Periodic Maintenance And Tune-Up Procedure; Servicing Of Engine; Engine Overhaul - Apache RTR 180 User 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 have to be replaced or repaired
and necessary adjustments to be made for certain items for consistent performance of the vehicle.
Note:
More frequent maintenance checks may be performed on vehicles that are used in severe c nditi ns like dusty
environment, dense traffic conditions, sustained full throttle operation and un-metalled roads.
For detailed Periodic maintenance and tune-up procedure on the following, refer Apa he servi e manual SER.MAN /
APACHE 01 - Revision 0, August 2006 (Page No. 2-4 to 2-35) and SIBs sent there after.
1. Cleaning of Air cleaner assembly
2. Replacement of Hose fuel
3. Cup Fuel Strainer
4. Engine cum transmission oil level check
5. Filter complete engine oil replacement
6. Compression pressure check, Decarbonising of Head complete cylind r, Piston, Piston rings, Valve,
Valve guide and Valve seat.
7. Setting of tappet clearance & Spark plug cleaning
8. Battery assembly
9. Head lamp beam adjustment
10.Cable free play adjustment - Throttle cable, Choke cable, Clutch cable
11 Front & Rear brake - Inspection of brake pads and brake flu d level, air bleeding from brake system and
brake fluid replacement, Inspection of hose complete brake
12. Wheel assembly front & rear
13. Inspection and adjustment of chain
14. Inspection of tyres and tyre pressure
15. Inspection of bolts & nuts
16. Lubrication points
For maintenance schedule and procedure for e gi e oil replacement, servicing of 'O" ring chain assembly, steering
adjustment and fork oil replacement, refer Apache RTR Service information manual SER INF. MAN / APACHE RTR -
Revision 0, June 2007 (Page No: 4 to 7) and SER INF. MAN / APACHE RTR - Revision 1, March 2008 (Page No: 3)
in addition to Apache Service manual SER.MAN/APACHE 01 - Revision 0, August 2006 (Page No : 2-4 to 2-35)
Before starting the engine overhaul, observe some of the engine conditions to familiarizes,
› Cleaning › Compression pressure› Any abnormal noise› Oil leak, seepage if any
To overhaul the gears, shaft comp. Counter shaft comp. Drive, kick starter and crank shaft assembly, the crank case need
to be separat d.
While some of the ngine parts are different from that of Apache RTR 160cc due to change in engine capacity to 180 cc, the
procedure for servicing the complete engine assembly as explained in Apache service manual ref SER.MAN / APACHE 02
- REVISION 0 February 2007 (Page No 1-1 to 1-56) and Apache RTR service information manual SER INF. MAN /
APACHE RTR - Revision 0, June 2007 ( Page No: 7 to 8)
For details on changes in Engine parts refer "Parts change details" chapter, Page No. 12 to 14 of this manual

2. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE

3. SERVICING OF ENGINE

ENGINE OVERHAUL

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