PT TVS MOTOR COMPANY INDONESIA

SERVICE MANUAL

RTR 160 & 180

TVS APACHE RTR 160 & 180 SERVICE MANUAL

PT TVS Motor Company Indonesia

JI. Surya Madya Kav. 1-30, Kawasan Industri Surya Cipta,

Desa Kutanegara, Ciampel, Karawang, Jawa Barat 41361, Indonesia

Telp: +62 267 86 10121 Fax: +62 267 86 10124

Factory

Gedung Wirausaha Lantai 3 JI. HR Rasuna Said Kav. C-5

Kuningan, Jakarta 12920, Indonesia

Telp : +62 21 300 20570 Fax: +62 21 300 20576 www.tvsmotor.co.id

Office Sales & Marketing

PT TVS Motor Company Indonesia

Printed in March 2010

PT TVS Motor Company Indonesia 2009, All rights reserved

PT TVS MOTOR COMPANY INDONESIA

SERVICE MANUAL

RTR 160 & 180

TVS APACHE RTR 160 & 180 SERVICE MANUAL

PT TVS Motor Company Indonesia

JI. Surya Madya Kav. 1-30, Kawasan Industri Surya Cipta,

Desa Kutanegara, Ciampel, Karawang, Jawa Barat 41361, Indonesia

Telp: +62 267 86 10121 Fax: +62 267 86 10124

Factory

Gedung Wirausaha Lantai 3 JI. HR Rasuna Said Kav. C-5

Kuningan, Jakarta 12920, Indonesia

Telp : +62 21 300 20570 Fax: +62 21 300 20576 www.tvsmotor.co.id

Office Sales & Marketing

PT TVS Motor Company Indonesia

Printed in March 2010

PT TVS Motor Company Indonesia 2009, All rights reserved

GROUP INDEX

1

GENERAL INFORMATION

Page 1-1 to 1-13

2

PERIODIC MAINTENANCE

Page 2-1 to 2-40

3

SERVICING OF ENGINE

Page 3-1 to 3-54

4

FUEL, LUBRICATION AND EXHAUST SYSTEM

Page 4-1 to 4-19

5

ELECTRICAL SYSTEM

Page 5-1 to 5-24

6

CHASSIS

Page 6-1 to 6-52

7

SERVICE INFORMATION

Page 7-1 to 7-15

DESCRIPTION

PAGE NO.

VIEWS OF TVS APACHE RTR SINGLE DISC - 160

1

VIEWS OF TVS APACHE RTR DUAL DISC - 160

1

VIEWS OF TVS APACHE RTR DUAL DISC - 180

2

VEHICLE IDENTIFICATION NUMBERS

2

FRAME NUMBER

3

ENGINE NUMBER

4

TECHNICAL SPECIFICATIONS

5

DIMENSIONS AND WEIGHT

5

ENGINE

5

TRANSMISSION

5

GEAR RATIO

6

CHASSIS

6

ELECTRICAL

6

CAPACITIES

7

RUNNING- IN PERIOD

8

PRECAUTIONS AND GENERAL INSTRUCTIONS

8

LIST OF HAND TOOLS REQUIRED

9

LIST OF SPECIAL TOOLS REQUIRED

9

APPLICATION OF SPECIAL TOOLS

10

CONTENTS

Chapter 1

Chapter 1

GENERAL INFORMATION

GENERAL INFORMATION

DESCRIPTION

PAGE NO.

PERIODIC MAINTENANCE SCHEDULE

1

LUBRICATION SCHEDULE

3

21 FREE SERVICE POINTS

4

MAINTENANCE AND TUNE-UP PROCEDURE

10

AIR CLEANER ASSEMBLY

10

CARBURETTOR ASSEMBLY

11

HOSE FUEL

12

CAP FUEL STRAINER

13

ENGINE CUM TRAMSISSION OIL CHANGE

13

ENGINE CUM TRAMSISSION OIL LEVEL

14

FILTER COMP ENGINE OIL

14

COMPRESSION PRESSURE

15

HEAD COMPLETE CYLINDER, PISTON AND PISTON RINGS

16

VALVE, VALVE GUIDE AND SEAT VALVE

16

VALVE (TAPPET) CLEARANCE

17

SPARK PLUG

19

BATTERY ASSEMBLY

20

HEAD LAMP BEAM ADJUSTMENT

21

CABLE ASSEMBLY THROTTLE - FREE PLAY

22

CABLE ASSEMBLY CLUTCH - FREE PLAY

22

BRAKES

23

FRONT BRAKE (DISC)

23

REAR BRAKE (DRUM )

27

REAR BRAKE (DISC)

28

WHEEL ASSEMBLY FRONT

30

WHEEL ASSEMBLY REAR ( DRUM)

31

INSPECTION

32

WHEEL ASSEMBLY REAR (DISC)

33

CHAIN ASSEMBLY DRIVE

34

STEERING

37

FRONT FORK OIL

38

TYRES

38

BOLTS AND NUTS

39

LUBRICATION POINTS

40

CONTENTS

Chapter 2

Chapter 2

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

DESCRIPTION

PAGE NO.

ENGINE OVERHAUL

1

CLUTCH REMOVAL AND SERVICING

1

INSPECTION

5

REASSEMBLY

6

ENGINE ASSEMBLY REMOVAL FROM VEHICLE

7

ENGINE ASSEMBLY - DISASSEMBLY

13

TRANSMISSION

29

SHAFT COMPLETE DRIVE DISMANTLING

29

INSPECTION

31

REASSEMBLY

31

COVER CYLINDER HEAD - DISASSEMBLY

32

INSPECTION

33

REASSEMBLY

34

HEAD COMPLETE REAR

34

DISASSEMBLY

34

DECARBONISING

36

INSPECTION

37

CYLINDER HEAD ASSEMBLY EXPLODED VIEW

40

REASSEMBLY

41

LEAK CHECK AND LAPPING

41

ENGINE COMPONENTS INSPECTION

42

ENGINE COMPONENTS REASSEMBLY

47

ENGINE ASSEMBLY REASSEMBLY

49

VALVE TIMING AND VALVE CLEARANCE

54

RUNNING IN AFTER OVERHAUL

54

CONTENTS

Chapter 3

Chapter 3

SERVICING OF ENGINE

SERVICING OF ENGINE

DESCRIPTION

PAGE NO.

COVER FUEL TANK - REMOVAL

1

REASSEMBLY

1

FUEL TANK COMPLETE AND FUEL COCK ASSEMBLY

2

REMOVAL

2

CLEANING

3

FUEL COCK ASSEMBLY

3

FUEL HOSES

3

CARBURETTOR ASSEMBLY

4

REMOVAL FROM THE VEHICLE

4

DISASSEMBLY

5

PISTON VALVE DISASSEMBLY

8

MAINTENANCE

9

CLEANING

9

INSPECTION - NEEDLE VALVE ASSEMBLY

10

REASSEMBLY

10

CARBURETTOR TUNING

11

LUBRICATION SYSTEM

12

OIL STRAINER

12

OIL PUMP ASSEMBLY

14

LUBRICATION FLOW CHART

14

FILTER COMP ENGINE OIL

14

EXHAUST EMISSION CONTROL

15

WHY DOES THE GASOLINE FAIL TO BURN COMPLETELY

15

POLLUTION CONTROL

15

EXHAUST SYSTEM

16

SECONDARY AIR INJECTION VALVE

16

WORKING PRINCIPLE

16

FUNCTION

17

REMOVAL

17

PREVENTIVE MAINTENANCE

18

MEASURING CO LEVEL IN EXHAUST EMISSSION

18

TO CHECK AND SET THE CO

18

CONTENTS

Chapter 4

Chapter 4

FUEL LUBRICATION AND EXHAUST SYSTEM

FUEL LUBRICATION AND EXHAUST SYSTEM

CONTENTS

Chapter 5

Chapter 5

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

DESCRIPTION

PAGE NO.

WIRE COLOUR CODE INDEX

1

PRECAUTIONS

2

CONNECTOR

2

COUPLER

2

FUSE

2

SEMI-CONDUCTOR EQUIPPED PART

2

CONNECTING BATTERY

3

IGNITION SYSTEM

3

IGNITION LOCK

4

ENGINE KILL SWITCH

5

PULSAR COIL

5

IGNITION COIL

5

SUPPRESSOR CAP

6

SPARK PLUG

6

THROTTLE SWITCH

6

LIGHTING SYSTEM

7

LIGHTING SWITCH

8

BEAM CONTROL SWITCH

8

AC DC PASS BY LAMP

8

PASS BY RELAY

8

PASS BY SWITCH

9

12V REGULATION SYSTEM

9

RR UNIT

9

LIGHTING PERFORMANCE CHECK

9

LIGHTING CUM CHARGING COIL

10

CHARGING AND DC SYSTEM

10

HORN 12V DC

11

TURN SIGNAL LAMP FRONT & REAR

11

NEUTRAL LAMP

12

STOP LAMP

12

FUEL LEVEL INDICATOR

13

CHARGING PERFORMANCE CHECK

13

CHARGING COIL

13

ELECTRIC STARTER SYSTEM

14

ELECTRIC STARTER SWITCH

15

SWITCH ASSEMBLY CLUTCH

15

STARTER RELAY

15

BULBS REPLACEMENT

16

LAMP ASSEMBLY TURN SIGNAL - BULB

16

HEAD LAMP ASSEMBLY LAMP

16

POSITION LAMP BULB REPLACEMENT

17

SPEEDOMETER ASSEMBLY

17

ODO / TRIP METER SETTING

17

DIGITAL CLOCK SETTING

18

REPLACEMENT

18

Continued...

CONTENTS

Chapter 5

Chapter 5

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

LAMP ASSEMBLY REAR COMBINATION

20

NUMBER PLATE ILLUMINATOR BULB

21

ADJUSTMENT

21

HEADLAMP BEAM ADJUSTMENT

21

SWITCH ASSEMBLY STOP LAMP

21

BATTERY ASSEMBLY

22

REMOVAL

22

SERVICING

22

ELECTROLYTE LEVEL

22

BATTERY CHARGER

23

CHARGING PROCEDURE

23

INDICATION OF FULL CHARGE

24

REVERSE POLARITY

24

CONTENTS

Chapter 6

Chapter 6

CHASSIS

CHASSIS

DESCRIPTION

PAGE NO.

WHEEL ASSEMBLY FRONT

1

DISC PLATE REPLACEMENT

1

INSPECTION

2

TUBELESS TYRE RTR 180

3

REASSEMBLY

4

DISC BRAKE SYSTEM

6

CALIPER ASSEMBLY FRONT -REMOVAL AND DISMANTLING

6

INSPECTION OF CALIPER ASSEMBLY

9

ASSEMBLING OF CALIPER ASSEMBLY

9

DISC PLATE SERVICING

10

DISC PLATE REPLACEMENT

10

MASTER CYLINDER - REMOVAL AND DISMANTLING

11

INSPECTION

13

REASSEMBLY

13

FORK ASSEMBLY FRONT

15

OIL REPLACEMENT

15

LEG ASSEMBLY FRONT FORK - DISMANTLING

19

INSPECTION

20

REASSEMBLY

21

LOWER BRACKET COMPLETE - DISMANTLING

22

INSPECTION

23

REASSEMBLY

24

WHEEL ASSEMBLY REAR (DISC BRAKE) - REMOVAL

26

DISC REPLACEMENT

26

REMOVAL OF BEARING

26

SPROCKET DRUM ASSEMBLY - REMOVAL

27

INSPECTION

29

REASSEMBLY

30

TUBELESS TYRE RTR 180

33

PUNCTURE REPAIR

33

VALVE TUBELESS TYRE REPLACEMENT

34

DISC BRAKE SYSTEM REAR

35

CALIPER ASSEMBLY -REMOVAL AND DISMANTLING

35

CALIPER ASSEMBLY - INSPECTION

38

CALIPER ASSEMBLY - REASSEMBLY

38

DISC PLATE SERVICING

39

DISC PLATE REPLACEMENT

39

MASTER CYLINDER - REMOVAL AND DISMANTLING

39

INSPECTION

42

REASSEMBLY

42

Continued...

CONTENTS

Chapter 6

Chapter 6

CHASSIS

CHASSIS

WHEEL ASSEMBLY REAR (DRUM BRAKE) - REMOVAL

44

PANEL ASSEMBLY REAR - DISMANTLING

44

REMOVAL OF BEARING

45

INSPECTION

45

REASSEMBLY

45

SWING ARM COMPLETE

47

REMOVAL

47

INSPECTION

49

REASSEMBLY

49

FLAP REAR FENDER (RTR 180)

51

MIRROR ASSEMBLY L&R

52

REMOVAL

52

REASSEMBLY

52

DESCRIPTION

PAGE NO.

SERVICE DATA

1

VALVE AND VALVE GUIDE

1

CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER

1

CYLINDER, PISTON AND RINGS PISTON

2

CRANKSHAFT COMPLETE

2

CLUTCH

3

TRANSMISSION SPECIFICATION

3

TRANSMISSION

3

SUSPENSION

3

BEARING SPECIFICATION

4

CARBURETTOR ASSEMBLY

5

ELECTRICAL

6

BRAKE AND WHEEL ASSEMBLY

7

TIGHTENING TORQUE - ENGINE

8

TIGHTENING TORQUE - CHASSIS

9

SPECIAL MATERIAL REQUIRED FOR MAINTENANCE

10

USE OF GENUINE TVS MOTOR COMPANY PARTS

10

FUEL

10

TROUBLE SHOOTING

11

STARTING TROUBLE

11

POOR PICK-UP

12

SMOKY EXHAUST (WHITE SMOKE)

12

SMOKY EXHAUST (BLACK SMOKE)

13

ENGINE OVER HEATING

13

HEAD LAMP NOT WORKING

13

HORN NOT WORKING

14

HIGH FUEL CONSUMPTION

14

EXCESSIVE CO

14

JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM

14

WIRING DIAGRAM- TVS APACHE RTR 160 & 180

15

CONTENTS

Chapter 7

Chapter 7

SERVICE INFORMATION

SERVICE INFORMATION

General information 1-1

1

TVS APACHE RTR160 SINGLE DISC

Fig. 1.1

GENERAL INFORMATION

TVS APACHE RTR160 DUAL DISC

Fig. 1.1

PLEASE REPLACE THIS IMAGE

Fig. 1.3

TVS APACHE RTR180 DUAL DISC

General information 1-2

GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBERS

LOCATIONS

FRAME NUMBER

ENGINE NUMBER

l The frame serial number is engraved on the frame

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

l The engine serial number is engraved on the left

side crankcase near cylinder block. (Fig. 1.5)

Fig. 1.5

Fig. 1.4

4

9

0

OE H 2213 95

D6 4

9

0

9

M

3 KE42 2H 90 6

L A

L

I

P E SE REP ACE TH S IMAGE

General information 1-3

GENERAL INFORMATION

1

M D 6

3

4

K E

4

2

9

2 H 0

9

0

9 6

M - Asia

D - India

K - Indonesia

Z - PT TVS MOTOR COMPANY INDONESIA

6 - TVS MOTOR COMPANY INDIA

Frame type

Vehicle type

Variant identifier

Engine type

Check digit

Plant code

Year code

Month code

Manufacturer serial no.

PT TVS MOTOR COMPANY INDONESIA

SYSTEM FOLLOWING IN FRAME NO. IDENTIFICATION