TVS APACHE RTR 200 4V Training Handbook
  1. Manuals
  2. Brands
  3. TVS Manuals
  4. Motorcycle
  5. Apache RTR 200 4V
  6. Training handbook

TVS APACHE RTR 200 4V Training Handbook

Hide thumbs Also See for APACHE RTR 200 4V:
Table of Contents

Advertisement

Quick Links

TRAINING HAND BOOK
NOTICE
All information included in this publication is based on the latest product information available at the time of approval for
printing.
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.
No part of this publication should be reproduced without written permission from TVS MOTOR COMPANY LIMITED.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the APACHE RTR 200 4V and is the answer not in the manual?

Questions and answers

Engin Kaya
May 2, 2025

Valve adjustment is constantly broken

0
1 comments:
Mr. Anderson
May 17, 2025

Common causes of valve adjustment issues in the TVS RTR 200 4V include:

1. Worn valve head thickness below the service limit (less than 0.500 mm).
2. Pitting or wear on the valve stem end face.
3. Valve springs with free length below the service limit (less than 38.75 mm for both inner and outer springs).
4. Damage or wear in the cam chain or tensioner cam chain, leading to improper valve timing.
5. Abnormalities or damage in the arm complete valve rocker, including faulty roller follower or missing needle bearings.

This answer is automatically generated

0

Related Manuals for TVS APACHE RTR 200 4V

Summary of Contents for TVS APACHE RTR 200 4V

  • Page 1 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. No part of this publication should be reproduced without written permission from TVS MOTOR COMPANY LIMITED.

  • Page 2: Right Side View

    TVS APACHE RTR 200 4V RIGHT SIDE VIEW LEFT SIDE VIEW...
  • Page 3 FEATURES OF TVS APACHE RTR 200 4V Petrol tank: Spilt seats: Massive fuel tank Foam - in- place racing seats Pillion grab rail: PDC grab handle Front fender: 3 piece sculptured front fender Rear Shocks: Y Spoke Race tuned KYB...
  • Page 4 FEATURES OF TVS APACHE RTR 200 4V Intelligent DC Head Lamp • Flicker-free constant beam headlamp, every single ride is a blessing on the roads. Furthermore, for safety with a nifty pass-by switch operation for day and night. Brighter Head lamp DC Supply.
  • Page 5 FEATURES OF TVS APACHE RTR 200 4V Digital speedometer : Shift RPM indicator Tachometer Gear shift indicator Speedometer Digital clock Fuel gauage Turn signal indicator right Turn signal indicator left Service reminder Low fuel indicator Low battery indicator Neutral indicator lamp High beam indicator lamp 1.
  • Page 6 Low fuel indication (serial no. 5) starts blinking and one bar will be visible when the fuel reaches to the minimum safe level 1.8 liters approximately. Refill the fuel immediately. Once the fuel level reaches 1.1 liters approximately, no bar will be visible and low fuel indication (serial no. 5) glows continuously. If all the fuel level bars in the speedometer are blinking and an error message ‘CHECK FUEL SENSOR’...
  • Page 7 Odometer / Trip meter 1 & 2 / Lap indicator / High speed indicator / Shortest time indicator Mode button Set button Shortest time indicator High speed indicator Trip meter Alpha numeric display Odometer A. Odometer Odometer registers the total distance covered by the vehicle in kilometer or mile as per the user’s preferred setting.
  • Page 8 D. Lap timer Lap timer indicates the time taken to complete the lap. In ‘TRIP 2’ meter mode, Press mode button once to enter lap timer mode. After speedometer enters lap timer mode, press SET button for more than 1 sec. After set button input, lap timer indicating digit blinks. Lap timer will start counting when the vehicle speed is more than 3 km/h and stops blinking once it starts counting .
  • Page 9 Digital clock setting Press and hold the ‘Mode’ button till ‘MPH’ icon blinks in display. Release and press the ‘Mode’ button once again so that the ‘Clock’ icon blinks. On pressing the ‘Set’ button, ‘CLOCK MODE’ scrolls in running display and the hour digit of the clock blinks. Now, press the ‘Mode’...

  • Page 10: Technical Specifications

    TECHNICAL SPECIFICATIONS DIMENSIONS AND WEIGHT Overall length 2050 mm Overall width 790 mm Overall height 1105 mm Wheel base 1353 mm Ground clearance 180 mm Kerb weight (with toolkit and 90% of fuel) 148 kg Pay load 130 kg Maximum laden weight 278 kg Steering angle 34º...
  • Page 11 Front fork oil capacity 352 ± 2 ml per leg Brake fluid TVS Girling, DOT 3 / DOT 4 The fuel tank is not a measuring instrument and the capacity of fuel tank may slightly vary from the indicated capacity.

  • Page 12: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE 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 Period from the date of sale 1 month 3 months 6 months 9 months 12 months Engine cum transmission oil I&T I&T I&T...

  • Page 13: Recommended Lubricants

    Application Manufacturer Brand Engine cum transmission oil 1200 ml (after draining) TVS Motor Company TVS TRU4 FULLY SYNTHETIC oil, 1400 ml (after disassembly) (SAE 10W30 API-SL, JASO MA2) Front fork oil 325 ± 2 ml / leg KYB G10 oil Disc brake fluid –...

  • Page 14: Lubrication Points

    DRIVE CHAIN SIDE STAND PIVOTS (TRU4 oil) (Grease) (TRU SPRAY) WARRANTY TVS Apache RTR 200 4V comes with a 24 months or 24000 Kms from the date of purchase, whichever is earlier. SERVICE SCHEDULE Pay service Free service Service Month...

  • Page 15: Carburettor Assembly

    ADJUSTMENTS Dotted line indicates RH side lubricating points Lubricate all cable ends using grease CLUTCH PLAY 8 ~ 15 mm THROTTLE GRIP FREE PLAY 1 ~ 2 mm IDLING RPM 1500 ± 100 DRIVE CHAIN SLACKNESS IDLING CO % AIR SCREW TURNS 20 - 25 mm <...

  • Page 16: Special Tools

    SPECIAL TOOLS Sl. no. Part no. Description M131 002 0 Magneto puller M131 007 0 Tappet adjuster M131 011 0 Puller assembly - crankcase N231 001 0 Clutch holder tool N231 002 0 Clutch nut tightening tool N931 009 0 Front fork oil seal installer N931 011 0 Tool fork cylinder holder...
  • Page 17 Tool pre-load adjuster - N931 012 0 Used to adjust the rear mono-shock spring pre-load. Tool cone bottom installer - N931 013 0 Used to assemble the cone bottom to the steering stem. Tool steering nut - N931 014 0 Used to remove / assemble the steering lock nut and arrester steering stem.
  • Page 18 Tool steering cup remover - N931 016 0 Used to remove the top and bottom steering cups. Tool assembly steering cups adjuster -NB31 004 0 Used to assemble the cup bottom and race steering inner during servicing of steering. COMMON TOOL Magneto tool assembly - N931 017 0 U s e d t o h o l d t h e m a g n e t o r o t o r w h i l e...

  • Page 19: Periodic Maintenance

    / sediment. Inspect the filter for any abnormality. Replace if required. Assemble back the oil filter and plug oil drain along with a ‘O’ ring. Fill TVS TRU4 FULLY SYNTHETIC oil (SAE 10W30 API-SL, JASO MA2). 1200 ml (after draining) Capacity...

  • Page 20: Spark Plug

    SPARK PLUG Clean the gap at initial 500 km if necessary. Replace the spark plug every 12000 km. Disconnect the spark plug cap and remove the spark plug. Plug spanner Carbon deposits on the spark plug gap will prevent good sparking and cause misfiring. Clean the deposits by sand blasting and cleaning with compressed air in the spark plug cleaning machine.

  • Page 21: Tappet Clearance

    CARBURETTOR ASSEMBLY Inspect and set engine idling rpm at initial 500 km and every 3000 km thereafter. Clean and adjust the carburettor at initial 500 km if required and every 12000 km thereafter. Inspect and set idling CO% at initial 500 km. Idling rpm 1500 ±...
  • Page 22 Note: At this point both the rocker arms should have free play. Otherwise rotate the rear wheel about 360º and align the marks once again. Check the valve clearance when the engine is in cold condition using a feeler gauge. Feeler gauge Valve Standard...

  • Page 23: Carburettor Rubber Ducts

    Caution: Care should be taken not to damage the fins while cleaning with the tool and compressed air. Inspect the oil cooler fins (A) for any deformation. If it so, straighten them with a thin, flat head screw driver. Note: If the air passages of the cooler assembly are blocked more than 20% by unremovable objects or if the fins of the cooler are un-repairable,...
  • Page 24 Using a blunt tool, unlock the lock washer locking arrester steering stem top and bottom. Small flat screw driver Using a special tool loosen and remove the arrester steering stem and take out the lock washer. N931 014 0 Tool steering nut 32 mm spanner Using the special tool turn the arrester steering stem bottom either clockwise or anti-clockwise to reduce...
  • Page 25 If slackness if found more or less, adjust the slackness as follows: Note: Excess chain slackness consumes more fuel. Slightly loosen the hexagonal flanged U-nut (M14x1.5) of axle rear. 22 mm spanner Loosen and adjust the chain adjusting bolts (A and B) ‘in’...

  • Page 26: Tyre Pressure

    RETAINER OIL SEAL (Drive shaft oil seal) Inspect at initial 500 - 750 km and every 3000 km thereafter. Replace the retainer every 9000 km. Remove the sprocket engine along with drive chain. Inspect the retainer oil seal for any physical damage. If found any.

  • Page 27: Wheel Balancing

    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 unbalanced wheels may be done by the manual procedure or by using an automatic wheel balancing machine as detailed below.
  • Page 28 3. Hold the wheel by hand and rotate it ¼ turn downwards (angle ‘L’ indicated in the figure) and leave. When the wheel is left, if the wheel does not rotate further (’up’ or ‘down’), it may be concluded Angle ‘L’ that the wheel is balanced.
  • Page 29 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 30: Service Reminder Resetting Procedure

    SERVICE REMINDER RESETTING PROCEDURE If the service reminder (R) is glowing, reset it after carrying out periodic services. Turn ‘ON’ the ignition and wait till the completion of speedometer’s self test cycle (till the ‘RACE ON’ message appears on the speedometer dial). Press the ‘Mode’...
  • Page 31 -30-...
  • Page 32 14) What is the Steering Greasing Interval in apache RTR 200 ? A) 12000 kms B) 15000 kms C) 18000 kms 15) The front fork oil capacity of TVS RTR200 is _________ A) 352 ± 2 ml B) 152 ± 1 ml C) 252 ± 2 ml...
  • Page 33 ELECTRICAL SYSTEM - IGNITION CIRCUIT MAGNETO ASSEMBLY FUSE 15A (DC) 12V - 200W TO SPEEDOMETER TO RELAY STARTER MOTOR BATTERY 12V, 9Ah RR UNIT PULSAR COIL 12V, DC IGNITION LOCK TO OTHER CIRCUITS TO RELAY STARTER / SELF START SWITCH ENGINE KILL SWITCH FUSE 10A...

  • Page 34: Electrical System

    ELECTRICAL SYSTEM - CHARGING AND DC CIRCUIT MAGNETO ASSEMBLY FUSE 15A (DC) 12V - 200W TO RELAY STARTER MOTOR TO FUSE HEAD LAMP / BATTERY ENGINE KILL SWITCH 12V, 9Ah RR UNIT IGNITION 12V, DC POSITION LAMPS LOCK 12V, LED FUEL SENDER UNIT GEAR POSITION SENSOR TO TCI UNIT...
  • Page 35 ELECTRICAL COMPONENTS CHECKING IGNITION COIL PRIMARY IGNITION COIL SECONDARY WINDING RESISTANCE CHECK WINDING RESISTANCE CHECK RESISTANCE:- 4.05 ~ 4.95 ohms RESISTANCE:- 10.8 ~ 12.32 k ohms (Bl WIRE - HT CORD) 4.10 12.14 FUSED FUSED FUSED FUSED PULSAR COIL RESISTANCE CHECK STATOR COIL RESISTANCE CHECK RESISTANCE:- 360 ~ 400 ohms (Br - W WIRES)

  • Page 36: Customer Installation

    Steering Usage of IFTEX for petrol (2ml/lts) Service schedule Running in period - Up to 1000 KM Vehicle Explain Service schedule of TVS Apache RTR 200 4V speed should be Max.50 as per owners manual kmph and vary the engine speed for better mating of Explain Speedometer features.

Table of Contents

Save PDF