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

SERVICE MANUAL

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.

FOREWORD

We are happy to provide you the first edition of new TVS APACHE RTR 200 4V DFiLOGIC

motorcycle’s service manual.

This manual is prepared to provide the assistance during the process of servicing the new TVS

APACHE RTR 200 4V DFiLOGIC 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 TVS APACHE RTR 200 4V DFiLOGIC motorcycle. We request you to carefully go

through this manual and follow the instructions given.

All the instructions and illustrations of this manual is prepared based on the recent information available

during the preparation of manual. Modifications or any improvements on product will be

communicated through ‘SERVICE INFORMATION BULLETINS’ from time to time.

This manual will help to the technicians who already have technical knowledge about motorcycles.

While servicing, certain parts may require replacement. For ordering spares please refer Parts

catalogue of TVS APACHE RTR 200 4V DFiLOGIC motorcycle. The illustrations in this manual may

not give you the exact name, part number and quantities.

Incase, you face any critical problems during the course of servicing and if you need any further

clarifications or technical assistance you may contact our area service personal.

You may also contact us at

TVS Motor Company Limited,

International Business (Service) Department,

Post box No.4, Harita, Hosur - 635 109,

Tamilnadu, India.

Caution / warning :- This indicates special procedures of precautions to be followed by the mechanics during

the service. Avoiding these messages may cause injury to them as well as damage to the

components.

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. Some of the exploded views occupy full pages. In between the running instructions we have used the

notations as per the examples given below:

Note:

Inspect and set the idling speed after

completing all other maintenance actions.

HOW TO READ THIS MANUAL

Heading:-

CHAIN ASSEMBLY DRIVE

Sub heading:-

Chain slackness

Note :- This provides further clarification for clear understanding of any particular information/operation/data.

Hand tools :-

17 mm spanner

Special tools :-

N231 002 0

Clutch nut tightening tool

Service limits :-

Service limit

0.05 mm

Part
number

Description

Caution:

Check that the gasket inlet is intact and in

good condition.

1

GENERAL INFORMATION

Page 1-1 to 1-14

2

Page 2-1 to 2-59

PERIODIC MAINTENANCE

3

Page 3-1 to 3-57

SERVICING OF ENGINE

4

Page 4-1 to 4-12

FUEL, LUBRICATION AND EXHAUST SYSTEM

5

Page 5-1 to 5-30

ELECTRICAL SYSTEM

6

Page 6-1 to 6-52

CHASSIS

7

Page 7-1 to 7-10

DIAGNOSTIC TOOL

8

Page 8-1 to 8-16

SERVICE INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

GROUP INDEX

TVS APACHE RTR 200

SERVICE MANUAL

DESCRIPTION

PAGE NO

VIEW OF TVS APACHE RTR 200 4V

1

VEHICLE IDENTIFICATION NUMBERS

2

FRAME NUMBER LOCATION

2

ENGINE NUMBER LOCATION

2

FRAME AND ENGINE NUMBER CODES

2

YEAR AND MONTH CODES

3

CODE FOR THE PRODUCTION YEAR

3

CODE FOR THE PRODUCTION MONTH

3

TECHNICAL SPECIFICATIONS

4

DIMENSIONS AND WEIGHT

4

ENGINE

4

TRANSMISSION

4

GEAR RATIO

5

CHASSIS

5

ELECTRICAL

5

CAPACITIES

6

ADVANTAGES AND SPECIAL FEATURES OF TVS APACHE RTR 200 4V

7

RUNNING- IN PERIOD

7

FUEL AND OIL RECOMMENDATIONS

8

PRECAUTIONS AND GENERAL INSTRUCTIONS

8

LIST OF HAND TOOLS REQUIRED

9

LIST OF SPECIAL TOOLS REQUIRED

9

SPECIAL TOOLS AND ITS APPLICATION

10

Chapter 1

GENERAL INFORMATION

CONTENTS

TVS APACHE RTR 200 4V

RIGHT SIDE

LEFT SIDE

Fig. 1.1

Fig. 1.2

TVS APACHE RTR 200

SERVICE MANUAL

GENERAL INFORMATION

1-1

FRAME AND ENGINE NUMBER CODES

FRAME NUMBER

ENGINE NUMBER

4

2

Manufacturing serial no.

Manufacturing serial no.

0

0

3

9

0

0

0

8

Month code

F

2

P

F

2

0

Year code

Year code

Plant code

Plant code

A

T

1

6

0

T

1

P

Engine type

Engine type

Variant identifier

Month code

Filler

Check digit

VEHICLE IDENTIFICATION NUMBERS

LOCATIONS

FRAME NUMBER

l The frame serial number is stamped on the

right side of the steering head tube. (Fig. 1.3)

ENGINE NUMBER

l The engine serial number is stamped on the

left side crankcase assembly near cylinder

block. (Fig. 1.4)

6

3

7

Frame type

Vehicle type

M

D

World manufacturer

identifier

Fig. 1.3

Fig. 1.4

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-2

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

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

A

JANUARY

B

FEBRUARY

C

MARCH

D

APRIL

E

MAY

F

JUNE

G

JULY

H

AUGUST

K

SEPTEMBER

L

OCTOBER

N

NOVEMBER

P

DECEMBER

CODE FOR THE PRODUCTION YEAR

CODE

CODE

YEAR

CODE FOR THE PRODUCTION MONTH

MONTH

YEAR AND MONTH CODES

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-3

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 (with toolkit and 90% of fuel)

148.5 kg

Pay load

130 kg

Maximum laden weight

278.5 kg

ENGINE

Type

4 stroke, Oil cooled, Single cylinder OHC, EFI

Bore

66 mm

Stroke

57.8 mm

Piston displacement

197.75 cc

Compression ratio

9.7 : 1

No. of valves

4

Throttle body

BOSCH

Air filter

Viscous Paper filter

Oil filter

Wire mesh and micronic paper filter

Lubrication system

Forced wet sump

Maximum power in kW

15.46 kW (21 PS) @ 8500 rpm

Maximum torque in Nm

18.1 Nm @ 7000 rpm

Maximum speed

Around 129 km / h

Engine idling rpm (under warm condition)

1400 ± 200 rpm

Starting system

Electric starter

TRANSMISSION

Clutch

Wet - multiplate type

Gear shift pattern

1 down and 4 up

Primary transmission

Helical gears

Secondary transmission

Chain and sprockets

TECHNICAL SPECIFICATIONS

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-4

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)

Front suspension

Telescopic oil damped

Rear suspension

Gas charged Mono shock absorber,

7 step adjustable with rectangular swing arm

Steering angle

34°

Caster angle

25.5°

Trail length

95.5 mm

Brakes

Front

Hand operated, 270 mm petal disc

Rear

Foot operated, 240 mm petal disc

Tyre*

Front

90/90 x 17 Tubeless

Rear

130/70 x 17 Tubeless

2

Tyre pressure

Front

1.75 kg/cm (25 PSI)

2

Rear

Solo

2.00 kg/cm (28 PSI)

2

Dual

2.25 kg/cm (32 PSI)

ELECTRICAL

Type

AC generator

Ignition system

ECU - 3D Ignition timing map

Spark plug

BOSCH UR4KE

Battery type

12V, 9 Ah

Body earthing

Negative terminal

Generator

Fly wheel magneto 12V, 260W

Head lamp

12V, 60/55W H4 x 1

Position lamp

LED lamp (2W) x 2

Tail / brake lamp

LED indicator (1W max. / 2.5W max.)

Turn signal lamp

12V, 10W x 4

Number plate lamp

12V, 5W x 1

Instrument panel

LCD / LED indicators

Horn

12V, DC x 2

Fuse

12V 20Ax1, 12V 15Ax1 and 12V 10Ax2 blade type

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-5

* The pneumatic tyres fitted in this vehicle meet the requirements specified by BIS and comply with

the requirements under Central Motor Vehicles Rules (CMVR), 1989.

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

indicated capacity.

TECHNICAL SPECIFICATIONS

CAPACITIES

Fuel type

Unleaded petrol

Fuel tank capacity*

12 litres (including reserve)

Reserve

2.5 litres

Engine cum transmission oil grade

TVS TRU4 FULLY SYNTHETIC oil

(SAE 10W30 API-SL, JASO MA2)

Engine cum transmission oil capacity

1200 ml (after draining)

1400 ml (incase of disassembly)

Front fork oil grade

TRU FORK oil

Front fork oil quantity

325 ± 2 cc

Brake fluid

TVS Griling DOT 3 / DOT 4

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-6

ADVANTAGES AND SPECIAL FEATURES OF TVS APACHE RTR 200 4V

l 200 CC, 4 valve, learn burn engine with the peak power of 21 PS @ 8500 rpm and peak torque of 18.1 Nm @ 7000

rpm helps to achieve 0 to 60 kmph speed in 3.9 secs.

l ECU - 3D Ignition timing map, tuned for smooth power delivery

l High combustion nanofriks-coated piston

l

6 plate clutch for racing launch

l 5 speed gear box for high speed

l

Large intake resonator - boosts low-end torque

l Paper filter in air cleaner for increased durability

l

Oil cooled along with ram air assisted cooling for optimum engine performance

l

Stainless steel exhaust pipe exhaust system

l

Double barrel exhaust engineered with European sound design techniques

l Race origin double cradle split syncro stiff frame

l

Double check valve bush front fork for excellent and smooth front suspension

l

KYB mono tube suspension for aggressive racing

l

Roto petal disc brakes

l

Race grip Remora tyres (Pirelli tyres optional)

l

Aluminium forged handle bars

l

Interactive racing display

l

All new - Day LED lamp

l

Aggressive tank cowl

l Racing ergo split seat assembly

l Longer wheel base for better stability

RUNNING - IN PERIOD

The first 1000 km is a crucial part. Proper running-in operation during this period helps in ensuring a longer life and

smooth performance of TVS APACHE RTR 200 4V DFiLOGIC.

The reliability and performance of TVS APACHE RTR 200 4V DFiLOGIC 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. Maximum recommended speed upto 750 km is 50 km/h.

Do not ride at constant low speed for a longer time during any portion of the running-in period. Keep varying the

engine speed for better mating of parts.

GENERAL INFORMATION

TVS APACHE RTR 200

SERVICE MANUAL

1-7