piston 2nd 4.400 (max)
  • Page 108 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Note: Avoid damage to the piston skirt surface and rings piston during installation. Before installing the piston, the rings should rotate freely in their respective grooves. Install the ring piston 1st and ring piston 2nd with the marking on the ring ‘TOP1’...

  • Page 109: Gear Box Assembly, Crankshaft Assembly And Balancer Shaft Assembly - Servicing

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL GEAR BOX ASSEMBLY, CRANK SHAFT A S S E M B L Y A N D B A L A N C E R S H A F T ASSEMBLY- SERVICING...
  • Page 110 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Pull out the sprocket engine along with drive chain assembly from shaft drive. (Fig. 3.104) Dislocate sprocket from the drive chain. Hang the drive chain in the frame itself. Fig. 3.104 Disconnect the speed sensor wiring socket from the main wiring harness.
  • Page 111 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal bolt (M6x16 - 1 no.) (A) and take out contact complete gear shift switch (B). (Fig. 3.108) 8 mm spanner Tightening torque 4 ± 1 Nm Note: While reassembling contact complete gear...
  • Page 112 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out gasket magneto cover and dowel pin (A) (2 nos.). (Fig. 3.112) Nose plier Fig. 3.112 Take out the spacer starter idle gear (A), pin magneto cover (B) and gear starter idle (C) either from the crankcase or from the cover magneto.
  • Page 113 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Carefully pull out the shaft complete gear shift. (Fig. 3.116) Fig. 3.116 Take out the pin holder complete from the cam gear shift. (Fig. 3.117) Fig. 3.117 Remove the E-ring from the oil pump shaft and take out gear oil pump driven.
  • Page 114 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Disconnect both the thermel from the battery assembly. (Fig. 3.120) Fig. 3.120 Dislocate the boot (A) from the starter motor terminal. (Fig. 3.121A) Remove the special screw (B) along with washer from the starter motor positive terminal and disconnect positive terminal.
  • Page 115 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolt (M6x25 - 1 no.) from the starter motor and remove the motor assembly starter along with a ‘O’ ring. (Fig. 3.124) 8 mm spanner Tightening torque 10 ±...
  • Page 116 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out key (4x4x15) from the crankshaft assembly. (Fig. 3.128) Nose plier Fig. 3.128 Using the special tool, hold the rotor assembly as explained earlier and remove the hexagonal flange nut (M12x1.25) from the balancer shaft assembly.
  • Page 117 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL If required, separate the gear complete starter clutch and remove the one way clutch from rotor assembly by removing the hexagonal socket head cap screw (M6x16 - 3 nos.) along with punched washers. (Fig. 3.132)

  • Page 118: Engine - Disassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolt (M8x100 - 1 no.) and (M8x120 - 1 no.) from the mounting of bracket engine mounting RH and take out the bracket. (Fig. 3.136) 12 mm spanner Tightening torque ±...
  • Page 119 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Remove hexagonal flange bolts (M6x55 - 5 nos. (A), M6x40 - 4 nos. (B), M6x75 - 4 nos (C) and M6x95 - 1 no. (D) from the crankcase mounting. (Fig. 3.140)
  • Page 120 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out gear assembly balancer shaft driven from the balancer shaft. (Fig. 3.144) Caution: While reassembling the gear assembly balancer shaft driven, align the balancer drive and driven gears to match the dot /...
  • Page 121 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Dislocate the fork gear shift no.1, fork gear shift no. 2 and fork gear shift high speed from cam gear shift and take out the cam gear shift (A). (Fig. 3.148) Fig.
  • Page 122 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out thrust washer from the drive shaft assembly gear 2nd driven seating area. (Fig. 3.152) Fig. 3.152 Pull out crankshaft assembly from the crankcase assembly LH by gently tapping it from the other side.
  • Page 123 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out the idler gear along with shims (11.2x18.5x1 - 2 nos.). (Fig. 3.156) Note: While reassembling the idler gear ensure the presence of shims on both side. Fig. 3.156 Using the special tool, remove the ball bearing (6207) from the crankshaft assembly (in case if t h e b e a r i n g c o m e s w i t h c r a n k s h a f t ) .

  • Page 124: Gear Assembly Balancer Shaft Driven

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL GEAR ASSEMBLY BALANCER SHAFT DRIVEN Gear balancer shaft driven can be separated from the race balancer gear driven by pushing it out. Note: While reassembling the gear balancer shaft ensure that the dots (A) on the race...

  • Page 125: Inspection

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Take out the star bush. (Fig. 3.164) Fig. 3.164 Take out the gear 5th driven. (Fig. 3.165) Fig. 3.165 INSPECTION Shaft complete drive / shaft complete counter (assembly) / cam gear shift / drive gears and driven gears.

  • Page 126: Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY Reverse the removal procedure of gears for re- assembly. While reassembling the gears, attention must be given to the locations and positions of washers and circlips. Caution: Never reuse circlips after removing from the shaft.

  • Page 127: Engine Components - Inspection

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL ENGINE COMPONENTS - INSPECTION PLAY PLAY Bearings Wash bearings with a cleaning solvent and lubricate them with engine oil before inspecting. Inspect the play of each bearing before fixing it. Hold inner race and rotate the outer race by hand and observe for any abnormal noise and smooth rotation.
  • Page 128 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Hold the crankshaft assembly in hand, shake the connecting rod to find out the radial play. If any play is noticed, then replace the crankshaft assembly with a new one. (Fig. 3.172) Fig.

  • Page 129: Engine Assembly - Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Support the balancer shaft with ‘V’ blocks or anvil. Mount the dial indicator at the position shown to read the runout. Runout should should be within the limit. (Fig. 3.176) Excessive runout of balancer shaft causes abnormal engine vibration and bearing noises.
  • Page 130 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL 3-52...

  • Page 131: Crankcase Assembly Lh & Rh - Reassembly

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL When fixing the oilseal over the shaft check that the lip seats over the shaft perfectly all around the circumference without any distortion. Apply engine oil on each running and sliding part before installing them during reassembly.
  • Page 132 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Assemble the retainer spring on the balancer shaft and secure it with the wood ruff key. (Fig. 3.181) Fig. 3.181 Assemble the gear balancer shaft driven assembly on the balancer shaft. (Fig. 3.182)
  • Page 133 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Assemble the counter shaft assembly (clutch shaft) and drive shaft assembly as set in crankcase assembly LH. (Fig. 3.184) Fig. 3.184 Assemble the fork gear shift no.1, fork gear shift no. 2 and fork gear shift high speed on their respective position.
  • Page 134 SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Assemble the shim (A) on the shaft complete drive. (Fig. 3.188) Assemble bearing kick starter driven gear along with shim and thrust washer (B) on the shaft complete counter. (Fig. 3.188)

  • Page 135: Valve Timing And Valve Clearance

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL Note: After tightening crankcase bolts, check for the free rotation of shaft complete drive, and shaft complete counter and crankshaft assembly. If large resistance is felt, gently tap on the shaft complete drive and shaft complete counter assemblies with nylon hammer.

  • Page 136: Running-In After Overhaul

    SERVICING OF ENGINE TVS APACHE RTR 200 SERVICE MANUAL RUNNING-IN AFTER OVERHAUL The rebuilt / overhauled engine should undergo running-in. Do not overload the engine immediately after overhaul as it may result in rapid wear of components due to overstrain, overheat and overload.
  • Page 137 CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 4 DESCRIPTION PAGE NO FUEL SYSTEM FUEL TANK COMPLETE REMOVAL CLEAR HOSE FUEL CARBURETTOR ASSEMBLY DISASSEMBLY MAINTENANCE INSPECTION REASSEMBLY IDLING ADJUSTMENT LUBRICATION SYSTEM OIL FILTER (STRAINER) OIL PUMP ASSEMBLY OIL COOLER ASSEMBLY...

  • Page 139: Fuel System

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL FUEL SYSTEM FUEL TANK COMPLETE The fuel tank complete is located on frame tube near the steering pivot with a lockable cap assembly fuel tank (A) and manually operated fuel cock assembly (B) at the bottom left side of the tank.
  • Page 140 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Dislocate the hose clamp and disconnect the hose drain from the fuel tank assembly. (Fig. 4.4) Nose plier Fig. 4.4 Remove hexagonal flanged bolt (M5x14 - 4 nos.) from the fuel sender unit mounting.

  • Page 141: Hose Fuel

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Clean the pencil filter periodically. Visually i n s p e c t f o r a n y d a m a g e . I n c a s e a n y...
  • Page 142 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL CAP RUBBER SCREW PLATE STAY - 2 Nos. HOLDER CABLE PLATE STAY BODY COMPLETE SCREW COVER DIAPHRAGM - 2 Nos. DIAPHRAGM COVER SPRING CLIP TUBE VALVE STARTER HOSE AIR VENT...
  • Page 143 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Fully loosen the throttle cable lock nut (A) while holding the adjuster (B). (Fig. 4.9) 10 mm spanner Fig. 4.9 Dislocate the hose clip and pull out the air vent hose from the cylinder head assembly.

  • Page 144: Disassembly

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL DISASSEMBLY Pull out the hose air vent (A) and drain hose (B) by dislocating clips. (Fig. 4.13) Nose plier Fig. 4.13 Remove CRR. pan head screws (2 nos.) and take out cover diaphragm.
  • Page 145 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Remove the CRR. pan head screws (4 nos.) from the float chamber mounting and take out the float chamber along with the gasket. (Fig. 4.17) Phillips head screw driver...

  • Page 146: Maintenance

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Piston valve - disassembly Remove holder jet needle using a allen key and take out the holder jet needle along with a spring. (Fig. 4.21) 4 mm allen key Fig.
  • Page 147 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL After cleaning the carburettor pages properly using the cleaner, blow the compressed air to clean the passages throughly. (Fig. 4.24) Caution: Do not use wires to clean the jets.
  • Page 148 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL While reassembling the carburettor always use new ‘O’ rings and sealing rings. Assemble piston valve in such a way that the hook like projection of diaphragm matches with the groove of carburettor body. (Fig. 4.26) Remount carburettor assembly on the vehicle in the reverse order of removal.
  • Page 149 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL MAGNETO ASSEMBLY GEARS CAM SPROCKET 16T, CRANKSHAFT BEARING CAM SPROCKET 32T, CAM CHAIN TM OIL GUIDE BEARING DRIVE ROCKER ARM SHAFT LH CONNECTING ROD SMALL END, PISTON PIN PISTON, PISTON RINGS, CYLINDER WALL...
  • Page 150 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Replace or replenish the lubricating oil as per the periodical maintenance schedule. OIL FILTER (STRAINER) Oil filter is provided on the right side crankcase at the bottom inside the cap oil strainer.
  • Page 151 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL If there is no oil flow through the inspection hole, check for the proper working of oil pump, clogged oil filter and for any block in the oil flow passages.
  • Page 152 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL EXHAUST EMISSION CONTROL The pollutants emitted from the exhaust system are harmful to environment. If combustion is absolutely complete, there would not be any atmospheric pollution from the exhaust system. Water and carbon dioxide are the products of perfect and complete combustion.

  • Page 153: Secondary Air Injection Valve

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL EXHAUST SYSTEM The exhaust system consist of parts right from the exhaust valve to muffler assembly through which the exhaust gasses passes. Normally in four stroke vehicle, the muffler will...

  • Page 154: Function

    FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Because of this after burn, high temperature is created in this system and this high temperature causes pre-ignition in the combustion chamber. Because of this pre- ignition, knocking effect is created and thus the efficiency of the engine is decreased.

  • Page 155: Preventive Maintenance (Emission)

    (Refer standard operating procedure manual, which is supplied with the mileage testing kit part no. K310520. Also the same procedure can be referred in “TVS Scooty Pep service manual” chapter “Fuel, lubrication and exhaust system” page no. 4-20). 4-17...
  • Page 156 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Guidelines: 1. Warm up the vehicle by running the engine in idling speed for 5 - 8 minutes or run the vehicle for 3 to 4 kms at 40 kmph speed.
  • Page 157 FUEL, LUBRICATION AND EXHAUST SYSTEM TVS APACHE RTR 200 SERVICE MANUAL 6. Press the key ‘M‘ for Horiba or ‘Enter Key‘ for Hermann exhaust gas analyser to measure the CO emission. 7. Wait for few seconds till the reading stabilizes on the screen.
  • Page 159 CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 5 DESCRIPTION PAGE NO WIRING COLOUR CODE CAUTION IGNITION SYSTEM IGNITION LOCK ENGINE KILL SWITCH CHECKING PULSAR COIL WITH POCKET TESTER CHECKING STATOR ASSEMBLY WITH POCKET TESTER CHECKING IGNITION COIL WITH POCKET TESTER...
  • Page 161 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL WIRE COLOUR CODE INDEX S.NO. CODE WIRE COLOUR BLACK BLACK WITH WHITE TRACER BLACK WITH BROWN TRACER BLACK WITH YELLOW TRACER BLUE BLUE WITH BLACK TRACER BLUE WITH GREEN TRACER BLUE WITH RED TRACER...

  • Page 162: Caution

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL CAUTION CONNECTOR CLICK When connecting a connector, be sure to push it in until a click sound is felt. (Fig. 5.1) I n s p e c t c o n n e c t o r f o r c o r r o s i o n , contamination and breakage on its cover.

  • Page 163: Ignition System

    Apply petroleum jelly on the terminals after completion of connection and cover the Fig. 5.5 positive terminal with the boot. (Fig. 5.5) TVS Apache RTR 200 electrical system is divided in to four basic systems (circuits) named: 1. Ignition circuit 2. Lighting circuit 3. Charging circuit 4.

  • Page 164: Ignition Lock

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL The pulsar coil produces the voltage signals whenever the pip on the magneto periphery passes nearer to it. Based on these signals, the microcontroller equipped in the TCI unit collapses the primary winding voltage of ignition coil in fraction of seconds.

  • Page 165: Checking Pulsar Coil With Pocket Tester

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL CHECKING THE PULSAR COIL WITH POCKET TESTER (MULTIMETER) Pocket tester Set pocket tester at 2000 ohms position. Disconnect the pulsar coil socket form wiring harness. Connect pocket tester ‘+ve‘ lead to the brown wire (Br) of pulsar coil and ‘–ve‘...

  • Page 166: Spark Plug

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL CHECKING THE IGNITION COIL ASSEMBLY WITH POCKET TESTER The ignition coil is mounted on the right side of the frame below the fuel tank assembly, near the cylinder head assembly. (Fig. 5.11) Disconnect the wiring socket connecting TCI unit and the ignition coil.

  • Page 167: Tci Unit

    The lighting system consists of magneto assembly, regulator cum rectifier unit (RR unit), battery, ignition lock, fuse 10A (head lamp), TCI unit and control switches. The working of lighting system of the TVS Apache RTR 200 4V are as follows. (Fig. 5.17) A DC output from the battery is connected to a 10A fuse (head lamp) through the ignition lock.
  • Page 168 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Similarly, when the switch lighting knob is slid to the ‘HL’ (head lamp ‘ON’) position, the output DC current from the switch is supplied to the TCI unit along with the position lamps and the tail lamp. Upon receiving the input from the switch lighting the TCI unit checks for the input from the pulsar coil to determine the engine running condition (head lamp works only for 10 seconds when the engine is in ‘OFF’...

  • Page 169: Switch Lighting

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL SWITCH LIGHTING Switch lighting is provided on the switch assembly RH at the right hand side of the handle bar. (Fig. 5.18) Check the switch for continuity with the pocket tester. Pocket tester SWITCH POSITION Fig.

  • Page 170: 12V Regulation System

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL 12V REGULATION SYSTEM REGULATOR CUM RECTIFIER (RR UNIT) The RR unit (regulator cum rectifier) is fitted below the rear seat assembly near the tail lamp assembly. (Fig. 5.21) The RR unit consists as the name implies,...
  • Page 171 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL A negative input from the common earth junction is directly connected to the position lamps. On switching ‘ON’ the ignition lock the lamps glows directly. Similarly, the smart phone charger also gets the negative input from the common earth junction and it will be ready for charging the smart phones.

  • Page 172: Turn Signal Lamps Front And Rear

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL TURN SIGNAL LAMPS FRONT AND REAR The DC output from the ignition lock is connected to the switch turn signal through a electronic flasher unit mounted below the seat assembly near the battery. (Fig. 5.25)

  • Page 173: Switch Assembly Stop Lamp Front And Rear

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL The resistance of gear position sensor at various position are as follows: GEAR POSITION RESISTANCE First gear 0.3 kilo ohms Neutral 0.75 kilo ohms Second gear 1.5 kilo ohms Third gear 2.7 kilo ohms Fourth gear 5.6 kilo ohms...

  • Page 174: Speed Sensor

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL To inspect the fuel sender unit, fuel tank FULL complete must be removed (refer chapter “Fuel, lubrication and exhaust system” page no. 4-1 for removal procedure). Inspect the fuel sender unit for continuity with pocket tester by connecting ‘+ve' lead of...
  • Page 175 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Turn ‘ON’ the ignition. Connect the pocket tester’s ‘+ve‘ lead to the orange grey wire (OrGr) of speed sensor coupler at the wiring harness side and ‘–ve‘ lead to the black yellow wire (BY) of speed sensor coupler at the wiring harness side and measure the voltage.

  • Page 176: Charging Performance Check

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Connect the pocket tester’s ‘+ve‘ lead to the orange grey wire (OrGr) and ‘–ve‘ lead to the black yellow wire (BY) of speed sensor coupler and measure the voltage. (Fig. 5.37) The voltage should be: Voltage 9 ±...

  • Page 177: Electric Starter System

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Gradually increase the throttle while observing the rpm indicator of speedometer. Once the rpm reaches 4000, check the pocket tester reading. The reading should be Charging 14.5 ± 0.3V at 2500 rpm and...

  • Page 178: Electric Starter Switch

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Electric starter system consists of battery, ignition lock, engine kill switch, electric starter switch, neutral switch, clutch switch, speedometer assembly, TCI unit, relay starter motor and the starter motor assembly. (Fig. 5.40) A DC output from the battery is connected to the ignition lock through a 15A fuse.

  • Page 179: Relay Self Starter

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL RELAY SELF STARTER (STARTER RELAY) Relay self starter is located on the right side of the vehicle on top of the air cleaner assembly. (Fig. 5.43) Inspect relay by checking the continuity using pocket tester.
  • Page 180 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL HEAD LAMP ASSEMBLY - BULB Remove the CRR pan head screw (M5x16 - 2 nos.) from the housing speedometer rear m o u n t i n g a n d r e m o v e t h e h o u s i n g speedometer rear.

  • Page 181: Head Lamp Bulb

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Take out head lamp bulb by snapping out the clip (A) and replace with a new one. (Fig 5.50) Head lamp bulb 12V, 60/55W H4 Reassemble the parts in the reverse order of removal.

  • Page 182: Digital Speedometer Assembly

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Remove the CRR flanged pan head tap screw (ST4.2x13 - 3 nos.) and takeout the position lamp assembly LH. (Fig. 5.54) Phillips head screw driver Tightening torque 1 ± 0.2 Nm Position lamp...

  • Page 183: Tail Lamp Assembly

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Disconnect coupler from the speedometer assembly by gently pressing the lock and take out the digital speedometer. (Fig. 5.57) Replace the new speedometer. Reassemble the parts in the reverse order of removal procedure.

  • Page 184: Adjustments

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Remove mounting nuts (M6 - 2 nos.) and take out the number plate illuminator as an assembly and pull out the rubber grommet. (Fig. 5.61A) 10 mm spanner Tightening torque 3 ± 1 Nm Pull out bulb holder along with the bulb.
  • Page 185 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Remove the clamp by removal of the CRR pan head screw (M6x16 - 1 no.) (A) and take out the battery assembly. (Fig. 5.64) Phillips head screw driver Tightening torque 3 ± 1 Nm Remove the battery from the vehicle and clean it thoroughly.

  • Page 186: Battery Charging

    ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Note: HYDROMETER To read the specific gravity on the hydrometer, bring the electrolyte in the hydrometer to eye level (Fig. 5.68) and read the graduations on the float scale bordering on the lower meniscus.
  • Page 187 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Turn the selector knob (A) of the charger to the 0.9 amps position incase of multiple battery charger. (Fig. 5.70) Caution: Ensure to select the charging current based the battery amphere only. If more or less current is selected the battery may get damaged.
  • Page 188 ELECTRICAL SYSTEM TVS APACHE RTR 200 SERVICE MANUAL Indication of full charge The following are the indication of full charge. HYDROMETER 1.28 Battery can be considered to be fully charged when three consecutive specific gravity (SG) readings taken at intervals of 30 minutes each, indicating a reading of 1.28.
  • Page 189 CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 6 DESCRIPTION PAGE NO WHEEL ASSEMBLY FRONT DISC PLATE REPLACEMENT REMOVAL INSPECTION REASSEMBLY DISC BRAKE SYSTEM FRONT BRAKE PADS BRAKE FLUID AND ITS HANDLING INSPECTION OF BRAKE FLUID LEVEL AIR BLEEDING FROM BRAKE SYSTEM...

  • Page 191: Wheel Assembly Front

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL WHEEL ASSEMBLY FRONT REMOVAL Support the motorcycle by center stand and place a jack or block to keep the front wheel off the ground. Remove the front wheel axle nut along with punched washer. (Fig. 6.1) 22 mm spanner Fig.

  • Page 192: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Gently tap out bearing left and right and spacer complete front hub with a suitable mandrel. (Fig. 6.5) Nylon hammer Drift INSPECTION Before inspection, clean all necessary components with suitable cleaning Fig. 6.5 solvent and lubricate them.

  • Page 193: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Tyre front Using the vehicle with excessively worn tyres will decrease riding stability and consequently invite a dangerous situation due to loss of control. It is highly recommended to replace the tyre with a new one when the groove...
  • Page 194 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Before tightening axle nut, stroke the fork assembly front several times to check for proper fork action. Tighten the axle nut only after ensuring the fork action. Note: While remounting front wheel assembly locate the disc in between the brake pads after removing cushion.

  • Page 195: Disc Brake System Front

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL DISC BRAKE SYSTEM - FRONT BRAKE PADS Take out lever RH (front brake lever) by removing the mounting bolt and flange nut. (Fig. 6.13) 10 mm spanner Tightening torque 11 ± 0.5 Nm Fig.

  • Page 196: Brake Fluid And Its Handling

    ‘Lower level’ mark provided on the reservoir, replenish the reservoir with the brake fluid graded below. (Fig. 6.19) TVS Grilling DOT 3 or DOT 4 Caution: Since the brake system of this motorcycle has glycol based brake fluid, do not use or...

  • Page 197: Air Bleeding From Brake System

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Caution: Do not place the removed reservoir cap on the speedometer or on any other painted surfaces. Brake fluid will damage the instrument cluster lenses and painted parts. Ensure no water enters the brake fluid container.

  • Page 198: Brake Fluid Replacement

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL 6. Remove the bleeder tube and install the cap bleeder. 7. After completing the bleeding operation, check the fluid level in the reservoir and replenish if necessary. Caution: Do not reuse the brake fluid drained from the system.

  • Page 199: Caliper Assembly - Removal And Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the banjo bolt (2 nos.) along with gaskets (2 nos. on each side) from both the ends of the hose complete brake. (Fig. 6.22) 12 mm spanner Tightening torque 30 ± 2 Nm...
  • Page 200 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove caliper assembly mounting bolts and brake pads as explained in page no. 6-5. Remove the spring pad from the caliper housing. (Fig. 6.25) Nose plier Fig. 6.25 Dislocating the boot-B and bush boot pin from the pin grooves and slide out the bracket complete front.
  • Page 201 (refer exploded view on page no. 6-16 for assembly details). Smear the piston with fresh TVS Girling DOT 3 or DOT 4 brake fluid and slowly insert into the bore of caliper body without tapering. Ensure the piston is sliding easily into the bore.

  • Page 202: Disc Plate Servicing

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Assemble the spring pad in the caliper body and fix back the boot-B and bush boot pin. Apply little grease on the pin bolts of bracket complete front and assemble the bracket into the caliper body while ensuring the proper seating of both boots in the pin bolt grooves.

  • Page 203: Master Cylinder - Removal And Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL M A S T E R C Y L I N D E R - R E M O V A L A N D DISASSEMBLY Dislocate the dust cap (A) and loosen the lock nut of rear view mirror.
  • Page 204 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the master cylinder fluid reservoir cap by unscrewing screws (2 nos.). (Fig. 6.37) Phillips head screw driver Tightening torque 1.5 ± 0.5 Nm Take out plate diaphragm and diaphragm from the reservoir.

  • Page 205: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Holding the master cylinder by hand slightly press the piston with thumb finger and remove the circlip from the master cylinder using a circlip plier without damaging the piston and cylinder. (Fig. 6.41)
  • Page 206 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL SCREW RESERVOIR CAP (2 Nos) BOOTS ASSEMBLY RESERVOIR CAP SNAP RING HAND LEVER BOLT PLATE DIAPHRAGM P CUP S CUP DIAPHRAGM PISTON HOLDER BOLT (2 Nos) SPRING HOLDER MASTER CYLINDER GASKET (4 Nos.) WAVE SPRING WASHER BANJO BOLTS (2 Nos.)

  • Page 207: Fork Assembly Front

    Fix the brake hose to the master cylinder outlet port along with the banjo bolt and gaskets. Fill the reservoir with fresh TVS Girling DOT3 or DOT4 brake fluid above the level ‘LOWER’ mark on the reservoir and bleed the system thoroughly.
  • Page 208 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove hexagonal screws (M8x20 - 4 nos.) along with wave spring washer (4 nos) from the fender front mounting. (Fig. 6.47) 13 mm spanner Tightening torque 18 ± 3 Nm Take out brace front fender along with spacer front fender (4 nos.).
  • Page 209 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Slightly pull out the fork leg assembly RH from the under bracket till the top nut is accessible and tighten the lower bracket hexagonal bolt again. (Fig. 6.50A) Caution: Do not over tight the lower mounting screw, as it may damage the inner tube assembly of fork leg.
  • Page 210 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Fill little more then the specified amount of fresh fork oil . (Fig. 6.54) Oil quantity 325 ± 2 cc per leg Oil specification KYB G10 Fig. 6.54 Adjust the special tool (oil level gauge) to the specified height.

  • Page 211: Leg Assembly Front Fork- Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL LEG ASSEMBLY FRONT FORK- DISASSEMBLY Remove both the leg assembly front fork LH and RH (refer page no. 6- Drain out the front fork oil as explained earlier. Remove the seal dust front fork (dust seal)

  • Page 212: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL INSPECTION Before inspection clean all the components with a cleaning solvent. Inspect piston front fork and ring damper piston for wear and any damage. (Fig.6.61) Replace with new one if any damage is noticed.

  • Page 213: Lower Bracket Complete - Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Assemble the washer spring seat, spacer front fork and washer Install the new oil seal using the special tool. (Fig. 6.64A) N931 009 0 Tool fork oil seal Note: Before installing the oil seal, apply little grease (MOS ) on the lip of oil seal.
  • Page 214 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal flange bolt (M6x16 - 2 nos.) from the bottom mounting housing head lamp (both LH and RH) while holding the housing by one hand. (Fig. 6.67) 10 mm spanner Tightening torque 3 ±...

  • Page 215: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the dust seal steering upper. (Fig. 6.71A) Remove cone top. (Fig. 6.71B) Remove upper and lower steering balls. Position Size Upper 18 nos 6.35 mm Lower 18 nos 6.35 mm Fig. 6.71A Fig.

  • Page 216: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY Reassemble the lower bracket complete, leg assembly front fork LH & RH, handle bar assembly and wheel assembly front in the reverse order of disassembly while carrying out the following steps: Refer lower bracket complete exploded view (Fig.
  • Page 217 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Steering balls Apply grease to the cup top and cup bottom. (Fig. 6.77) Bechem premium grade 3 Install specified quantity of steering balls at cup top and cup bottom (refer page no. 6-25 for the specified quantity).

  • Page 218: Wheel Assembly Rear - Removal

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Warning: Steering should be adjusted correctly for smooth movement of handlebar and safe riding. Stiff steering prevents smooth movement of handlebar resulting in poor directional stability and too loose steering will cause vibration and damage to the steering races .
  • Page 219 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the screw special (M8 - 3 nos) from the disc plate mounting and take out disc plate from the alloy wheel rear. (Fig. 6.83) 6 mm allen key Tightening torque 31 ± 3 Nm Fig.

  • Page 220: Sprocket Drum Assembly - Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Draw out the bearing from the wheel assembly rear. (Fig. 6.87) Drift Nylon hammer Fig. 6.87 S P R O C K E T D R U M A S S E M B L Y -...

  • Page 221: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Heat the drum rear sprocket on a hot plate to approximately 125° C. (Fig. 6.91A) Hot plate Draw out ball bearing, from drum rear sprocket along with the shaft rear sprocket. (Fig. 6.91B)

  • Page 222: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY Reassemble and remount the wheel assembly rear in the reverse order of disassembly. Also carry out the following steps. Refer wheel assembly exploded view (Fig. 6.95) for assembly details. Before assembling rear wheel assembly, lubricate the axle rear and bearings.

  • Page 223: Tubeless Tyre

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Make sure that the slot (A) in the bracket complete caliper assembly fits over the stopper (B) on the swing arm assembly. (Fig. 6.96) Note: While reassembling the disc plate apply specified thread lock to the disc plate mounting bolts.

  • Page 224: Replacement Of Valve Tubeless Tyre

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Take a cold mending strip and insert it between the strip holding jaws of strip inserting tool. (Fig. 6.99) Note: After inserting the strip, ensure that strip is held at the middle point of strip length.
  • Page 225 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the tyre from the alloy wheel. Caution: Use of normal tyre levers for removal of tubeless tyre by any puncture repair shop may cause severe damage to the tyre seating area of alloy wheel, which leads to improper sealing and loss of air.

  • Page 226: Disc Brake System Rear

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL DISC BRAKE SYSTEM REAR BRAKE PADS Remove wheel assy rear along with the disc plate (refer page no. 6-28 for wheel assy rear removal procedure). Take out the bracket complete along with the caliper assembly and take out the caliper cover.

  • Page 227: Brake Fluid

    Remove the cap and take out the diaphragm fill fresh brake fluid of recommended grade. (Fig. 6.110) Brake fluid TVS Griling DOT3 / DOT4 Air bleeding If the rear brake pedal travel becomes more or if any soft or spongy feel is observed in the Fig.

  • Page 228: Caliper Assembly - Removal And Disassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the banjo bolt (2 nos.) along with gaskets (2 nos. on each side) from both the ends of the hose complete brake. (Fig. 6.111) 12 mm spanner Tightening torque 33 ± 5 Nm...
  • Page 229 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove wheel assy rear along with the disc plate (refer page no. 6-28 for wheel assy rear removal). Take out bracket complete along with the caliper assembly. Remove plug pin from the caliper housing.
  • Page 230 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the bracket complete rear caliper by sliding out after dislocating boot-B and bush boot pin from the pin grooves. (Fig. 6.117) Fig. 6.117 Carefully pull out the cap piston (A) and boots (B)from the caliper assembly housing.
  • Page 231 (refer exploded view on page no. 6-43 for details). Smear the piston with fresh TVS Girling DOT 3 or DOT 4 brake fluid and slowly insert into the bore of caliper body without tapering. Ensure the piston is sliding easily into the bore.

  • Page 232: Disc Plate - Servicing

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Assemble the pin hangers by locating it properly in the holes of the pad inner and outer. Fix the plug pin, bleeder screw and cap bleeder. Remount wheel assembly rear along with spacer RH.
  • Page 233 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the split pin and take out cotter pin from the rear master cylinder. (Fig. 6.123) Nose plier Fig. 6.123 Remove clip hose (A) and take out hose oil (B). (Fig. 6. 124) Nose plier Fig.

  • Page 234: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Take out the ‘O’ ring from the master cylinder assembly. (Fig. 6.127) Fig. 6.127 Carefully lift the boot from the cylinder by using a blunt tool. (Fig. 6.128A) Note: While removing the boot care should be taken not to damage it.

  • Page 235: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY Reassemble master cylinder in the reverse order of dismantling. Refer exploded view for assembly details. (Fig. 6.130) HOSE DISC BRAKE REAR CAP OIL RESERVOIR COVER DISC REAR BANJO BOLT (2 Nos.) PLATE DIAPHRAGM GASKET (4 Nos.)

  • Page 236: Rear Shock Absorber - Removal

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Caution: Apply brake fluid to the cylinder bore and all internal parts before inserting the piston into the bore. Fix the hose complete brake rear to the master cylinder outlet port along with the banjo bolt and gaskets.
  • Page 237 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the CRR pan head screw (M6x16 - 2 nos.) along with the punched washers and take out the air celaner assembly. (Fig. 6.133) Philips head screw driver Tightening torque 5 ± 1 Nm Fig.

  • Page 238: Swing Arm Complete

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the hexagonal bolt (M12x55) along with punched washer from the bottom mounting of shockabsorber rear shock absorber. (Fig. 6.137) Dislocate and take out the rear shock absorber. 17mm spanner Tightening torque 40 ± 4 Nm Reassemble the rear shock absorber and other parts in the reverse order of removal.
  • Page 239 CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove hexagonal flange bolt (M12x55 - 1 no.) of shockabsorber rear lower mounting from swing arm complete. (Fig. 6.141) 17 mm spanner Tightening torque 40 ± 4 Nm Fig. 6.141 Remove ‘U’ nut (M12) rear swing arm pivot mounting.

  • Page 240: Inspection

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL Remove the dust seal (2 nos.) from swing arm assembly. (Fig. 6.145) Fig. 6.145 Using the special tool remove the needle bearing (2 nos.) from the swing arm assembly. (Fig. 6.146) N931 015 0...

  • Page 241: Reassembly

    CHASSIS TVS APACHE RTR 200 SERVICE MANUAL REASSEMBLY Reassemble and remount swing arm complete in the reverse order of removal. Refer exploded view for assembly details. (Fig. 6.149) AXLE SWING ARM SWING ARM COMPLETE SLEEVE SWING ARM - 2 Nos.
  • Page 243 CONTENTS TVS APACHE RTR 200 SERVICE MANUAL Chapter 7 DESCRIPTION PAGE NO. SERVICE DATA VALVE AND VALVE GUIDE CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER CYLINDER, PISTON AND RINGS PISTON CRANKSHAFT COMPLETE AND BALANCER SHAFT CLUTCH TRANSMISSION SPECIFICATION TRANSMISSION SUSPENSION...

  • Page 245: Service Data

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL SERVICE DATA VALVE AND VALVE GUIDE Unit : mm S.No. DESCRIPTION STANDARD SERVICE LIMIT Valve diameter Inlet 24.900 – Exhaust 19.300 Valve clearance Inlet 0.06 – Exhaust 0.08 Valve stem (OD) Inlet 4.470 ~ 4.455...

  • Page 246: Cylinder, Piston And Rings Piston

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL CYLINDER, PISTON AND RINGS PISTON Unit : mm S.No. DESCRIPTION STANDARD SERVICE LIMIT Compression pressure – 90 ~ 120 psi @ 640 RPM – (6.3 ~ 8.4 kg/cm²) Cylinder to piston clearance –...

  • Page 247: Clutch

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL CLUTCH Unit : mm S.No. DESCRIPTION STANDARD SERVICE LIMIT Cable clutch free play at lever end (in engin cold condition) 8 ~ 15 – Plate clutch drive thickness 2.920 ~ 3.080 2.600 Plate clutch drive claw thickness 15.750 ~ 15.850...

  • Page 248: Bearing Specification

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL BEARING SPECIFICATION 6302Z/C3 (15x42x13) 6302Z/C3 (15x42x13) (ON WHEEL HUB RH) (ON WHEEL HUB LH) AXLE FRONT 6004/C3 (20x42x12) 6001/C3/RS (12x28x8) LH SIDE - CAM SPROCKET END (RH SIDE) CAM SHAFT 6207 (35x72x17)

  • Page 249: Carburettor Assembly

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL CARBURETTOR ASSEMBLY S.No. DESCRIPTION SPECIFICATION Carburettor type KEIHIN CV 30VE Carburettor identification number Main Jet Needle jet Jet needle NUQA E - Ring position Pilot Jet Piston valve Air screw turns 1~ 4 turns Idling rpm 1500 ±...

  • Page 250: Electrical

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL ELECTRICAL S.No. DESCRIPTION SPECIFICATION Ignition timing 5° ± 2° BTDC @ 1400 rpm & 37° ± 5° BTDC @ 5500 ± 200 rpm Spark plug type BOSCH UR4KE Spark plug gap 0.7 mm...

  • Page 251: Brake And Wheel Assembly

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL BRAKE AND WHEEL ASSEMBLY Unit : mm S.No. DESCRIPTION STANDARD SERVICE LIMIT Disc plate face out 0.05 0.10 Disc plate thickness Disc pad thickness – Alloy wheel runout (front and rear) Axial –...

  • Page 252: Tightening Torque - Engine

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TIGHTENING TORQUE ENGINE S.No. DESCRIPTION QUANTITY TORQUE IN Nm Bolt, cover cylinder head mounting 10 ± 2 Bolt, cylinder head mounting 24.5 ± 2.5 Bolt, cam chain tensioner 12 ± 2 Nut, cylinder head mounting (at side) 7 ±...

  • Page 253: Tightening Torque - Chassis

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TIGHTENING TORQUE CHASSIS S.No. DESCRIPTION QUANTITY TORQUE IN Nm U nut, axle front 76 ± 18 Special screw, Disc plate (Front wheel ) 31 ± 3 19 ± 2 Hexagonal socket head cap screw, front fork upper mounting (upper bracket) Bolt, front fork lower mounting (under bracket complete) 36 ±...

  • Page 254: Special Material Required For Maintenance

    DOT 3 / DOT 4 USE OF GENUINE TVS MOTOR COMPANY PARTS When replacing any part of the machine, always use TVS-M genuine parts only. Non genuine parts will reduce the performance of TVS Apache RTR 200 4V and cause failures.

  • Page 255: Trouble Shooting

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TROUBLE SHOOTING A. STARTING TROUBLE STEP REASON POSSIBLE CAUSE COUNTER MEASURE Self starter not working Battery voltage is less Charge the battery / replace Loose connection Tighten Defective starter motor Replace Defective starter relay...

  • Page 256: Poor Pick-Up

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TROUBLE SHOOTING A. STARTING TROUBLE (Contd.) STEP REASON POSSIBLE CAUSE COUNTER MEASURE Improper carburation Sticky / worn out float needle Clean / replace Loose main jet / pilot jet Tighten Blocked passages...

  • Page 257: Gear Shifting Related

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TROUBLE SHOOTING C. GEAR SHIFTING RELATED STEP REASON POSSIBLE CAUSE COUNTER MEASURE Gear shifting hard Improper free play in clutch lever Adjust free play to specification Gear shift lever fouling with foot rest...

  • Page 258: Engine Over Heating

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TROUBLE SHOOTING F. ENGINE OVER HEATING STEP REASON POSSIBLE CAUSE COUNTER MEASURE Poor cooling Cooling fins covered with mud Clean No free movement of vehicle Refer complaint No. B1 Incorrect ignition Refer complaint No. A3...

  • Page 259: Jerky Movement / Abnormality Of Engine Rpm

    SERVICE INFORMATION TVS APACHE RTR 200 SERVICE MANUAL TROUBLE SHOOTING I. JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM STEP REASON POSSIBLE CAUSE COUNTER MEASURE Excessive CO Improper idling rpm Adjust idling J. HEAD LAMP NOT WORKING STEP REASON POSSIBLE CAUSE...

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