Service Manual

table of contents

general information

TVS APACHE RR310....................................................................................................... 1

vehicle identification numbers......................................................................... 2

technical specifications..................................................................................... 4

Running-in Recommendations............................................................................. 7

safety and regulations....................................................................................... 8

workshop tools and equipments .................................................................... 9

general PROCEDURES

Parking the vehicle on Paddock stand....................................................... 19

operating the ramp.............................................................................................. 20

Cowls Identification............................................................................................ 21

bottom cover front and rear........................................................................ 22

engine guard center........................................................................................... 23

side cowl upper lh and rh................................................................................. 24

housing headlamp rear lh and rh................................................................. 25

fuel tank cover assembly................................................................................. 26

engine guard........................................................................................................... 27

Headlamp housing components...................................................................... 29

housing instrument cluster............................................................................ 31

Headlamp assembly.............................................................................................. 32

fender rear assembly......................................................................................... 33

tail cover assembly............................................................................................. 34

tail cover center front.................................................................................... 36

seat assembly removal....................................................................................... 37

PERIODIC MAINTENANCE

periodic maintenance table............................................................................. 38

Engine Oil level check........................................................................................ 40

Engine oil and oil filter replacement ........................................................ 41

Air cleaner element replacement................................................................ 43

spark plug replacement................................................................................... 44

tappet valve clearance adjust...................................................................... 46

clutch play adjustment..................................................................................... 49

throttle cable play adjustment................................................................... 50

Steering play adjustment procedure......................................................... 51

Suspension system - check................................................................................ 52

wheel bearing - check......................................................................................... 53

Air suction breather - check........................................................................... 54

Fork oil and oil seal............................................................................................ 55

Nut, bolt and washers condition................................................................... 62

drive chain slackness - check........................................................................ 63

drive chain lubrication...................................................................................... 64

Drive Chain and guide wear............................................................................... 65

Service Manual

table of contents

Drive chain adjustment...................................................................................... 66

lights and horn - check...................................................................................... 67

head lamp beam adjustment............................................................................. 68

battery voltage - check..................................................................................... 69

brake light switch operation......................................................................... 70

brake fluid levels check.................................................................................. 71

brake pad wear check........................................................................................ 73

brake disc thickness check............................................................................. 75

Brake Hose / Rubber Parts................................................................................ 76

master cylinder.................................................................................................... 77

tyre air pressure - check.................................................................................. 78

Wheel speed sensor............................................................................................. 79

Coolant Level and water hoses..................................................................... 80

radiator fins and fan operation - check................................................... 81

Fuel hose and system.......................................................................................... 82

Fuel filter and hoses.......................................................................................... 83

swing arm bearing - check................................................................................ 84

side stand operation - check.......................................................................... 85

Reading out Faulty Memory from Diagnostic Tool................................ 86

Fuse Box and fuse puller.................................................................................. 87

Ignition cum Steering lock............................................................................... 88

ENGINE, GEARBOX AND CLUTCH

engine exploded view.......................................................................................... 89

engine removal....................................................................................................... 91

engine INSTALLaTION.............................................................................................. 97

Exploded view - cylinder head....................................................................... . 101

CYLINDER HEAD - REMOVAL AND INSTALLATION................................................ . 102

CYLINDER HEAD........................................................................................................ . 109

CYLINDER HEAD........................................................................................................ . 110

Exploded view - Crankcase upper............................................................... . 111

Exploded view - piston and connecting rod............................................. . 112

Exploded view - Crankshaft

and Balancing Shafts........................................................................................ . 113

engine and gearbox............................................................................................ . 114

engine service data............................................................................................. . 121

engine and gearbox............................................................................................ . 124

Clutch exploded view........................................................................................ . 133

Clutch removal..................................................................................................... . 134

Clutch installation............................................................................................ . 139

OTHER SYSTEMS

Air filter housing and ducts........................................................................... . 143

Throttle body removal..................................................................................... . 146

exhaust system - removal and installation............................................. . 148

Service Manual

table of contents

Canister.................................................................................................................... . 150

Canister Purge Valve......................................................................................... . 151

FUEL Injectors....................................................................................................... . 152

Fuel tank.................................................................................................................. . 153

radiator AND FAN................................................................................................... . 155

Coolant pump......................................................................................................... . 159

thermostat.............................................................................................................. . 162

Oil pump..................................................................................................................... . 164

Ignition Coil............................................................................................................. . 166

DRIVETRAIN, SUSPENSION AND STEERING

Front sprocket..................................................................................................... . 167

Rear wheel sprocket ........................................................................................ . 168

Drive chain removal and installation........................................................ . 169

drive chain guide.................................................................................................. . 172

Fork............................................................................................................................ . 173

rear shock absorber........................................................................................ . 176

swing arm bearing replace............................................................................. . 177

Front wheel removal......................................................................................... . 179

Rear wheel.............................................................................................................. . 181

Tyre............................................................................................................................ . 182

wheel bearing........................................................................................................ . 183

Handle LH & RH....................................................................................................... . 185

Upper bracket....................................................................................................... . 187

lower bracket...................................................................................................... . 188

BRAKES

Front brake disc.................................................................................................. . 190

brakes bleeding - front.................................................................................... . 191

Rear wheel disk ................................................................................................... . 194

brakes bleeding - rear...................................................................................... . 195

front brake pad replacement ...................................................................... . 197

rear brake pad replacement ........................................................................ . 198

master cylinder front and rear.................................................................. . 199

brake caliper assembly - front and rear................................................. . 202

Brake Lines.............................................................................................................. . 205

Hydraulic Electronic Control Unit ........................................................... . 206

ELECTRICAL SYSTEM

Electrical SYSTEM................................................................................................ . 208

ECU.............................................................................................................................. . 226

RIDE sCAN TOOL AND DIAGNOSTICS

tvs ride scan tool............................................................................................... . 229

Service Manual

general information

1

TVS APACHE RR310

RIGHT SIDE VIEW

LEFT SIDE VIEW

Service Manual

general information

2

vehicle identification numbers

Frame Number

The frame serial number is stamped on the RHS of the

steering head tube.

Engine Number

The engine serial number is stamped on the LHS

crankcase assembly near cylinder block.

Frame Number Codes

Engine Number Codes

Service Manual

general information

3

Introduction to Antilock Braking System (ABS)

Apache RR310 is the bike with an Antilock Braking System. The ABS is an Electronically controlled Hydraulic device

designed to prevent skidding and help riders to maintain steering control during an emergency-stopping situation.

ABS prevents locking of wheels thereby preventing skidding and loss of steering control of the bike. The ABS pro-

vides complete control of the bike when brakes are applied hard in dry or wet road, at any speed. The rider can be

assured that the vehicle is stopped and it is in his control even in emergency braking situation. The ABS uses con-

tinuous wheel speed monitoring system ie. wheel speed sensors & toner rings and a Hydraulic Electronic Control

Unit (HECU) to control the vehicle at limits. During normal operation ABS works similar to a normal brake, but

functions only when the wheel tends to lock up. The speed sensors fitted on both the wheel measures the rota-

tional speed of the wheel, when the wheel rotation reduces rapidly, the HECU modulates the pressure in the brake

circuit and there by preventing the wheel from locking.

During hard stop the brake pedal / brake lever feels different, i.e., a rapid pulsation in the brake pedal / brake

lever; This is absolutely normal. It is not mandatory to have this pulsation feel every time the brake is applied.

This pulsation feel also depends on the road condition (dry / wet / slippery / mud). The ABS can apply and release

the pressure in the brake line much faster than that the rider can do with brake pedal / brake lever to avoid wheel

locking, so, there is no need to pump the brake, it requires only continuous application.

Code

Year

1

2001

2

2002

3

2003

4

2004

5

2005

6

2006

7

2007

8

2008

9

2009

A

2010

B

2011

C

2012

D

2013

E

2014

F

2015

Code

Year

G

2016

H

2017

J

2018

K

2019

L

2020

M

2021

N

2022

P

2023

R

2024

S

2025

T

2026

V

2027

W

2028

X

2029

Y

2030

Year and Month Codes

Code

Month

A

JANUARY

B

FEBRUARY

C

MARCH

D

APRIL

E

MAY

F

JUNE

G

JULY

H

AUGUST

K

SEPTEMBER

L

OCTOBER

N

NOVEMBER

P

DECEMBER

Service Manual

general information

4

technical specifications

Dimensions and Weight

Overall length

2001 ± 20 mm

Overall width

786 ± 5 mm

Overall height

1135 ± 10 mm

Seat height

811 ± 10 mm

Ground clearance

180 ± 5 mm

Wheel base

1365 ± 12 mm

Kerb weight

169.5 kg

Pay load

130 kg

Max. laden weight

299.5 kg

Engine

Bore

80 mm

Stroke

62.1 mm

Piston displacement

312.2 cc

Compression ratio

10.9 ± 0.5 : 1

No. of valves

4

Air filter

Dry paper type

Oil filter

Wire mesh and Micronic paper filter

Lubrication system

Wet sump lubrication

Maximum power in kW

33.5 bhp (25 kW) @ 9700 rpm

Maximum torque in Nm

27.5 ± 1.1 Nm @ 7700 ± 200 rpm

Maximum speed

160 km/hr

Engine idling rpm (warm)

1700 ± 200 rpm

Starting system

Electric starter

Camshaft

Dual camshaft

Fuel feed

Closed loop EFI system

Cooling system

Liquid cooling

Air filter

Dry paper type

Oil filter

Wire mesh and Micronic paper filter

Lubrication system

Wet sump lubrication

Starting system

Electric starter

Transmission

Clutch type

Wet multiplate type

Gear shift pattern

One down five up

Primary transmission

Spur gears

Secondary transmission

Chain and sprockets

Service Manual

general information

5

Gear ratio

First gear

3.000

Second gear

2.060

Third gear

1.590

Forth gear

1.290

Fifth gear

1.100

Sixth gear ratio

0.950

Primary reduction

3.080

Secondary reduction

2.470

Chassis

Frame

Trellis type frame

Front suspension

USD fork 41 mm diameter

Rear suspension

Steering angle

Solid Die cast Aluminium swing arm directly

hinged monoshox, pre-load adjustable.

Caster angle

25° ± 1°

Tail length

136 mm

Front brake

Hand operated 300 mm disc

Rear brake

Foot operated 240 mm disc

Front tyre

Michelin - Pilot street radial

Rear tyre

Michelin - Pilot street radial

Front tyre pressure

2.25 kg (32 PSI) for both solo and dual

Rear tyre pressure

Solo 2.25 kg (32 PSI)

Dual 2.25 kg (32 PSI)

Electrical

Type

AC generator

Ignition system

Closed loop EFI system

Spark plug

NGK (LMAR9D - J)

Battery type

12V / 8 Ah MF lead acid battery

Body earthing

Two grounds are mounted on engine body

(1. Engine ground and 2. Ignition ground)

Generator

12V, 290W @ 6000 rpm

Head lamp

12V, LED

Position lamp

12V, LED

Tail / brake lamp

12V, LED (2W / 2W approx.)

Turn signal lamp

12V, LED (2W each)

Number plate lamp

12V LED

Instrument panel

LCD / LED indicators

Horn

12V DC two numbers

Fuse

Mini fuse - 7.5A x 2, 10A x 2, 20A x 1 and

30A x 1

Service Manual

general information

6

Capacities

Recommended Fuel and Lubricants

Fuel type

BSIV / Unleaded petrol (91% octane rating by

research method)

Fuel tank capacity

Approx. 11 ± 0.5 liters (including reserve)

Reserve

2 liters

Engine & transmission oil grade

TVS TRU4 / MOTUL 3000 4T plus (SAE 15W50 API SJ /

JASO MA2)

Engine & transmission oil capacity

1700 ml (fresh assembly / full drain along with filter

change)

Front fork oil grade

KWT KHL 15-10

Front fork oil capacity

440 ml per leg

Brake fluid

DOT 4

Chain cleaner

MOTUL

Chain lubricant

MOTUL

Coolant

Recommended manufacturer

Glysantin

Recommended grade

G48

Recommended quantity

1 liter (coolant and distilled water ratio 50:50)

Cone set grease

Recommended manufacturer

Klueberplex

Recommended grade

BEM 34-132

Recommended quantity

15 gm (in sachet)

Free plays

Clutch free play

8 - 12 mm

Throttle free play

5 ± 2 mm

Drive chain free play

40 - 50 mm

7

Service Manual

general information

Running-in Recommendations

On completion of running -in period, scheduled

maintenance service should be observed carefully

without fail.

Failure to comply with this will result in damage to the

engine or shorter engine life.

Keeping to the running-in recommendations will ensures

longer engine life and reduce the need for overhauls and

re-tuning.

CAUTION

Running-in is essential to preserve engine life and performance over time. Twisty roads and gradients are ideal to

run in the engine, brakes and suspension effectively. The first 1000 km is a running-in period for your motorcycle.

Maximum engine speed during running-in 0 to 1000 km - below 7000 rpm

During the first 1000 km, avoid the full throttle starts and rapid acceleration, which could expose the engine parts

to excessive stress. It is advisable to run the engine at varying load and rpm, though still within recommended

rpm limit. Avoid riding at constant engine rpm for prolonged periods.

During initial running, use brakes gently. Do not brake hard or keep brake applied for too long to enable a correct

break-in of brake pad friction material against the brake discs.

To allow all the mechanical parts of motorcycle to adapt each another, and to avoid reduction of engine components

life, it is advisable to avoid sudden acceleration and running the engine at high rpm for too long, especially uphill.

Check the drive chain frequently and if required adjust it. Also ensure that the chain is lubricated as required to

increase its service life.

Service Manual

general information

8

safety and regulations

Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the

treatment of some of the substances that advanced technology requires, sound judgment should govern the use

and disposal of products of a chemical and petrochemical nature.

Familiarize yourself with the local legislation and make sure that you understand this legislation. Where no legisla-

tion exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with

regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these

substances.

Helpful hints

• Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery sys-

tems may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances

that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake

fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can

dispose of the fluids in a proper way that complies with all local legislation and available resources.

• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.

• Repair any leaks or defects in the engine cooling system immediately.

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of

oils, coolant, etc.

Mandatory battery recycling

Batteries and electric accumulators contain several substances that can have a harmful effect on the environ-

ment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil,

groundwater, and waterways. TVS strongly recommends that you return all used batteries to a TVS dealer, who will

dispose of the used batteries or recycle the used batteries properly.

Do not dispose of batteries in your household garbage.

Points of sale are obliged to:

• Accept the return of your used batteries

• Store the returned batteries in a suitable location

• Send the returned batteries to the battery manufacturer for recycling

Spare parts

Only use TVS Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original

parts, as they are the same parts that are assembled during standard production. Only TVS Original Parts can offer

this guarantee.

Service Manual

general information

9

workshop tools and equipments

Special tools

Part Number

Description of tools

Image

NB310090

U69 ENGINE HOLDER AND RO-

TARY STAND

N7310140

TOOL TDC LOCK

NB310100

TOOL PISTON RING ASSY

N7310110

TOOL ONEWAY CLUTCH ASSY

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general information

10

Part Number

Description of tools

Image

N7310170

ADAPTER COMPRESSION

GAUGE

N7310150

ADAPTER MAGNETO PULLER

N7310090

TOOL IG INDEX - TOOL IGNI-

TION COIL

NB310080

TOOL PISTON CIRCLIP ASSY.

Service Manual

general information

11

Part Number

Description of tools

Image

N7310160

SERVICE TOOL CLUTCH NUT

N7310280

MANDREL COOLANT SEAL 35

27

N7310240

MANDREL BALL BEARING 26 10

N7310230

MANDREL NEEDLE BEARING 12

8

Service Manual

general information

12

Part Number

Description of tools

Image

N7310220

MANDREL NEEDLE BEARING 20

14

N7310190

MANDREL OIL SEAL 24 15

N7310070

PISTON ROD HOLDER

N7310210

MANDREL NEEDLE BEARING 32

25