MANUAL DE SERVICIO

[Link]/TVS APACHE RTR 200 4V - REVISIÓN - 0

 DARSE CUENTA

Toda la información incluida en esta publicación se basa en la información más reciente disponible en
el momento de aprobarse la impresión.

Todas las ilustraciones que aparecen en este manual pueden ser diferentes de los vehículos reales.

TVS Motor Company Limited se reserva el derecho a realizar cambios en cualquier

momento sin previo aviso y sin incurrir en ningún tipo de obligación.

Ninguna parte de esta publicación debe ser reproducida sin el permiso por escrito de TVS
Motor Company Limited.
 PREFACIO

Estamos encantados de ofrecerle la primera edición de la nueva Televisores Apache RTR 200 4V manual de servicio de la motocicleta.

Este manual está preparada para proporcionar la asistencia durante el proceso del servicio de la nueva Televisores Apache RTR 200 4V motocicleta.
En este manual se describe acerca de las operaciones básicas de este nuevo producto, qué hacer y qué no lo es, los límites de servicio de los
componentes individuales y subsistemas cuando dé servicio al
Televisores Apache RTR 200 4V motocicleta. Le rogamos que siga cuidadosamente este manual y siga las instrucciones dadas.

Todas las instrucciones e ilustraciones de este manual se preparan con base en la información reciente disponible durante la
preparación del manual. Modificaciones o cualquier mejora en el producto serán comunicadas a través de ' Boletines de
información SERVICIO ' de vez en cuando.

Este manual le ayudará a los técnicos que ya tienen conocimientos técnicos sobre las motocicletas.

Si bien el servicio, algunas partes pueden necesitar ser reemplazados. Para ordenar repuestos consulte Catálogo de piezas de TVS
APACHE RTR 200 4V motocicleta. Las ilustraciones de este manual no le puede dar el nombre exacto, número de pieza y cantidades.

En caso, se enfrentan a problemas críticos durante el curso de mantenimiento y si necesita cualquier otra aclaración o asistencia técnica
puede contactar con nuestro servicio de área personal.

También puede ponerse en contacto con nosotros en

TVS Motor Company Limited, Marketing (Servicio)

Departamento, Post cuadro No.4, HARITA, Hosur -
635 109, Tamil Nadu, India.
CÓMO LEER ESTE MANUAL

Este manual de servicio está dividida en siete capítulos como “Información general”, “Mantenimiento periódico”, “Mantenimiento del motor”, “Sistema de
combustible, lubricación y de escape”, “Sistema eléctrico”, “chasis” y “Información de servicio”.

Sobre todo las páginas se disponen en dos columnas en las páginas interiores con las instrucciones en el lado izquierdo y las ilustraciones en el lado derecho. Algunos de los dibujos de

despiece ocupan páginas enteras. En medio de las instrucciones de funcionamiento que hemos utilizado las anotaciones como por los ejemplos que se dan a continuación:

Título:- CADENA conjunto de accionamiento

Sub partida: - laxitud cadena

Nota :- Esto proporciona una mayor clarificación de comprensión clara de cualquier información / operación / datos en particular.

Nota:
Inspeccionar y ajustar la velocidad de ralentí después de completar
todas las otras acciones de mantenimiento.

Precaución / advertencia: - Esto indica procedimientos especiales de las precauciones que han de seguirse por la mecánica durante
el servicio. Evitar estos mensajes puede causar daño a ellos, así como daños en los componentes.

Precaución:
Compruebe que la entrada de junta está intacta y en buenas
condiciones.

Herramientas manuales :- 17 mm llave

Parte? Número Descripción

Herramientas especiales :- N231 002 0 herramienta de apriete la tuerca del embrague

Límites de servicio: - límite de servicio 0,05 mm

 ÍNDICE DE GRUPO
Televisores Apache RTR 200 MANUAL DE SERVICIO

1 INFORMACIÓN GENERAL Página 1-1 a 1-14

2 MANTENIMIENTO PERIÓDICO Página 2-1 a 2-52

3 MANTENIMIENTO DE MOTOR Página 3-1 a 3-58

4 COMBUSTIBLE, lubricación y SISTEMA DE ESCAPE Página 4-1 a 4-19

5 SISTEMA ELÉCTRICO Página 5-1 a 5-28

6 CHASIS Página 6-1 a 6-51

7 SERVICIO DE INFORMACIÓN Página 7-1 a 7-15

 CONTENIDO
Televisores Apache RTR 200 MANUAL DE SERVICIO

DESCRIPCIÓN PÁGINA NO
Capítulo 1
VISTAS televisores Apache RTR 200 4V 1
NÚMEROS DE IDENTIFICACIÓN DEL VEHÍCULO 2
NÚMERO DE MARCO DE UBICACIÓN 2
NÚMERO DE UBICACIÓN DEL MOTOR 2
Bastidor y del motor códigos numéricos 2
Año y mes CÓDIGOS 3
CÓDIGO DE LA PRODUCCIÓN DE AÑO 3
CÓDIGO PARA LA PRODUCCIÓN DE MES 3
ESPECIFICACIONES TÉCNICAS 4
DIMENSIONES Y PESO 4
MOTOR 4
TRANSMISIÓN 4
RELACIÓN DE TRANSMISIÓN 5
CHASIS 5
ELÉCTRICO 5
CAPACIDADES 6
Ventajas y particularidades de televisores APACHE RTR 200 4V 7
TÉRMINOS DE GARANTIA 7
Running-EN PERIODO 7

GENERAL INFORMATION
Combustible y aceite RECOMENDACIONES 8
PRECAUCIONES E INSTRUCCIONES GENERALES 8
LISTA DE necesidad de usar herramientas 9
Lista de herramientas especiales que se requieren 9
HERRAMIENTAS ESPECIALES Y SU APLICACIÓN 10
 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

Televisores Apache RTR 200 4V

Fig. 1.1 LADO DERECHO

Fig. 1.2 LADO IZQUIERDO

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

NÚMEROS DE IDENTIFICACIÓN DEL VEHÍCULO

LOCALIDADES

NÚMERO DE CUADRO

l El número de serie del bastidor está impreso en el

lado derecho de la pipa de dirección. (Fig. 1.3)

Fig. 1.3

NÚMERO DE MOTOR

l El número de serie del motor está estampado en la

montaje izquierda del cárter lateral cerca de bloque de cilindros. (Fig.
1.4)

Fig. 1.4

Bastidor y del motor códigos numéricos

NÚMERO DE CUADRO Maryland 637 AR 1 6 F2P 0039 4

Identificador fabricante de vehículo código de un mes

mundial Fabricación de número de serie.
Marco Tipo Tipo dígito de control Código de planta

Variant Tipo de motor Tipo de motor código del año

código de un mes

identificador código del año

Fabricación de número de serie.

Código de planta
Relleno

NÚMERO DE MOTOR 0R1P F20 0008 2

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

Año y mes CÓDIGOS

CÓDIGO DE LA PRODUCCIÓN DE AÑO CÓDIGO PARA LA PRODUCCIÓN DE MES

CÓDIGO AÑO CÓDIGO MES

1 2001 UNA ENERO

2 2002 segundo FEBRERO
3 2003 do MARZO
4 2004 re ABRIL
5 2005 mi MAYO

6 2006 F JUNIO

7 2007 sol JULIO

8 2008 H AGOSTO
9 2009 K SEPTIEMBRE
UNA 2010 L OCTUBRE
segundo 2011 norte NOVIEMBRE
do 2012 PAG DICIEMBRE
re 2013
mi 2014
F 2015
sol 2016
H 2017
J 2018
K 2019
L 2020
METRO 2021
norte 2022
PAG 2023
R 2024
S 2025
T 2026
V 2027
W 2028
X 2029
Y 2030

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

ESPECIFICACIONES TÉCNICAS

DIMENSIONES Y PESO

Longitud total 2050 mm

Ancho promedio 790 mm

Altura total 1105 mm

Altura del asiento 800 mm

Claridad del piso 180 mm

Distancia entre ejes 1353 mm

Peso en vacío ( con conjunto de herramientas y el 90% de combustible) 148 kg

carga útil 130 kg

peso máximo de carga 278 kg

MOTOR

Tipo 4 tiempos, refrigerado por aceite, monocilindro OHC

Aburrir 66 mm

Carrera 57,8 mm

Desplazamiento del pistón 197,75 cc

Índice de compresión 9.7: 1

No. de válvulas 4

tipo de carburador Keihin CV 30 VE

Filtro de aire El filtro de papel viscoso

Filtro de aceite malla de alambre y papel de filtro micrónico

Sistema de lubricación cárter húmedo forzado

La potencia máxima en kW 15,09 kW (20,5 PS) @ 8500 rpm

El par máximo en Nm 18,1 Nm @ 7000 rpm

Velocidad máxima Alrededor de 128 kmh

rpm de ralentí del motor (en la condición caliente) 1500 ± 100 rpm

Sistema de arranque Arrancador eléctrico

TRANSMISIÓN

Embrague Wet - tipo multidisco

patrón de cambio de marcha 1 hacia abajo y 4 hasta

transmisión primaria Los engranajes helicoidales

transmisión secundaria Cadena y piñones

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

ESPECIFICACIONES TÉCNICAS

RELACIÓN DE TRANSMISIÓN

Primera marcha 2,917

Segunda marcha 1.857
tercera velocidad 1,333
cuarta velocidad 1.050
Quinta velocidad 0,880
reducción primaria 2,818
reducción secundaria 3,461

CHASIS

Cuadro Doble TIESO Cuna de Split Synchro (DCSSS)

Suspensión delantera aceite telescópica amortiguada

Suspensión trasera Gas amortiguador Mono cargada, de 7 pasos ajustable

con brazo basculante rectangular
Ángulo de dirección 34 °

Ángulo de avance 25,5 °

longitud Trail 95,5 mm

Frenos Frente Mano operado, 270 mm disco pétalo
Posterior Foot operado, 240 mm disco pétalo
Neumático* Frente 90/90 x 17 Tubeless
Posterior 130/70 x 17 Tubeless
2
Presión de los neumáticos Frente 1,75 kg / cm (25 PSI)
2
Posterior Solo 2,00 kg / cm (28 PSI)
2
Doble 2,25 kg / cm (32 PSI)

ELÉCTRICO

Tipo generador de corriente alterna

Sistema de encendido La carga del motor de encendido digital basada - IDI

Bujía BOSCH - UR4KE

Tipo de Batería 12V, 9 Ah
puesta a tierra del cuerpo terminal negativo
Generador Fly rueda magneto 12V, 200W
lámpara de cabeza 12V, 60 / 55W H4 x 1
La luz de posición lámpara de LED (2W) x 2

Lámpara de cola / freno indicador LED (1W máx. / 2,5 W máx.)

Intermitente 12V, 10W x 4
alumbrado de la placa Número 12V, 5W x 1
Tablero de instrumentos LCD / LED indicadores
cuerno 12V, DC x 2
Fusible 12V, 15A y 10A (cada uno)

* Los neumáticos instalados en este vehículo cumplen los requisitos especificados por BIS y cumplen con los requisitos establecidos en
Central Motor Vehículos reglas (CMVR), 1989.

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

ESPECIFICACIONES TÉCNICAS

CAPACIDADES

Tipo de combustible gasolina sin plomo

Capacidad del tanque de combustible* 12 litros (incluyendo reserva)

reserva 2,5 litros

grado de aceite de la transmisión del motor cum TVS TRU4 aceite completamente sintético (SAE
10W30 API SL, JASO MA2)

capacidad de aceite de la transmisión del motor cum 1200 ml (después de drenaje) 1400 ml
(encajona de desmontaje)

Frente grado de aceite tenedor aceite de KYB G10

cantidad de aceite tenedor delante 325 ± 2 cc

Líquido de los frenos TVS Griling DOT 3 / DOT 4

Nota:
Especificación están sujetos a cambios en la cuenta de mejoras continuas en el producto.

* El depósito de combustible no es un instrumento de medida y la capacidad del depósito de combustible puede variar de la capacidad indicada.

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

Ventajas y particularidades de televisores APACHE RTR 200 4V

l 200 CC, 4 de válvula, aprender quemar el motor con la potencia de pico de 20,5 PS @ 8500 rpm y un par máximo de 18,1 Nm
@ 7000 rpm ayuda a alcanzar la velocidad de 0 a 60 kilómetros por hora en 3,9 segundos.

l IDI - La carga del motor basa encendido digital, en sintonía para la entrega de potencia suave

l Alta combustión pistón nanofriks recubierto

l6 embrague de disco para el lanzamiento de carreras

l caja de cambios de 5 velocidades para alta velocidad

l Large resonador de admisión - aumenta el par de gama baja

l filtro de papel en el filtro de aire para una mayor durabilidad

l Aceite enfrió junto con refrigeración asistida de aire dinámico para un rendimiento óptimo del motor

l sistema de escape tubo de escape de acero inoxidable

l Doble escape barril diseñado con técnicas de diseño de sonido Europea

l origen Race doble cuna división Syncro marco rígido

l válvula de retención doble frente arbusto tenedor de suspensión delantera excelente y suave

l KYB suspensión tubo mono para las carreras agresivo

l Los frenos de disco lobulado roto

l neumáticos Remora agarre Race (neumáticos Pirelli opcional)

l Aluminio forjado manillar

l pantalla interactiva de carreras

l Todo nuevo - la lámpara del día del LED

l carenado tanque agresivo

l Racing conjunto de asiento de división ergo

l Longer base de la rueda para una mejor estabilidad

TÉRMINOS DE GARANTIA

Televisores Apache RTR 200 4V

24 meses desde la fecha de venta o 30.000 km, cualquiera de los dos ocurra primero

RUNNING - EN PERIODO

Los primeros 1000 km es una parte crucial. Buen funcionamiento en funcionamiento durante este período ayuda a la hora de garantizar una vida más larga y un funcionamiento sin

problemas de Televisores Apache RTR 200 4V.

La fiabilidad y el rendimiento de Televisores Apache RTR 200 4V depende de cuidados especiales y restringir ejercido durante el período de rodaje. Es especialmente
importante que evite el funcionamiento del motor de una manera, que podría dejar expuestas las piezas del motor a un calor excesivo. La velocidad máxima
recomendada hasta 750 km es de 50 km / h.

No circule a baja velocidad constante durante un tiempo más largo durante cualquier parte del período de rodaje. Mantener la variación de la velocidad del motor para un mejor

acoplamiento de las piezas.

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

Combustible y aceite RECOMENDACIONES

Televisores Apache RTR 200 4V tiene un motor de cuatro tiempos. No mezcle el aceite con la gasolina. Asegúrese de utilizar el siguiente combustible y el aceite especificado.

Combustible:

l gasolina sin plomo con número de octano entre 85 a 95 por el método de investigación.

l Utilice aditivos de combustible IFTEX en la gasolina según lo recomendado por el fabricante para la deposición de bajo carbono.

aceites:

Solicitud Cantidad fabricante Marca

aceite de la transmisión cum motor de 1200 ml ( durante el servicio regular) TVS-M TVS TRU4 aceite completamente sintético
1400 ml ( en caso de desmontaje) (SAE 10W30 API SL, JASO MA2)

aceite de tenedor delante 325 ± 2 cc KYB aceite de KYB G10

aceite de los frenos de disco - TVS Girling DOT 3 / DOT 4

Otro lubricante:

Solicitud Cantidad Fabricante Marca

Grasa - Bharat petróleo MP Grease no. 3

COI Servo Gem no. 3
Bechem Bechem prima de grado 3
Klüber Lubrication Kluber Centoplex 2

lubricante para cadenas - TVS Motor Company SPRAY TRU

PRECAUCIONES E INSTRUCCIONES GENERALES

Tenga en cuenta las siguientes precauciones sin fallar cuando desmontaje y el montaje.

l No haga funcionar el motor en espacios cerrados con poca o ninguna ventilación.

l Asegúrese de reemplazar las juntas, las juntas tóricas, anillos de seguridad y chavetas por otras nuevas, para la seguridad.

l Al apretar tuercas y tornillos, empezar primero con los más grandes o centro. Apretar estos con el par especificado
usando un patrón cruzado.
l Uso especifica solamente herramientas especiales y comunes.

l Cuando el motor y los componentes de accionamiento finales son desmontados y inspeccionado, revestir las superficies de acoplamiento con una

lubricante para evitar la corrosión.

l Durante el montaje de los componentes, el uso de lubricantes recomendados.

l Después de montar, comprobar cada parte para su correcta instalación, el movimiento y el funcionamiento.

l garantizar siempre la seguridad mutua cuando se trabaja con los socios.

l Utilice únicamente TVS Motor Company piezas y lubricantes recomendados.

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

LISTA DE necesidad de usar herramientas

1. Llaves de cabeza plana:

7 mm, 8 mm, 10 mm, 12 mm, 14 mm y 21 mm

2. Llaves de:
8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm, 17 mm, 22 mm, 24 mm, 27 mm y 32 mm
3. llaves tubulares:
8 mm, 10 mm, 12 mm, 14 mm, 16 mm y 17 mm
4. llaves de vaso:
12 mm, 14 mm, 17 mm, 22 mm, 27 mm y 32 mm
5. Teclas de Allen:

4 mm, 6 mm, 8 mm, 10 mm y 12 mm

6. conductores de tornillo:

controlador-pequeño tornillo plana, destornillador plano, cabeza Phillips no.1 destornillador, cabeza Phillips destornillador no. 2 y Phillips cabeza del tornillo conductor no.
3

7. Martillos:
martillo Nylon, mazo de goma y un martillo de metal

8. Alicates:

alicates recta nariz, la combinación de los alicates, alicates bomba de agua, externo circlip alicates-6 pulgadas y el anillo elástico circlip alicates-7 pulgadas

9. Otros:
Deriva, cincel, tapón de llave, el medidor de compresión, adoptante especial, micrómetro, calibrador Vernier, un medidor de escala, placa de superficie y un plato caliente

Lista de herramientas especiales que se requieren

Sl. no. Número de parte. Descripción

1 M131 002 0 extractor de Magneto

2 M131 007 0 ajustador de empujador

3 M131 011 0 estructura de tracción - cárter

4 N231 001 0 herramienta útil de embrague

5 N231 002 0 herramienta de apriete la tuerca del embrague

6 N931 009 0 Frente tenedor instalador de sello de aceite

7 N931 011 0 soporte del cilindro tenedor Tool

8 N931 012 0 Herramienta de precarga

9 N931 013 0 Herramienta de instalación de cono inferior

10 N931 014 0 Herramienta para tuercas de dirección

11 N931 015 0 Herramienta de servicio de brazo oscilante

12 N931 016 0 Herramienta de taza de dirección removedor

13 N931 017 0 conjunto de herramienta Magneto

14 NB31 004 0 Herramienta de montaje copas de dirección ajustador

15 S131 002 0 entrada Extractor y la válvula de escape

dieciséis S131 050 0 Teniendo conjunto instalador

17
18 S131 111 0 extractor de cojinete principal

031 180 0 indicador de nivel de aceite tenedor delante

19 031 240 1 removedor de la junta de aceite universal

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 INFORMACIÓN GENERAL
Televisores Apache RTR 200 MANUAL DE SERVICIO

HERRAMIENTAS ESPECIALES Y SU APLICACIÓN

1. Magneto puller - M131 002 0 (Fig 1.5A).

l Se utiliza para quitar el rotor del magneto de la

conjunto del cigüeñal. (Fig.1.5B)

Fig. 1.5A Fig. 1.5b

2. Varilla de levantamiento ajustador - M131 007 0 (Fig.1 6A)

l Se utiliza para ajustar el juego de válvulas de la válvula.

(Fig. 1.6B)

Fig. 1.6A Fig. 1.6B

3. Conjunto de tirador de cárter - M131 011 0 (Fig 1,7A).

l Se utiliza para separar la parte izquierda ya la derecha

cárteres. (Fig. 1.7b)

Fig. 1,7A Fig. 1.7b

4. herramienta de soporte de embrague - N231 001 0 (Fig.1.8A)

l Se utiliza para mantener el conjunto de embrague durante

conjunto de embrague de montaje eliminación tuerca. (Fig. 1.8B)

Fig. 1.8A Fig. 1.8B

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5. Embrague herramienta de tuerca de apriete - N231 002 0 (Fig.1.9A)

l Se utiliza para quitar / volver a montar la tuerca del embrague

durante el mantenimiento del embrague. (Fig. 1.9B)

Fig. 1.9A Fig. 1.9B

6. Frente instalador sello de aceite tenedor - N931 009 0 (Fig 1.10A).

l Se utiliza para montar el sello de aceite tenedor frontal y

tapa contra el polvo. (Fig. 1.10b)

Fig. 1.10A Fig. 1.10b

7. Herramienta de soporte del cilindro tenedor - N931 011 0 (Fig. 1.11A)

l Se utiliza para mantener el cilindro tenedor frontal durante el tenedor

desmantelamiento conjunto de pata. (Fig. 1.11b)

Fig. 1.11A Fig. 1.11b

8. Herramienta de pre-carga ajustador - N931 012 0 (Fig. 1.12A)

l Se utiliza para ajustar el monoamortiguador trasero pre-primavera

carga. (Fig. 1.12b)

Fig. 1.12A Fig. 1.12b

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9. Herramienta de cono inferior instalador - N931 013 0 (Fig. 1.13a)

l Se utiliza para montar la parte inferior del cono a la

vástago de dirección. (Fig. 1.13b)

Fig. 1.13a Fig. 1.13b

10. Herramienta de tuerca de dirección - N931 014 0 (Fig. 1.14a)

l Se utiliza para eliminar / montar el bloqueo de dirección

tuerca y vástago de dirección descargador. (Fig. 1.14b)

Fig. 1.14a Fig. 1.14b

11. Herramienta de servicio de brazo basculante - N931 015 0 (Fig. 1.15a)

l Se utiliza para eliminar y volver a montar el columpio

armar cojinetes de agujas. (Fig. 1.15b)

Fig. 1.15a Fig. 1.15b

12. Herramienta de taza de dirección remover - N931 016 0 (Fig. 1.16a)

l Se utiliza para eliminar la dirección superior e inferior

tazas. (Fig. 1.16B)

Fig. 1.16a Fig. 1.16B

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Televisores Apache RTR 200 MANUAL DE SERVICIO

13. conjunto de herramienta Magneto - N931 017 0 (Fig. 1.17A)

l Se utiliza para mantener el magne al rotor mientras

la eliminación / montaje de las tuercas de engranaje de arrastre y del rotor
magneto primarios. (Fig. 1.17B)

Fig. 1.17A Fig. 1.17B

14. Herramienta de tazas de dirección conjunto ajustador - NB31 004 0

(Fig. 1.18a)

l Se utiliza para montar el fondo de la copa y la raza

gobierno interior durante el mantenimiento de la dirección. (Fig. 1.18b)

Fig. 1.18a Fig. 1.18b

15. Extractor de entrada y la válvula de escape - S131 002 0

(Fig. 1.19a)

l Se utiliza para mantener la compresa la entrada y

primavera valor de escape durante la eliminación de válvulas. (Fig. 1.19B)

Fig. 1.19a Fig. 1.19B

16. oso ing conjunto ler instal - S131 050 0 (Fig. 1.20A)

l Se utiliza para eliminar / montar los cojinetes,

sellos de aceite y arbustos. (Fig. 1.20B)

Fig. 1.20A Fig. 1.20B

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17. extractor de rodamientos principal - S131 111 0 (Fig. 1.21A)

l Se utiliza para eliminar el cojinete principal de la

cigüeñal. (Fig. 1.21b)

Fig. 1.21A Fig. 1.21b

18. Frente indicador de nivel de aceite tenedor - 031 180 0 (Fig. 1.22A)

l Se utiliza para mantener el nivel de aceite tenedor delante en el

altura especificada. (Fig. 1.22B)

Fig. 1.22A Fig. 1.22B

[Link] sello de aceite remover - 031 240 1 (Fig. 1.23A)

l Se utiliza para eliminar los retenes instalados.

(Fig. 1.23B)

Fig. 1.23A Fig. 1.23B

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 CONTENIDO
Televisores Apache RTR 200 MANUAL DE SERVICIO

DESCRIPCIÓN PÁGINA NO
Capitulo 2
PROGRAMA DE MANTENIMIENTO PERIÓDICO 1
PROCEDIMIENTO DE EXTRACCIÓN DEL ASIENTO 3
MARCO DE L & R DESMONTAJE 4
DEPÓSITO DE COMBUSTIBLE DESMONTAJE COMPLETO 5
DESMONTAJE DE LA CUBIERTA DEL DEPÓSITO DE COMBUSTIBLE 6
COLA DESMONTAJE CUBIERTA 10
MANTENIMIENTO PERIÓDICO Y PROCEDIMIENTO DE AJUSTE EN MARCHA 12
ACEITE DE MOTOR CUM TRANSMISIÓN 12
FILTRO DE ACEITE DE MOTOR COMPLETO 13
BUJÍA 14
Filtro de aire Elemento dieciséis

MONTAJE CARBURADOR 18
el juego de válvulas 19
CONJUNTO DEL MOTOR enfriador de aceite 21
PLACAS DE EMBRAGUE 24
MANGUERA DE MOTOR DE RESPIRO 24
DUCTOS CARBURADOR DE GOMA 24
GALLO DE COMBUSTIBLE cubeta de sedimentos 25
MANGUERA DE COMBUSTIBLE 25

PERIODIC MAINTENANCE
CONJUNTO CABLE EMBRAGUE 25
CABLE acelerador 26
PUÑO DE GAS 27
CHOCK FUNCIONAMIENTO 28
JUEGO DE DIRECCIÓN Y Refinado 28
FRENTE TENEDOR DE ACEITE 31
Suspensiones delanteras y traseras 31
Todos los sujetadores 32
CADENA DE TRANSMISIÓN 32
GUARDAGOTAS SEAL 36
PARTE INFERIOR guía de la cadena 37
Todos los focos, la bocina y INTERRUPTORES 38
CABEZA faros o 38
montaje de la batería 39
FRENOS 40
LLANTAS 43
RALENTÍ CO% 44
Bola del engranaje CONJUNTA DE CAMBIOS DE VELOCIDAD 45
CENTRO Y SOPORTE LATERAL PIVOT 45
RODAMIENTOS balanceo de los brazos 45
equilibrado de ruedas 48
PUNTOS DE LUBRICACIÓN 51
SERVICIO DE PROCEDIMIENTO DE REPOSICIÓN DEL RECORDATORIO 52
 MANTENIMIENTO PERIÓDICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

MANTENIMIENTO PERIÓDICO

Gratis una actuación problemas del vehículo y su vida más larga, el vehículo debe ser inspeccionado periódicamente para el desgaste de los componentes, los
depósitos de carbón, cables estirados, etc. Los componentes gastados ser reemplazados o reparados y ajustes necesarios para garantizar unos elementos para
un mejor rendimiento del vehículo, como se indica en la tabla.

Nota:
Más frecuentes revisiones de mantenimiento se pueden realizar en los vehículos que se utilizan en condiciones graves como el ambiente polvoriento, las
condiciones de tráfico denso, pleno accionamiento de mariposa sostenido y caminos empedrados-ONU.

PERIODICA DE MANTENIMIENTO - SERVICIOS GRATUITOS

ít En servicio gratuito Después de servicio gratuito

Servicio primero segundo tercero cuarto quinto observaciones

Cada Cada
km 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000 kilometros
Período comprendido entre la fecha de venta 1 mes 3 meses 6 meses 9 meses 12 meses

aceite de la transmisión del motor cum R ESO R ESO R ESO R

filtro de aceite (colador) do - do - do - do

filtro de aceite (filtro de papel) R - R - R - R

Bujía I&C - - - R - - Cambiar cada 12000 km

Aire elemento del filtro - - - - R - - Cambiar cada 12000 km

el montaje del carburador C&A - - - C&A - - C & A cada 12000 km

el juego de válvulas IA - IA - IA - IA

Las aletas del refrigerador de aceite - - I&C I&C I&C I&C -

Aceite de pipas más frías - yo yo yo yo yo - Inspeccionar y sustituir en caso

necesario cada 15.000 km

placas de embrague - - - - - - - Inspeccionar y sustituir en caso

necesario cada 21000 km

manguera de ventilación del motor yo yo yo yo yo yo - Cambiar cada 21000 km

si es requerido

conductos de goma del carburador - yo yo yo yo yo - Cambiar cada 21000 km

si es requerido

Combustible de la cuba gallo sedimentos do do do do do do -

manguera de combustible yo yo yo yo yo yo - Cambiar cada tres años

1
Juego del cable del embrague y del acelerador I, A & L I, A & L I, A & L I, A & L I, A & L I, A & L -

El puño del acelerador - - L - L -L Lubricar con grasa

el funcionamiento del estrangulador yo yo yo yo yo yo -

2
Directivo de la Operación / reproducción suave IA - - - C, L & A - - C & L con Bechem fresca
prima de grado 3 grasa
cada 12000 km

aceite de tenedor delante - - - - - - - Cambiar cada 18000 km

3
Suspensiones delanteras y traseras yo yo yo yo yo yo -

todos los sujetadores I & TI I & TI I & TI I & TI I & TI I & TI - Apretar si es necesario

Cadena de transmisión** C, L & AC, L & AC, L & AC, L & A C, L & AC, L & A - Ajustar si es necesario

R - Sustituir; I - Inspeccione; T - Completar; C - Limpio; A - Ajuste; TI - Apriete; L - Lubricar; S - Ajuste

1
Inspeccionar para su correcto funcionamiento y ajustar el juego. Lubricar termina con grasa.
2
Inspeccionar para la rotación dirección suave, dirigiendo sacudida / ruido. Ajuste de la dirección si es necesario.
3
Controlar por función suave y adecuado de suspensión delantera y trasera. También inspeccione por cualquier daño visual y la pérdida de aceite.

** Limpiar la cadena con un paño seco y aplicar el aceite de TRU SPRAY / TRU 4 con una frecuencia de 500 km para una mejor vida de la cadena y el vehículo en marcha sin problemas.

2-1
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

ít En servicio gratuito Después de servicio gratuito

Servicio primero segundo tercero cuarto 5th Remarks

Every Every
km 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
4
Retainer oil seal I I I R I I – Replace every 9000 km
5
Chain guide bottom I I I R I I – Replace every 9000 km

All bulbs, horn and switches I I I I I I – Inspect for proper

functioning

Head lamp beam I&A I&A I&A I&A I&A I&A –

Battery electrolyte level I&T I&T I&T I&T I&T I&T –

6
Specific gravity and voltage I I I I I I –

Brake effectiveness I I I I I I –

Brake pedal shaft L L L L L L – Lubricate using TRU4 oil

Brake pad wear I I I I I I – Replace if necessary

Brake fluid I&T I&T I&T I&T I&T I&T – Replace every 21000 km

Brake hose I I I I I I – Replace every three years

Master cylinder cups – – – – – – – Replace every 21000 km

Wheel freeness I I I I I I –

Tyre pressure at cold condition I&S I&S I&S I&S I&S I&S –

Engine idling RPM I&S I&S I&S I&S I&S I&S –

7
Idling CO% I&S – – – – – – I & S every 12000 km

Ball joint gear shift lever – – L – L –L Lubricate using grease

Centre / side stand pivot L L L L L L – Lubricate using TRU4 oil

Swing arm bearings – – – – – – – C & L with fresh Bechem premium

grade 3 grease

every two years

8
Wheel balancing – – – – I – –

R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; TI - Tighten; L - Lubricate; S - Set

4&5 Inspect at every service. Replace if found damaged. However the retainer oil seal and the chain guide bottom need to be

replaced every 9000 km.

6 Recharge if necessary.

7
Idling CO% should be set with the help of exhaust gas analyser and tachometer only.
8 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.

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

SEAT ASSEMBLIES

REMOVAL

Rear seat (passenger seat) removal

l Insert the ignition key into the seat lock (A).

l Turn it in clockwise, then pull and release the

front section of the seat (1) first, followed by the rear section
as shown in the figure. (Fig. 2.1)

1
l To reassemble the rear seat, reverse the
removal procedure.

A
Utility box removal

l To remove the utility box (A), remove the rear

seat. (refer Fig. 2.1) Fig. 2.1

l Take out the utility box by dislocating it from

the seat release cable (B). (Fig. 2.2) B

l To reassemble the utility box, reverse the

removal procedure.

Front seat (rider seat) removal

A
l To remove the front seat (2), remove the rear
seat (refer Fig. 2.1) and take out the key from the lock.
Fig. 2.2

l Pull the seat release cable (A) to release seat

lock. Keeping the seat release cable pulled, lift the seat A
from rear end and slide it backward to remove. (Fig. 2.3) 2

l To reassemble the front seat, reverse the

removal procedure.

Caution:
Make sure that the seat is locked securely in position
after installation.

Fig. 2.3

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

COVER FRAME R & L

REMOVAL

l Remove the seats as explained earlier.

l Remove the CRR pan head screw (M6x16 -

3 nos.) from the cover frame R. (Fig. 2.4)

Phillips head screw driver

l Take out the cover frame R by carefully

dislocating it from the lugs. Fig. 2.4

l Remove the CRR pan head screw (M6x16 -

3 nos.) from the cover frame L. (Fig. 2.5)

Phillips head screw driver

l Take out the cover frame L by carefully

dislocating it from the lugs.

l To reassemble the cover frame R & L, locate

the lugs of the cover frame at the holes provided on the
frame and install the CRR pan head screw (M6x16 - 3
nos. each side).
Fig. 2.5
Phillips head screw driver

Tightening torque 3 ± 1 Nm

Caution:
Make sure that the cover frame is locked securely in
position after installation.

Note:
Ensure the availability of cushions in the cover frame
1front lug mounting area (at fuel tank).

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

FUEL TANK COMPLETE

REMOVAL

l Remove the seats and cover frame assembly

as explained earlier.

l Turn fuel cock knob to ‘OFF’ position and

disconnect the fuel hose from the carburettor assembly.
(Fig. 2.6)

Nose plier
Fig. 2.6

l Remove the hexagonal screw (M6x38 - 2 nos.)

along with plain washers from the fuel tank rear mounting.
(Fig. 2.7)

10 mm spanner

Tightening torque 10 ± 2 Nm

l Remove the cushion fuel tank rear upper

(2 nos.)

Fig. 2.7

l Carefully lift the rear portion of fuel tank and

disconnect the fuel sender unit wiring socket. (Fig. 2.8)

l Take out the cushion fuel tank rear lower

(2 nos) from the fuel tank mounting.

l Remove fuel tank complete along with drain

hose by sliding it out from both the cushion fuel tank front.

Note:
While reassembling fuel tank complete, ensure that
fuel sender unit wiring socket is connected and fuel Fig. 2.8
tank drain hose is routed properly.

Ensure the fitment of both lower and upper fuel tank

cushions rear and proper seating of the fuel tank at
cushion fuel tank front during reassembly.

2-5
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

COVER FUEL TANK ASSEMBLY

B
REMOVAL

l Remove the fuel tank as explained earlier.

A
l Remove the CRR flanged pan head tap screw
(A) (ST4.2x13 - 2 nos.) from the mounting of deflector.
(Fig. 2.9)

Phillips head screw driver

Tightening torque 1.5 ± 0.5 Nm Fig. 2.9

l Similarly, remove the CRR pan head screw (B)

(M6x12 - 1 no.) from the mounting of deflector with cover
fuel tank. (Fig. 2.9)

Tightening torque 10 ± 2 Nm

l Take out the deflector by carefully dislocating it

from the lugs.

l Remove the CRR pan head screw (M6x12 -

1 no.) from the mounting of cover fuel tank inner L with the
fuel tank. (Fig. 2.10)
Fig. 2.10
Phillips head screw driver

Tightening torque 10 ± 2 Nm

l Remove the CRR pan head screw (M6x12 -

2 nos.) from the cover fuel tank front mounting. (Fig. 2.11A)

l Similarly, remove the CRR pan head screw

(M6x12 - 1 no.) from the cover fuel tank rear mounting.
(Fig. 2.11B)

Phillips head screw driver

Fig. 2.11A Fig. 2.11B

Tightening torque 10 ± 2 Nm

l Remove the CRR pan head screw (M6x12 -

2 nos.) from the cover fuel tank rear mounting. (Fig. 2.12)

Phillips head screw driver

Tightening torque 10 ± 2 Nm

Note:
Ensure the presence of retainer clips before installing
the screws during re-assembly.

Fig. 2.12

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Remove hexagonal socket cap screw (M5x30 -

3 nos.) from the mounting of fuel tank cap assembly. (Fig. A

2.13)

4 mm allen key B

Tightening torque 4.5 ± 0.5 Nm

Note: C
Remove only the marked screws (refer Fig. 2.13). Do
not disturb the other screws as they do not required
any removal.
Fig. 2.13
Caution:
Do not use the screws having more than 14 mm length
as it may puncture the tank and lead to fuel leakage.

l Open the fuel tank cap by using the control

key. (Fig. 2.14)

Fig. 2.14
l Remove the CRR pan head screw (M5x12)
from the fuel tank cap inner mounting. (Fig. 2.15)

Phillips head screw driver

Tightening torque 4.5 ± 0.5 Nm

l Take out the fuel tank cap assembly along with

seal fuel tank cap.

Note:
Ensure the presence of seal in the fuel cap assembly
before re-installing the cap.
Fig. 2.15

l Carefully dislocate and remove the cover fuel

tank assembly from the fuel tank.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 3 nos.) from the mounting of cover fuel tank
inner R. (Fig. 2.16)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Dislocate the cover fuel tank inner R from the

cover fuel tank assembly.
Fig. 2.16

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Similarly remove the cover fuel tank inner L

from the cover fuel tank assembly.

Note:
While reassembling, ensure the presence of clips
(clip nut ST4) before installing the screws.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 3 nos.) from the mounting of cover fuel tank
outer R. (Fig. 2.17)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Carefully dislocate and take out the cover fuel

tank outer R from the cover fuel tank top.

Fig. 2.17

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 4 nos.) from the mounting of cover fuel tank
outer L. (Fig. 2.18)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Carefully dislocate the cover fuel tank outer L

from the cover fuel tank top.

Fig. 2.18

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 2 nos.) from the mounting of grill cover fuel
tank R. (Fig. 2.19)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Dislocate and take out the grill cover fuel tank

from the cover fuel tank outer R.

l In similar manner, remove the grill cover fuel

tank L from the cover fuel tank outer L.
Fig. 2.19

2-8
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l For re-assembly, reverse the procedure removal. Assemble the covers separately and then assemble them as a
set into the fuel tank.

l Refer exploded view for assembly details. (Fig. 2.20)

Note:
Before assembling the cover fuel tank assembly into the fuel tank. Ensure the availability of cushions at the respective places.
Else it may create rattling noise.

CAP FUEL TANK

SEAL CAP

INLET FUEL TANK COMPLETE

O’ RING
COVER FUEL TANK OUTER L

GRILL COVER FUEL TANK R

COVER FUEL TANK TOP

GRILL COVER FUEL TANK L

COVER FUEL TANK INNER L

DEFLECTOR
FUEL TANK COMPLETE
COVER FUEL TANK INNER R

COVER FUEL TANK OUTER R

Fig. 2.20

2-9
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

TAIL COVER ASSEMBLY

REMOVAL

l Remove the seats and cover frame L & R as

explained earlier (refer page nos. 2-3 & 2-4).

l Remove the hexagonal socket cap screw

(M8x25 - 4 nos.) from the mounting of pillion handle and take
out the pillion handle. (Fig. 2.21)

6 mm allen key Fig. 2.21

Tightening torque 22 ± 2 Nm

l Disconnect the tail lamp coupler (A) from the

wiring harness. (Fig. 2.22) C

l Disconnect the rear seat lock cable (B) from

the seat latch and release it from its locating bracket. (Fig.
B
2.22)
A
l Similarly, release the seat release cable (C) of
front seat from its locating bracket. (Fig. 2.22)

Fig. 2.22

l Remove hexagonal bolt (M6x20 - 4 nos.) along

with punched washers from the mounting the tail cover
assembly with the chassis. (Fig. 2.23)

10 mm spanner

Tightening torque 6 ± 2 Nm

Fig. 2.23

l Remove hexagonal bolt (M6x20 - 1 no.) along

with the cup washer from the mounting of tail cover
assembly with the chassis. (Fig. 2.24)

10 mm spanner

Tightening torque 6 ± 2 Nm

Fig. 2.24

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the CRR pan head screw (M6x16)

from the tail cover centre rear. (Fig. 2.25)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Dislocate the tail cover centre rear from tail

cover assembly.

Fig. 2.25

l Remove the CRR pan head screw (M6x16 -

4 nos.) from the mounting of tail cover assembly bottom.
(Fig. 2.26 )

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Gently dislocate and take out the tail cover

assembly from the vehicle.

l Reassemble the parts in the reverse order of

removal. Fig. 2.26

Note:
Ensure the availability of cushions at the top
mounting of tail cover assembly.

2-11
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

PERIODIC MAINTENANCE AND TUNE- UP

PROCEDURE

ENGINE CUM TRANSMISSION OIL

Replacement

Replace at initial 500 - 750 km and every 6000 km

there after. Inspect and top-up every 3000 km.

After long period of use, the engine cum transmission oil will
get contaminated and accelerates the wear of sliding and
interlocking surface. Replace the engine cum transmission oil
periodically by following the procedure given below:

l Place the vehicle on center stand. Using a

clean cloth clean the surrounding surfaces of gauge oil
level and plug complete oil drain. Start the engine and
warm to normal operating temperature and switch ‘OFF’.

l Remove the gauge oil level to facilitate easy

draining of oil. (Fig. 2.27)
Fig. 2.27
l Loosen and remove the hexagonal flange head
bolts (M6x20 - 3 nos.). (Fig. 2.28)

8mm spanner

Tightening torque 10 ± 2 Nm

l Remove the cap oil strainer along with ‘O’ ring

and drain the engine cum transmission oil.

Oil filter (Strainer)

l Loosen the CRR pan head screw (M5x12 - Fig. 2.28

2 nos.) and remove the strainer complete engine oil along
with a ‘O’ ring. Inspect the strainer for any damage.
Replace if necessary. Otherwise clean and reassemble
the parts in the revers order of removal. (Fig. 2.29)

Phillips head screw driver

Tightening torque 8 ± 2 Nm

Note:
Check the condition of the ‘O’ ring and replace if
required. Ensure the availability of ‘O’ ring in the cap
during reassembly. Fig. 2.29

2-12
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Fill TVS TRU4 FULLY SYNTHETIC oil (SAE

10W30 API-SL, JASO MA2).

1200 ml (after draining)

Capacity
1400 ml (after disassembly)

Note:
Before adding the fresh oil, replace the filter
complete engine oil without fail.

l Refit gauge oil level.

Oil level check

l Ensure that the engine is in cold condition.

Place the vehicle on center stand on a flat surface with
front wheel touching the ground.

l Unscrew the gauge oil level and wipe it clean.

Insert the gauge in its hole by threading it in completely.

l Check the oil level. The oil level should be

between minimum and maximum levels. (Fig. 2.30)

A
MAXIMUM
l If the oil level is below the minimum level,
top-up with the TVS TRU4 FULLY SYNTHETIC oil (SAE
10W30 API-SL, JASO MA2) upto the maximum level.

MINIMUM
Note:
Check the condition of the ‘O’ ring (A) and replace if
required. Ensure the availability of ‘O’ ring in the
gauge during reassembly.
Fig. 2.30

FILTER COMPLETE ENGINE OIL

Replace at initial 500 - 750 km and every 6000 km

there after.

l Before removing the filter complete engine oil,

drain the engine cum transmission oil as per the
guidelines mentioned above.

l Loosen and remove the hexagonal flange bolts

(M6x16 - 2 nos. and M6x75 - 1 no.). (Fig. 2.31)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Remove the cap oil filter along with the ‘O’ ring
and spring oil filter cap.
Fig. 2.31

2-13
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the filter complete engine oil and

‘O’ ring (A). (Fig. 2.32)

Note:
Keep an oil bowl while opening the cap oil filter to
A
collect the left over oil.

While reassembling, ensure to assemble the ‘O’ rings

(A & C) and spring oil filter (B). (Fig. 2.33)

Locate the seal end (1) of the filter towards crankshaft.

(Fig. 2.33)
Fig. 2.32

Whenever the filter complete engine oil is replaced, it

is recommended to replace the engine cum A
transmission oil along with it.

l Reassemble the parts in the reverse order of B

1
dismantling.
C

SPARK PLUG

Fig. 2.33
l Check the type of the spark plug.

Inspect and clean at initial 500 - 750 km. Replace

spark plug every 12000 km.

l Neglecting the spark plug leads to difficulty

in starting and poor performance.

l Before removing the spark plug, clean the

spark plug surroundings to prevent any foreign materials
from falling inside the cylinder bore.

l Disconnect the sparkplug cap and remove the

spark plug. (Fig. 2.34)

Plug spanner

l Carbon deposits on the spark plug electrodes

prevents good sparking and causes misfiring. Clean the
deposits by blasting sand and compressed air using a
spark plug cleaning machine as explained below:

l Ensure the air and power supply to the spark

plug machine is on. Fig. 2.34

2-14
 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Fix the spark plug into the machine as shown in A

the figure. (Fig. 2.35)

l Blast the sand (abrasive) by pulling the lever (A)

towards sand blasting mode while rotating the spark plug.
(Fig. 2.35)

l Now, blow the air by pushing the lever (A)

towards air blasting mode. This will remove any sand
material stuck into the plug. (Fig. 2.35)

l Remove the plug from the machine and once Fig. 2.35
again confirm cleanliness of the plug.

Caution:
Do not use flared steel cables to clean the spark plug
as it may spoil the spark plug’s electrodes.

l Check the spark plug for wear of central (A) and

ground electrode (B). If either of them are worn-out
replace the spark plug with a new one. (Fig. 2.36)

Caution:
Use only the recommended make and type of spark 0.7 mm

plug for the good performance of the engine. Do not

A
use spark plug that fallen from the hand/carton box
(internally they may have crack and the profile may
change). B

Fig. 2.36
Sparkplug BOSCH UR4KE

l Visually inspect the spark plug gap. If the gap is

found more, replace the plug with a new.

Spark plug gap 0.7 mm

Caution:
Since hook profile spark plug is used, do not try to
adjust the gap as it may affects the profile.

l Check the spark plug for correct spark

performance in the spark plug tester as instructed below:

A
l Rotate the plug gap setting knob (A) and match
the plug gap reading (0.7 mm) with the red line (B) marked
B
in the pressure gauge. (Fig. 2.37A) Fix the spark plug in the

machine
l plug as shown(at
testing socket) and connect the HT card of

the machine to the plug. (Fig. 2.37B) Fig. 2.37A Fig. 2.37B

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Open the air control knob (A) and adjust the air
pressure of the tester in such way that the pressure gauge
needle is lying either in yellow band or in green band. (Fig.
2.38)

Fig. 2.38

l Now, press the spark testing button of the

machine and look for strong, blue continuous spark
through the window (A) of the machine. (Fig. 2.39)

l After confirming the performance, fix the spark

plug back and connect the HT card.

Caution:
A
Do not over tighten or cross thread the spark plug to
avoid the cylinder head threads damage.

Fig. 2.39
It is advised to tighten the spark plug by hand till the
end and then tighten using the right sized spark plug
spanner. (Tightening torque : 10 ~ 15 Nm)

AIR CLEANER ELEMENT

Replace cleaner element every 12000 km.

Note:
Replace the air cleaner element (filter holder
complete) early if it is clogged with excessive dirt
(based on the usage and environment) or found with
any damage. Cleaning the air cleaner element with
solvent / other chemicals can damage the element
and consequently reduces the life of engine parts.

l Clogged air cleaner element increases the air

intake resistance which results in decreased power output
and increased fuel consumption. Incase any such
complaints observed in the vehicle, check and replace the
air cleaner element in the following manner:

l Remove the seats as explained earlier.

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Disconnect the tube inlet from the cover filter

element. (Fig. 2.40)

Fig. 2.40

l Remove the CRR pan head screw (M5x16 -

4 nos.) from the cover filter element. (Fig. 2.41)

Phillips head screw driver

Tightening torque 2 ± 0.2 Nm

l Take out the cover filter element from the

case air cleaner complete.

Fig. 2.41
l Remove and inspect the air cleaner element
for any blockage / abnormality. Replace the element if any
block or damage is found. (Fig. 2.42)

Caution:
Do not wash or clean the air cleaner element. It needs
only replacement. However the air cleaner element
must be replaced at every 12000 km.

Note:
While removing / reassembling the air cleaner
element do not hold the paper element portion. Hold
Fig. 2.42
only at the sides.

l Inspect and ensure that the cover air cleaner A

and case air cleaner assembly is clear from any dust, dirt and
B
foreign particles. (Fig. 2.43)

l Before reassembling the air cleaner element,

clean the case air cleaner and cover air cleaner using a cloth
and cleaning solvent.

Note:
Before reassembling the cover, ensure the
availability and the intactness of seal cleaner (A & B)
in both cover and the case.
Fig. 2.43

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l Reassemble the parts in the reverse order of

removal while ensuring the following:

- Use only hands to assemble paper filter. Do not use any

tool. Ensure that the hands are free from oil and dust.

- Position the air filter snugly and correctly in the case air
cleaner so that no incoming air will by pass it.
Remember rapid wear of valves guide valves valve oil
seals piston, piston rings and cylinder is often caused
by a defective or incorrectly fitted air filter.

CARBURETTOR ASSEMBLY

Clean and adjust carburettor at initial 500 - 750 km and

every 12000 km there after.

Inspect and set engine idling rpm at initial 500 - 750

km and every 3000 km there after.

Inspect and set idling CO% at initial 500 - 750 km and

every 12000 km there after.

l If the engine performance is good, the mixture

volume control screw (A) (MCS screw) need not to be
disturb. The idling speed can be adjust only with idling
screw (B) to specified limit. (Fig. 2.44)

Idling rpm 1500 ± 100 rpm

A
Note:
A
Inspect and set the idling speed after attending all
other maintenance job

l If there is a performance deterioration, clean

Fig. 2.44
the carburettor and tune.

Cleaning:

l For removing, dismantling and cleaning of

carburettor assembly refer chapter “Fuel, lubrication and
exhaust system” page no. 4-3.

Note:
After remounting the carburettor check for smooth
operation of throttle grip.

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Tuning:

Note:
Before tuning the carburettor, correct the free play of
throttle cable as explained in page no. 26.

l Turn out the MCS (mixture control screw) to

the specified limit from fully-in (tight) position. (Fig. 2.45)

MCS turns 1 ~ 4 turns

Flat screw driver (small)

Caution:
Do not over tight the mixture volume control screw
against its seat as it will damage in the mixing body
assembly and its seating.

Fig. 2.45

l Start the engine and allow it to warm up.

l Select the mode for four stroke in tachometer

and connect the tachometer cord to HT lead to measure
the engine rpm.

Tachometer

l Turn the idling screw so that the engine idles at

the specified idling rpm (1400 ± 100 rpm). (Fig. 2.46)

l After adjusting the idling rpm check the CO%.

If necessary, readjust the mixture control screw to set the
CO% to the specified limit (refer page no. 4-17 for CO
setting procedure).

Idling CO% 1.0 to 3.0 % (with SAI & CAT)

Fig. 2.46
TAPPET CLEARANCE

Inspect and adjust at initial 500 - 750 km and every

6000 km there after.

l For inspecting and adjusting the tappet

clearance, fuel tank assembly need to be removed. Refer
page no. 2-5 for fuel tank removal procedure.

l Disconnect HT card and remove the sparkplug.

( Fig. 2.47 )

Plug spanner
Fig. 2.47

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l Remove the hexagonal flange bolt (M6x20 -

2 nos.) mounting the ignition coil assembly with the frame.
(Fig. 2.48)

10 mm spanner

Tightening torque 5.5 ± 1 Nm

l Dislocate and take out the ignition coil

assembly from the frame.

Fig. 2.48

l Remove the hexagonal bolt (M6x25 - 4 nos.)

from the mounting of cover cylinder head. (Fig. 2.49)

10 mm spanner

Tightening torque 10 ± 2 Nm

l Dislocate the cover cylinder from the left hand

side of the vehicle as shown in the figure.

Fig. 2.49

l Remove plug TDC (A) along with the gasket.

(Fig. 2.50)

A
17 mm spanner

Tightening torque 27.5 ± 2.5 Nm

B
l Remove plug crankshaft hole (B). (Fig. 2.50)

10 mm allen key

Tightening torque 10 ± 2 Nm

Fig. 2.50

l Align the TDC mark (A) on rotor assembly with

centre of the inspection hole provided in the cover magneto
by rotating the rotor assembly. (
Fig. 2.51 )

17 mm tubular spanner A

Note:
At this point both the rocker arm should have free
play. Otherwise rotate the rotor assembly one more
complete round and align the mark again.

Fig. 2.51

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l Check the valve clearance when the engine is

in cold condition. ( Fig. 2.52)

Feeler gauge

Valve Standard

Inlet valve 0.06 mm

Exhaust 0.08mm

Fig. 2.52

l If the clearance measured is not within the

specified limit, loosen the nut tappet adjusting. ( Fig. 2.53)

9 mm spanner

l Adjust valve clearance using a special tool.

M13 100 70 Tool, tappet adjuster

Feeler gauge

l After adjusting to the specified clearance,

Fig. 2.53
tighten the nut tappet adjusting, while holding the screw
tappet adjusting in the same position using special tool. (Fig.
2.54)

M13 100 70 Tool, tappet adjuster

Feeler gauge

l Reassemble the parts in the reverse order of

removal.

ENGINE OIL COOLER ASSEMBLY

Fig. 2.54
Removal

l Remove the hexagonal flange bolt (M6x20 -

1 no.) mounting the pipe complete outlet with the cover
clutch assembly. (Fig. 2.55A)

l Remove the hexagonal flange bolts (M6x16 -

2 nos.) mounting the pipe complete outlet with the oil cooler
assembly. Dislocate and take out the pipe complete outlet.
(Fig. 2.55B)

8 mm spanner

Tightening torque 10 ± 2 Nm
Fig. 2.55A Fig. 2.55B

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l Remove the hexagonal flange bolt (M6x20 -

1 no.) mounting the pipe complete inlet with the crankcase
assembly R. (Fig. 2.56A)

l Remove the hexagonal flange bolts (M6x16 -

2 nos.) mounting the pipe complete inlet with the oil cooler
assembly. Dislocate and take out the pipe complete inlet.
(Fig. 2.56B)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 2.56A Fig. 2.56B

l Remove the hexagonal flange bolts (M6x25 -

2 nos.) from the oil cooler assembly mounting and take out
the oil cooler assembly. (Fig. 2.57)

10 mm spanner

Tightening torque 10 ± 2 Nm

Oil cooler assembly fins

Fig. 2.57
Inspect and clean at 6000 km first and every 3000 km
thereafter.

l Gently dislocate the guard oil cooler along with

cup washers from the oil cooler assembly. (Fig. 2.58)

l Visually inspect the oil cooler fins for any

blockage.

l If found any, clean them using a small blend

tool and compressed air.

Caution:
Fig. 2.58
Care should be taken not to damage the fins while
cleaning with the tool and compressed air.

l Inspect the oi l cooler fins (A) for any

deformation. If it so, straighten them with a thin, flat head
screw driver. (Fig. 2.59)

Note:
A
If the air passages of the cooler assembly a r e b l o c
k e d mo r e t h a n 2 0% b y unremovable objects or if
the fins of the cooler are un-repairable, replace the
cooler assembly with a new one.

Fig. 2.59

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Oil cooler assembly pipes

Inspect at every 3000 km. Replace every 15000 km if

required.

l Visually inspect the cooler assembly inlet and

outlet pipes for any crack, leakage, damage or deformation.
(Fig. 2.60)

l If found any replace the oil cooler pipes with a

new one.

Fig. 2.60
Re-assembly

l Reassemble the parts in the reverse order of

removal. Refer exploded view for details. (Fig. 2.61)

Note:
Ensure to assemble the ‘O’ rings at both inlet and
outlet pipes ends.

Ensure the availability of grommet and cup washers at

the mounting area of oil cooler assembly.

WASHER M6 - 4 Nos.

GROMMET - 2 Nos.

OIL COOLER ASSEMBLY

HEXAGONAL FLANGE BOLT (M6x16) - 4 Nos.

GUARD OIL COOLER

PIPE COMPLETE OUTLET

PIPE COMPLETE INLET

HEXAGONAL FLANGE BOLT (M6x25) - 2 Nos. CUP

HEXAGONAL FLANGE BOLT (M6x20) - 2 Nos.

O-RING AIR INJECTION - 4 Nos.

Fig. 2.61

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CLUTCH PLATES (Plate clutch drive & driven)

Inspect the plate clutch drive and driven at every

21000 km. Replace if required.

l Normally clutch is serviced for:

- Lose of power / low pick-up

- Jerking of vehicle
- Any abnormal noise from clutch

l But as a precaution measure the clutch drive

and driven plates must be inspected and if required Fig. 2.62
replaced at every 21000 km for the better performance of
the vehicle. (Fig. 2.62)

l Refer chapter “Servicing of engine” page no.

3- for clutch removal and servicing procedure. 2

ENGINE BREATHER HOSE

Inspect at every service. Replace every 21000 km if

required.

l Visually inspect the engine breather hose for

any crack, leakage, damage or deformation. If found any,
replace the engine breather hose. (Fig. 2.63)

Fig. 2.63

CARBURETTOR RUBBER DUCTS (Pipe intake complete

and Tube outlet)

Inspect at every 3000 km. Replace every 21000 km if

required.

l Visually inspect the pipe intake complete and

air cleaner tube outlet for any crack, leakage, damage or
deformation. (Fig. 2.64)

l If found any, replace the pipe intake complete

and air cleaner tube outlet.

Note:
Since the air cleaner tube outlet is pasted with the
case complete air cleaner, the air cleaner outlet tube
must be changed along with the case.

Fig. 2.64

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FUEL COCK SEDIMENT BOWL

Clean at initial 500 - 750 km and every 3000 km

thereafter.

l Dirty, fuel cock sediment bowl with sediment

or water affects the smooth flow of petrol and may cause
loss of engine power.

l Turn the fuel cock assembly lever to ‘OFF’

position and remove the fuel cock sediment bowl. (Fig.
2.65)
Fig. 2.65
10 mm spanner

l Take out the ‘O’ ring and fuel filter. (Fig. 2.66) FILTER

l Clean the fuel filter and sediment bowl using

cleaning solvent.
O’ RING

l Reassemble the parts in the reverse order of

removal.

Caution:
Care should be taken not to damage the thr eads o f
sed iment bowl wh i l e reassembling as it may lead
to fuel leak. Fig. 2.66

HOSE FUEL

Inspect hose fuel at initial 500 - 750 km and every

3000 km thereafter. Replace every three years.

l Inspect the hose fuel and connections for

damage and leakage. (Fig. 2.67)

l If any abnormality is found replace the hose

fuel. However fuel hose must be replaced every three
years.
Fig. 2.67

CABLE ASSEMBLY CLUTCH - FREE PLAY

Inspect, adjust and lubricate ends with grease at

initial 500 - 750 km and every 3000 km there after

l Cable assembly clutch free play is one of the

most important adjustments, which may need to check
regularly for better life of the clutch plates.

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Measure the free play at the lever assembly

clutch end as shown in the figure, before the clutch begins
8 ~ 15 mm
to disengage. (Fig. 2.68)

Free play 8 ~ 15 mm

Fig. 2.68

l If the play is more or less, loosen the lock nut

(A) and turn the adjusting nut (B) ‘in’ or ‘out’ until the
specified play is obtained. And then tighten the lock nut (A),
while holding the adjusting nut (B) in the same position. (Fig.
2.69) AB

12 mm spanner

Note:
Adjust the clutch play when the engine is in cold
condition

Fig. 2.69

CABLE ASSEMBLY THROTTLE - FREE PLAY

Inspect, adjust and lubricate ends with grease at

initial 500 - 750 km and every 3000 km there after

l For checking the cable assembly throttle

(throttle cable) free play, first dislocate the boot throttle (A)
from its position. (Fig. 2.70)

Fig. 2.70
l Gently pull the throttle cable while holding the
adjuster (A) to check the free play. (Fig. 2.71) If the free play
is more or less adjust as follow:

Free play 1 ~ 2 mm

l Loosen the lock nut (B) and turn the adjuster

(A) ‘in’ or ‘out’ until the specified play is obtained.

10 mm / 8 mm spanner
B A
l Tighten the lock nut (B) while holding the
adjuster (A) in place.
Fig. 2.71

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l After adjusting, start the vehicle, let the engine

run in idle, turn the handle bar to extreme right, left and
check whether idling rpm varies. If it varies check the
routing of throttle cable and if required correct it. Readjust
the free play once again.

l The throttle cable also can be adjusted at the

carburettor end. Follow the procedure to adjust the play.

l Measure the throttle cable free play as

explained earlier.

l If the measured free play is more or less,

loosen the lock nut (A) and turn the adjuster nut (B) ‘in’ or
‘out’ until the specified play is obtained. And then tighten
the lock nut (A), while holding the cable adjuster (C). (Fig.
2.72)

10 mm spanner

ACB

Fig. 2.72

THROTTLE GRIP

Lubricate with grease every 6000 km.

l Inspect throttle grip for smooth rotation. If

found hard remove and lubricate as explained below:

l Remove the throttle cable locking screw from

throttle case lower. (Fig. 2.73)

Phillips head screw driver

Fig. 2.73
Tightening torque 2.25 ± 0.25 Nm

l Remove the CRR pan head screws (M5x30

2 nos.) from the throttle case upper and lower mounting.
(Fig. 2.74)

Phillips head screw driver

Tightening torque 1.75 ± 0.25 Nm

l Gently dislocate the throttle case upper and

lower. Disconnect the throttle cable from grip complete
throttle.

Fig. 2.74

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TVS APACHE RTR 200 SERVICE MANUAL

l Clean the dust and grease from both the cases

and grip. Apply fresh grease.

l Reconnect the throttle cable to the grip and

reassemble the parts in the reverse order of removal.

Note:
After assembling the cases, ensure the proper
locking of throttle cable with throttle case lower. Also
check the free play of throttle cable. If found more,
adjust as explained in page no. 2-26.

CHOKE OPERATION

Inspect every 3000 km.

l Inspect for proper operation of choke lever by

applying the choke. (Fig. 2.75)

l If any abnormality is found, inspect the choke

lever at the carburettor for any stuck up. Incase found any,
remove and clean the choke assembly as explained in
chapter “Fuel, lubrication and exhaust system” page no. 4- .
3
Fig. 2.75

STEERING PLAY AND FREENESS

Inspect at initial 500 - 750 km. Adjust if necessary.

Clean and lubricate the steering with Bechem
premium grade 3 grease every 12000 km.

l Steering should be adjust correctly for smooth

movement of handle bar and safe riding. Stiff steering
prevents smooth movement of handle bar resulting in poor
directional stability. Too loose steering will cause vibration
and damage to the steering bearings.

l Check to see that there is no play in the

steering bearings. (Fig. 2.76)

Fig. 2.76

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l If any play is found, remove the CRR pan head

screw (M6x20 - 2 nos.) housing head lamp front top
mounting. (Fig. 2.77)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 2.77

l Loosen both side bottom mounting hexagonal

flange bolt of housing head lamp and tilt the housing head
lamp forward. (Fig. 2.78)

10 mm spanner

Tightening torque 4.5 ± 1.5 Nm

Fig. 2.78

l Take out the cap lock nut (A) and remove the
lock nut steering along with a special washer. (Fig. 2.79)

32 mm spanner

Tightening torque 80 ± 20 Nm

Fig. 2.79
l Loosen hexagonal socket head cap screws (A)
(M8x30 - 2 nos.) from the mounting of handle bar
assembly with the front fork. (Fig. 2.80)

B A A
6 mm allen key B

Tightening torque 16 ± 2 Nm

l Similarly, loosen hexagonal socket head cap

screws (B) (M8x45 - 2 nos.) from the mounting of lower
bracket complete (fork upper mounting). (Fig. 2.80)

Tightening torque 19 ± 2 Nm
Fig. 2.80

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Gently lift the handle bar assembly. Support

and hang the handle bar assembly on the vehicle itself.

Note:
Ensure that the cables are not too much stretched or
bent and the surfaces of fuel tank assembly and head
lamp assembly not got damaged.

l Using a blunt tool, unlock the lock washer

locking arrester steering stem top and bottom. (Fig. 2.81)
Fig. 2.81

Small flat screw driver

l Using a special tool loosen and remove the

arrester steering stem and take out the lock washer. (Fig.
2.82)

N931 014 0 Tool steering nut

32 mm spanner

l Using the special tool turn the arrester

steering stem bottom either clockwise or anticlockwise to
reduce or to increase steering play respectively. (Fig. 2.83)
Fig. 2.82

N931 014 0 Tool steering nut

32 mm spanner

l After ensuring there is no play in the steering,

assemble the lock washer and arrester steering stem top.

l Locate the lock washer properly and tighten

the steering stem top. Finally lock the lock washer and
then assemble the other parts in the reverse order of
removal.
Fig. 2.83

l Finally, tighten the steering lock nut to the

specified torque.

Note:
After adjustment the steering, ensure the handle bar
moves smoothly without any jerk or sticky. When
slowly moved by hand the handle bar moves freely
from center position to either left or right with its own
weight.

Check the head lamp beam position and adjust if

required after reassembling.

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l If any play is still found, inspect the following

items and replace the affected parts, if necessary (refer
chapter “Chassis” page no. 6-23 for removal, checking and
reassembly procedures)

l Wear of the race steering inner and outer .

l Wear of cup bottom and cone bottom.

l Wear or damage of steering balls.
l Number of balls in cage.
l Distortion of lower bracket complete.
l Rusting of races and balls
l Grease washout

Note:
However, the steering need to be cleaned and
lubricated with fresh grease every 12000 km.

FRONT FORK OIL

Replace every 18000 km.

l Inspect both the leg assemblies of front fork

for any oil leak / abnormality. (Fig. 2.84) If found any, front
fork leg assemblies need to be serviced.

l However, the front fork oil need to be replaced

every 18000 km. Refer chapter “Chassis” page no. 6-17
for service and oil replacement procedure of front fork.

Fig. 2.84

FRONT AND REAR SUSPENSION

Inspect for proper function at initial 500 - 750 km and

every 3000 km thereafter.

l Inspect the front fork (both the legs) for

smooth operation / proper action. If found any abnormality
service the leg assemblies as explained in chapter
“Chassis” page no. 6-17. (Fig. 2.85)

l Similarly, inspect the rear shock absorber for

smooth operation / proper action. If found any abnormality
replace the shock absorber. Check the shock absorber for
any mud / dirt accumulation. If found with mud or dirt,
clean them thoroughly. (Fig. 2.85)

Fig. 2.85

l Inspect for any oil leak in shock absorber.

Replace the shock absorber if found leaking.

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ALL FASTENERS (Bolts and nuts)

Inspect and tighten at initial 500 - 750 km and every

3000 km there after.

l All the bolts and nuts must be in good

condition, for safety. They must be checked and
re-tightened, as necessary to the specified torque (refer
chapter “Service information“ page no. 7-8 & 7-9 for torque
details).

CHAIN ASSEMBLY DRIVE (Drive chain)

Clean, lubricate and adjust at 500 - 750 km and every

3000 km thereafter.

Note:
However, the drive chain must be cleaned (on the
vehicle) with dry cloth and lubricated with TRU
SPRAY / TRU 4 oil as frequently as every 500 km for
better chain life and smooth vehicle running.

l If dirt / dust particles deposition on the drive

chain is found less, the drive chain can be cleaned and
lubricated on the vehicle itself.

l Place the vehicle on the center stand.

l Clean the drive chain thoroughly using a cloth

wet with kerosene while rotating the wheel assembly.

l Allow 3 minutes for the drive chain surface to

dry and wipe the surface with dry cloth.

l After cleaning the drive chain, check the

slackness of drive chain as shown. (Fig. 2.86)

Slackness 20 ~ 25 mm
Fig. 2.86

l If slackness if found more or less, adjust the

slackness as follows:

Note:
Excess chain slackness consumes more fuel.

l Slightly loosen the hexagonal flanged U-nut

(M14x1.5) of axle rear. Fig. 2.87)
(

22 mm spanner

Tightening torque 78 ± 18 Nm
Fig. 2.87

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l Loosen and adjust the chain adjusting bolts (A

and B) ‘in’ or ‘out’ equally by looking at the line mark (C and
D) on chain adjusters until the specified play (slackness) is
obtained. (Fig. 2.88 A & B)
A

B
12 mm spanner

C
Caution:
Adjust both the chain adjuster exactly the same D
amount to maintain correct wheel alignment

Fig. 2.88A Fig. 2.88B

l After obtaining the specified play, rotate the
rear wheel by hand and apply rear brake.

l Hold the brake pedal in applied condition and

tighten the rear axle nut to the specified torque.

l Now, tighten the chain adjusting bolts (A and

B). (Fig. 2.88 A & B)

l Using TRU SPRAY lubricate the chain while

rotating the wheel slowly. (Fig. 2.89)

Note:
Shake TRU SPRAY container well before use. Attach
the extension tube to the TRU SPRAY container for
pin point application. Hold the container upright and
spray from a distance of 4-6 inches as shown in the
figure.
Fig. 2.89

l If dirt / dust particles deposition on the drive

chain is found more, it is recommended for the first time
alone to follow the procedure given below:

l Remove the seats and cover frame assembly

as explained earlier.

l Remove the hexagonal bolt (M6x20) from the

gear shift linkage assembly and dislocate the gear shift
linkage from the shaft gear shift. (Fig. 2.90)

10 mm spanner

Tightening torque 12 ± 2 Nm

Fig. 2.90

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l Remove the CRR pan head screws (M6x20 -

2 nos.) from the cover engine sprocket mounting and take
out the cover. Fig. 2.91) (

Phillips head screw driver

Tightening torque 10 ± 2 Nm

Fig. 2.91

l Remove the hexagonal flange bolt (M6x16 -

1 no.) from speed sensor cable guide mounting and dislocate
the cable guide so that the sprocket mounting screws are
visible. ( Fig. 2.92)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 2.92
l In-order to remove the foot rest assembly,
remove the swing arm axle nut along with punched
washer. Fig. 2.93) (

17 mm spanner

Tightening torque 40 ± 4 Nm

l Also, remove the hexagonal socket head cap

screw (M10x25 - 1 no.) along with punched washer from
the rider foot rest assembly and take out the rider foot rest
assembly. (Fig. 2.93)

8 mm allen key
Fig. 2.93

Tightening torque 18 ± 2 Nm

l Remove the hexagonal bolts (2 nos.) and take

out the lock washer by rotating it either clockwise or
anti-clockwise from the sprocket engine. Fig. 2.94A & B)
(

8 mm spanner

Tightening torque 8 ± 1 Nm

l Dislocate the sprocket engine along with the

chain from the drive shaft.
Fig. 2.94A Fig. 2.94B

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the hexagonal bolts (M6x16 - 4 nos.)

from both LH & RH mounting wheel hugger rear mounting.
(Fig. 2.95A & B)

10 mm spanner

Tightening torque 8 ± 2 Nm

2.95A Fig. 2.95B

l Loosen the hexagonal f langed U-nut

(M14x1.5) of axle rear. Fig. 2.96A)
(

22 mm spanner A
C
Tightening torque 78 ± 18 Nm

l Similarly, loosen the chain adjuster bolts (A and

B) to some extended in order to remove the chain. (Fig. B
2.96B)

12 mm spanner

2.96A Fig. Fig. 2.96B

l Remove the hexagonal bolts (M6x12 - 2 nos.)

along with the washers from the chain guard.
( Fig. 2.97)

10 mm spanner

Tightening torque 8 ± 2 Nm

Fig. 2.97 Fig.

l Push the rear wheel from the back towards

front so that the drive chain loosens and hangs as shown.
(Fig. 2.98)

l Now, lift the chain guard upward. Gently take

out the drive chain by dislocating it from the rear sprocket
and swing arm assembly.

l Clean the drive chain by dipping it in kerosene.

Brush off any dirt / dust sticking to it.

l Drain / dry the kerosene by hanging the chain

for 5 minutes.
Fig. 2.98

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Visually inspect the chain assembly drive for

the below listed possible malfunctions.

l Loose pins
l Damaged rollers
l Excessive wear

l If found any defects, the chain assembly drive

must be replaced with a new one.

l Similarly, to check the drive chain elongation,

count 21 pins on the drive chain and measure the distance
between 20 pitch. (Fig. 2.99)

Vernier caliper

Service limit 256 mm

l If the measured distance exceeds the service

limits, replace the driver chain with a new one.

l If the drive chain is found OK, assemble back to

the vehicle. Adjust the drive chain slackness and lubricate. Fig. 2.99

RETAINER OIL SEAL (Drive shaft oil seal)

Inspect at initial 500 - 750 km and every 3000 km

thereafter. Replace the retainer every 9000 km.

l Remove the sprocket engine along with drive

chain as explained in page no. 2-33. Inspect the retainer
oil seal for any physical damage. If found any,

l Remove the hexagonal flange bolt (M6x16 -

2 nos.) from the mounting of retainer oil seal and take out.
(Fig. 2.100)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Replace the retainer with a new one.

Note:
Please remember the retainer oil seal must be
replaced at every 9000 km irrespective its condition. Fig. 2.100

l Reassemble the parts in the reverse order of

dismantling. Check the drive chain play and if required
readjust as explained earlier.

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CHAIN GUIDE BOTTOM (Drive chain guide)

Inspect at initial 500 - 750 km and every 3000 km

thereafter. Replace the chain guide bottom at every
9000 km.

l Remove the hexagonal bolt (M6x20) from the

gear shift linkage assembly and dislocate the gear shift
linkage from the shaft gear shift. (Fig. 2.101)

10 mm spanner
Fig. 2.101
Tightening torque 12 ± 2 Nm

l In-order to remove the foot rest assembly,

remove the swing arm axle nut along with punched
washer. Fig. 2.102) (

17 mm spanner

Tightening torque 50 ± 5 Nm

l Also, remove the hexagonal socket head cap

screw (M10x25 - 1 no.) along with punched washer from the
rider foot rest assembly and take out the rider foot rest
assembly. (Fig. 2.102)
Fig. 2.102

8 mm allen key

Tightening torque 18 ± 2 Nm

l Remove the hexagonal flange bolt (M6x16 -

2 nos.) from the mounting of chain guide bottom and take
out the chain guide. (Fig. 2.103)

10 mm spanner

Fig. 2.103

l Inspect the chain guide bottom and its bushes

for any damage / deformation. If found any replace the
guide / bushes with a new one. (Fig. 2.104)

Note:
Please remember the chain guide bottom must be
replaced at every 9000 km irrespective its condition.

l Reassemble the parts in the reverse order of

dismantling.

Fig. 2.104

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ALL BULBS, HORN AND SWITCHES

Inspect at initial 500 - 750 km and every 3000 km

thereafter.

l Inspect for the proper functioning of all bulbs,

horn and switches.

l Incase found any abnormality, replace them.

Refer chapter “Electrical system” page no. 5-19 for checking
and replacement procedure.

HEAD LAMP BEAM ADJUSTMENT

Inspect and adjust at initial 500 - 750 km and every

3000 km there after.

l Keeping the bike in a straight line, sit on the

bike to aim the head lamp beam vertically. Focus head
lamp high beam on a vertical screen, which is at a distance
of 10 meter from the head lamp bulb‘s center point. Adjust
head lamp assembly such that the focal point of high beam
on the screen is 100 mm lower than the head lamp bulb’s
center. (Fig. 2.105)

RIDER WEIGHT

Head lamp bulb center

100 mm

Head beam focal point

10 meters

Fig. 2.105

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 PERIODIC MAINTENANCE
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Note:
Head lamp focus should be adjusted only when the
head lamp in high beam.

l To adjust the head lamp focus, insert a small

phillips head screw driver into the slot provided on the left
side the head lamp and rotate the head lamp adjuster till
the focus is adjusted to specification described earlier.
(Fig. 2.106)

Small phillips head screw driver

Fig. 2.106

BATTERY ASSEMBLY

Inspect and top-up electrolyte level / Inspect the

electrolyte specific gravity and battery voltage at
initial 500 - 750 km and every 3000 km thereafter.
Recharge if necessary.

l Remove the battery from the vehicle as

explained in the chapter “Electrical system” page no.
5-24.

Note:
While removing the battery terminals, remove the '-
ve' terminal first. While reconnecting, connect the'+
ve' terminal at last.

l Visually inspect the surface of the battery

container. If any sign of cracking or electrolyte leakage
from the sides of battery is noticed, replace the battery
with a new.

l Measure the open circuit voltage of battery

using pocket tester. (Fig. 2.107)

Pocket tester

Open circuit voltage 12.9 Volts

l If the voltage measure is less than 12 Volts,

then charge the battery using constant current battery
charger by referring the procedure mentioned in chapter
“Electrical system” page no. 5-24.

Fig. 2.107
l If the battery lead terminals are found rusty
with acidic white powdery substance, then clean them with
sandpaper / warm water.

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Add distilled water as necessary, to ensure the

electrolyte is above the minimum level line but not above Maximum

the maximum level line. (Fig. 2.108)

Caution:
Do not add tap water or acid for topping up the
battery. Use only distilled water.
Minimum
O

Electrolyte specific gravity at 20 C

Battery type Normal Under charged

12V, 9.0 Ah 1.28 1.25

Fig. 2.108

l If the specific gravity reading is not in normal

condition the battery needs charging. (Fig. 2.109) Recharge
the battery with constant current battery charger (refer
chapter “Electrical system” page no. 5-26 for charging Hyderometer
procedure). 1.28

l After doing the necessary check and charging,

re-fit the battery in the reverse order of removal and
reconnect the terminals. Apply petroleum gelly in the
terminals to avoid corrosion.

Fig. 2.109
BRAKES

Inspect the front brake and rear brake effectiveness

at initial 500 - 750 km and every 3000 km thereafter.

Inspect front and rear brake fluid level and top-up at

initial 500 - 750 km and every 3000 km thereafter.
Replace brake fluid every 21000 km.

Inspect front and rear brake pad wear at initial 500 -

750 km and every 3000 km thereafter. Replace if
necessary.

Inspect brake hose at initial 500 - 750 km and every

3000 km thereafter. Replace brake hose and master
cylinder cups every 21000 km.

Brake effectiveness

l Inspect the front and rear brake for its

effectiveness. If the brakes are more spongy or ineffective,
it may be because of air entry in the brake system which
needs bleeding. Refer chapter “Chassis” page no. 6-7 for
the procedure of brake bleeding.

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TVS APACHE RTR 200 SERVICE MANUAL

Brake fluid level - front brake

l Place the vehicle on center stand. Keep the

handle bar straight. Ensure that the master cylinder is
parallel to the ground.

l Inspect the brake fluid level in master cylinder

through the inspection window. The level should be above
the lower mark (A) provided on the reservoir body. (Fig.
2.110)

l If the level is found below the lower level mark

on the cylinder, then replenish the level up to the top by
Fig. 2.110
following the procedure given below:

l Remove the mounting screw of reservoir cap.

(Fig. 2.111)

l Remove the reservoir cap and take out the

plate diaphragm and diaphragm.

l Fill fresh brake fluid of recommended grade

Brake fluid TVS Griling DOT3 / DOT4

l Reassemble the parts and apply the front Fig. 2.111

brake to check the effectiveness.

l If the lever travel is more or the lever feels soft

or spongy, air bleeding from the system to be carried out.
Refer chapter “Chassis” page no. 6-7 for bleeding
procedure. MAXIMUM

Brake fluid level - Rear brake MINIMUM

l Remove cover frame R. (refer page 2-4 for

removal procedure) Place the vehicle in center stand.
Inspect the brake fluid level in the reservoir.

Fig. 2.112
l The brake fluid level in the reservoir should be
at the maximum mark provided in the reservoir. Fig. 2.112)
(

l If the level is found the lower level mark on the

reservoir, then replenish the level up to the maximum
level.

l Remove the cap and take out the diaphragm.

(Fig. 2.113)

l Fill fresh brake fluid of recommended grade.

Brake fluid TVS Griling DOT3 / DOT4

Fig. 2.113

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l Reassemble the parts and apply the rear

brake to check the effectiveness.

l If the brake pedal travel is more or the pedal

feels soft or spongy, air bleeding from the brake system to
be carried out. Refer chapter “Chassis” page no. 6-7 for
bleeding procedure.

Caution:
Please remember to be replace the brake fluid every
21000 km without fail for the better performance of
the brake system.

Disc pad wear - Front & Rear

l Observe the wear limit line marked on the pad

and check wear condition of brake pads. (Fig. 2.114)

l When the wear exceeds the limit line replace

Wear limit
the pad as a set. Refer chapter “Chassis” page no. 6- &
page no.
5 6-36 for the front and rear
pads replacement procedure.

Note:
Brake pad wear can be checked without removing
the caliper assembly from the fork and rear wheel.

Fig. 2.114

Caution:
Replace the brake pad with set, otherwise braking
performance will be adversely affected.

Front & rear brake hoses

l Inspect the front and rear brake hoses for any

visual damage / crack and oil leak. If found any, replace
the respective hose. However the brake hoses must be
replace every three years without fail for the safety. (Fig.
2.115)

l 37
Refer chapter “Chassis” page no. 6-8 and 6for the brake
hoses front and rear replacement procedures.

Fig. 2.115

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TVS APACHE RTR 200 SERVICE MANUAL

WHEEL FREENESS

Inspect at initial 500 - 750 km and every 3000 km

thereafter.

l Slowly rotate both the wheels by hand and

observe for any abnormal noise / tightness. (Fig. 2.116)

l If found any, inspect for the proper functioning

of brakes. If found OK then, inspect for the proper play in the
drive chain (refer page no. 2-32). Also inspect for
correctness of wheel bearing, alloy wheel etc., (refer chapter Fig. 2.116
“Chassis“ page no. 6-1 & 6-28 for removal and inspection
procedure).

Note:
Tight wheel rotation increases fuel consumption.

TYRES

Inspect at initial 500 - 750 km and at every 3000 km

thereafter.

Tyre tread condition:

l Using the vehicle with excessively worn tyres

will decrease riding stability and consequently invite a
dangerous situation due to loss of control. It is highly
recommended to replace the tyre with a new one when
the groove depth of tyre from tread surface reaches the
following specifications: (Fig. 2.117)

Service limit
Tyre depth
Front 1.5 mm

Rear 1.5 mm
Fig. 2.117

Tyre depth gauge

Note:
Tyre depth also can be checked by tyre wear
indicator. (Fig. 2.118)

Fig. 2.118

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TVS APACHE RTR 200 SERVICE MANUAL

Tyre rotation direction

l While reassembling the tyre, after removing

from the wheel rim, ensure that the arrow mark (A)
provided on the tyre facing the direction of wheel rotation.
(Fig. 2.119)
A

Fig. 2.119

Tyre pressure:

l Under inflated tyres wear faster, affect stability

and smooth cornering. Over inflated tyres decrease area
of tyre contact with ground causing skid or loss of control.
(Fig. 2.120)

l Maintain proper tyre pressure for good road

stability and longer tyre life. Inflate tyres in cold condition to
the pressure as given below:

T yre pressure gauge

Fig. 2.120
Tyre pressure Front Rear
Kg/cm² (psi) Kg/cm² (psi)
Solo riding 1.75 (25) 2.00 (28)

Dual riding 1.75 (25) 2.25 (32)

Note:
Low tyre pressure consumes more fuel.

IDLING CO%

Inspect and adjust at initial 500 - 750 km and every

12000 km thereafter.

l When the engine performance is generally

good, tuning of carburettor assembly by adjusting mixture
control screw and idling screw will help to control the CO
level in exhaust gases.

l Refer chapter “Fuel, lubrication and exhaust

system” page no. 4-17 for CO checking and setting
procedure.

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TVS APACHE RTR 200 SERVICE MANUAL

BALL JOINT GEAR SHIFT LEVER

Lubricate every 6000 km using grease

l Lubricate the ball joint gear shift lever using

grease every 6000 km for easy operation of lever and
smooth gear shifting. (Fig. 2.121)

Fig. 2.121

CENTER AND SIDE STAND PIVOT

Lubricate at initial 500 - 750 km and every 3000 km

thereafter.

l Lubricate the pivots of center stand and side

stand using TRU4 oil for smooth operation. (Fig. 2.122)

SWING ARM BEARINGS Fig. 2.122

Lubricate using grease every two years.

l Loosen hexagonal screw (M6x20 - 1 no) from

the arm gear shifter lever mounting and dislocate the gear
shift lever from the shaft assembly gear shift. (Fig. 2.123)

10 mm spanner

Tightening torque 10 ± 2 Nm

l Remove the swing arm axle ‘U’ nut (M12)

along with punched washer. Fig. 2.124)
(
Fig. 2.123

17 mm spanner

Tightening torque 50 ± 5 Nm

l Also, remove the hexagonal socket head cap

screw (M10x25 - 1 no.) along with punched washer from the
rider foot rest assembly LH and take out the foot rest
assembly. (Fig. 2.124)

8 mm allen key

Tightening torque 18 ± 2 Nm
Fig. 2.124

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Disconnect the spring of stop lamp switch

from the rear brake pedal. (Fig. 2.125)

Nose plier

Note:
Ensure to reconnect the spring during reassembly for
proper working of brake lamp.

Fig. 2.125

l Remove the hexagonal socket head cap screw

(M10x25 - 1 no.) along with punched washer from the rider
foot rest assembly RH. (Fig. 2.126)

8 mm allen key

Tightening torque 18 ± 2 Nm

Fig. 2.126

l Remove the CRR pan head screw (M6x16 -

1 no.) from the rider foot rest assembly RH top mounting.
(Fig. 2.127)

Phillips head screw driver

Tightening torque 10 ± 2 Nm

Fig. 2.127

l Draw out shaft complete swing arm by gently

tapping at the other side. (Fig. 2.128)

Nylon hammer

Note:
Use a suitable guide in place of shaft complete swing
arm to prevent the swing arm declining from its
position.

Fig. 2.128

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

l Take out the foot rest assembly RH along with

rear master cylinder assembly and brake pedal assembly
and hang it carefully.

Caution:
Care should be taken not to stretch / damage brake
hose during the removal foot rest assembly.

l Take out the dust seal swinging arm and

sleeve swing arm from the RH side of the swing arm
assembly. (Fig. 2.129)

Combination plier

l Clean the sleeve, dust seal, swing arm needle

bearing and the swing arm shaft using a clean cloth and
lubricate them with Bechem premium grade 3 grease.

l Assemble back the foot rest assembly RH

while ensuring the proper routing of brake hoses and Fig. 2.129
tighten the mounting bolts.

l Insert the shaft complete swing arm from the

RH side while carefully removing the guide (inserted
earlier) from the other side.

Note:
Insert the swing arm shaft in such a way that the LH
side dust seal swing arm and sleeve can be removed
easily and the needle bearing can be accessed for
lubrication.

l Now, take out the dust seal swinging arm and

sleeve swing arm from the LH side of the swing arm
assembly. (Fig. 2.130)

l Clean the sleeve, dust seal and swing arm

needle bearing using a clean cloth and lubricate them with Bechem
premium grade 3 grease.

l Reassemble the foot rest assembly LH and

tighten the mounting bolts.

l Assemble the shaft swing arm’s ‘U’ nut and

tighten it to the specified torque. Fig. 2.130

l Reconnect the gear shift lever to the shaft gear

shifting and tighten the mounting bolt.

l Reconnect the spring stop lamp switch and

ensure the proper working of brake lamp while applying the
rear brake.

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TVS APACHE RTR 200 SERVICE MANUAL

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.

Inspection of wheel balance and balancing the wheel

(manual method)

l Remove front or rear wheel assembly which

needs to be checked for unbalance from the vehicle.

l Support the wheel as shown in figure using a

fixture (A) and an axle. (Fig. 2.131)
Marking
Q
Note:
Ensure that the wheel is rotating freely on the fixture
without any obstruction.

Ensure the axle is in horizontal position and the

wheel is not having any axial movement on the
fixture.

l Rotate the wheel by hand and mark (Q) at the

top as shown in the figure when the wheel stops rotating
(comes to a halt). (Fig. 2.131)

l Rotate the wheel five times.

Fixture (A)

l If the ‘Q’ marked on the wheel stops randomly

at different positions on each of the five rotations, then the
wheel is considered as balanced sufficiently.
Fig. 2.131

l Else, if the ‘Q’ marked on the wheel stops at

one position on each of the five rotation, then the wheel is
unbalanced and it need to be balanced again.

Follow the procedure given below for balancing the wheel

manually.

1. Clean the exposed surface (A) of the wheel rim with IP 80%
solution (cleaning agent) at the position ‘Q’ marked. (Fig.
Weights
2.132)
Equal amount of balancing weights to be pasted on both the surfaces of the wheel rim

Fig. 2.132

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

2. Temporarily fix a 10 gram (5 gram each on both the side)

A
balancing weight on the wheel rim near the ‘Q’ marked
area, using a temporary adhesive tape (wi thout removing
the protective cover on the balancing weight). Angle ‘L’

3. Hold the wheel by hand and rotate it ¼ turn downwards

(angle ‘L’ indicated in the figure) and leave. (Fig. 2.133)
When the wheel is left, if the wheel does not rotate further
(’up’ or ‘down’), it may be concluded that the wheel is Q
B
balanced. If the wheel rotates ‘up’ or ‘down’, then the
wheel needs to be balanced further.

4. If the wheel rotates and the weight goes up, replace the
weight with next heavier size by referring Table 1. Further,
if the wheel rotates and the weight goes down, replace the
weight with the next lighter size from the Table 1.

Fig. 2.133
5. Repeat the steps 3 & 4 till the wheel remains at rest after
being rotated ¼ turn.
Table 1
6. For final confirmation, rotate the wheel further ¼ turn (by [Link]. Part No. Weight
hand) and yet again another ¼ turn. In both the cases, if
1 N732 016 0 5g
the wheel comes to a rest after ¼ turn rotation, it may be
concluded that the wheel is balanced. 2 N732 017 0 10 g

3 N732 018 0 15 g

4 N732 019 0 20 g
After final confirmation, the balancing weight must be fixed
permanently at the locations decided earlier. Follow the 5 N732 020 0 25 g
procedure given below for fixing the weight permanently.
6 N732 021 0 30 g

1. Remove the temporarily fixed balancing weights and clean

the wheel rim surface with IP 80% solution (cleaning
agent) at the designated location where the balancing
weight needs to be fixed again.

2. Remove (peel off ) the protective cover on the back side of

the balancing weight as shown. (Fig. 2.134)

3. Stick the balancing weight at the cleaned location on the

wheel rim with a minimum
2
pressure of 1 kg/cm and hold for 3 Sec (min).

Fig. 2.134

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 PERIODIC MAINTENANCE
TVS APACHE RTR 200 SERVICE MANUAL

Inspection of wheel balance and balancing the wheel

(using automatic wheel balancing machine)

l Alternatively, in lieu of the manual procedure,

the unbalance in the wheel may be checked and balancing
of the wheel may be done using an automatic wheel
balancing machine. For instructions, please refer to the
User’s manual of the automatic wheel balancing machine.

l After checking, fix the balancing weights

permanently to the wheel rim by referring the procedure
given in the previous page.

l After the balancing procedure is completed

using an automatic wheel balancing machine, the wheel
may be deemed to be balanced if the permissible residual
unbalance (Uper) in the wheel assembly is less than 2122
g-mm (in front wheel) and 2117 g-mm (in rear wheel), for
balance quality grade G40 as per the method of
unbalance measurement specified in ISO 1940-1:2003.

Note:
The sum total of all balancing weights fixed on a
single wheel rim shall not exceed 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:

l As the balancing weight is of “Stick-on” type, it

may be removed from the wheel rim by application of
sufficient force by hand. Do not use sharp objects to
remove the balancing weight, as it may damage the wheel
rim surface. After removal, clean the location on the wheel
rim from where the balancing weight was removed, with IP
80% solution (cleaning agent) before fixing any more
balancing weights.

Caution:
Vehicle with unbalanced wheels are unsafe to ride.
Ensure that the balancing weights are not loosely
fixed on the wheels.

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TVS APACHE RTR 200 SERVICE MANUAL

LUBRICATION POINTS

Note:
Lubricate the exposed parts which are subject to
rust, with either engine oil or grease as mentioned in
the schedule or whenever the vehicle has been
operated under wet or rainy conditions.

Before lubricating each part, clean off any rusty

spots and wipe off any grease, oil, dirt or grime.

Dotted line indicates RH side lubricating points Lubricate all

cable ends using grease

THROTTLE GRIP
(Grease) BRAKE PEDAL SHAFT
(TRU4 oil)

STEERING BEARINGS
(Grease)

DRIVE CHAIN
(TRU SPRAY)

SWING ARM BEARINGS & BALL JOINT

CENTRE STAND AND SIDE STAND
GEAR SHIFT LEVER (Grease)
PIVOTS (TRU4 oil)

Fig. 2.135

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SERVICEREMINDERRESETTING
PROCEDURE A B

If the service reminder (R) is glowing, reset it after

carrying out periodic services. 0 1 2 3 4 5 6 7 8 9 10 11
12

l Turn ‘ON’ the ignition and wait till the R

completion of speedometer’s self test cycle (till the ‘RACE
ON’ message appears on the speedometer dial).

l Press the ‘Mode’ button (A) till the display

changes to ’HIGH SPEED’ mode ( ). Fig. 2.136
(Fig. 2.136)

Note:
Please remember that the service reminder indicator
of speedometer can be reset only in ‘HIGH SPEED’
mode.

l Now, press and hold both ‘Mode’ and ‘Set’

buttons (A & B) till the service reminder indicator A B
disappears. (Fig. 2.137)

l Turn ‘OFF’ and turn ‘ON’ the ignition and once 3 4 5 6 7 8 9

2 10 11
0 1 12

again confirm that the indicator is reset (not appearing

again).

Fig. 2.137

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 CONTENTS
TVS APACHE RTR 200 SERVICE MANUAL

DESCRIPTION PAGE NO Chapter 3

ENGINE OVERHAUL 1
COMPRESSION PRESSURE 1
CLUTCH - SERVICING 2
REMOVAL 2
INSPECTION 6
REASSEMBLY 7
CYLINDER HEAD ASSEMBLY - SERVICING 8
REMOVAL 8
CYLINDER HEAD ASSEMBLY - DISASSEMBLY 13
DECARBONISING 16
INSPECTION 17
REASSEMBLY 21
CYLINDER HEAD ASSEMBLY - RE-FIXING 23
CYLINDER BLOCK, PISTON AND RINGS PISTON - SERVICING 24
REMOVAL 24
INSPECTION 26
REASSEMBLY 29
GEAR BOX ASSEMBLY, CRANKSHAFT ASSEMBLY AND BALANCER
SHAFT ASSEMBLY - SERVICING 31
REMOVAL OF ENGINE ASSEMBLY FROM THE VEHICLE 31

SERVICING OF ENGINE
ENGINE - DISASSEMBLY 40
GEAR ASSEMBLY BALANCER SHAFT DRIVEN 46
SHAFT COMPLETE DRIVE - DISASSEMBLY 46
INSPECTION 47
REASSEMBLY 48
ENGINE COMPONENTS - INSPECTION 49
ENGINE ASSEMBLY - REASSEMBLY 51
CRANKCASE ASSEMBLY LH & RH - REASSEMBLY 53
VALVE TIMING AND VALVE CLEARANCE 57
RUNNING-IN AFTER OVERHAUL 58
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

ENGINE OVERHAUL
Before beginning engine overhaul, observe engine conditions
for the following:

- Cleanliness
- Compression pressure
- Any abnormal noise
- Oil leak, seepage if any

To overhaul the gears, balancer shaft, shaft complete counter,

shaft complete drive and crankshaft assembly, the crank
cases need to be separated.

COMPRESSION PRESSURE

l Warm-up the engine to normal operating

temperature before checking the compression pressure.

l Stop the engine and remove the spark plug.

Plug spanner

l Mount the compression gauge adaptor to the

plug hole, taking care to make the connection leak proof.
(Fig. 3.1)

Compression gauge and special adopter

Caution :
Before mounting the gauge, enure that the gauge is
calibrated. Similarly, after mounting the gauge ensure
that there is no leakage in the line.

l With the fuel cock knob in ‘OFF’ position,

Fig. 3.1
switch ‘OFF’ the ignition, open the throttle fully and crank
the engine five to six times with the electric starter, until
the maximum reading achieved in the compression gauge.

2
Standard 6.3 ~ 8.4 kg/cm (90 ~ 120 psi)

Service limit

l If the compression pressure is high, it indicates

that high carbon deposit on the combustion chamber and
the piston crown.

3-1
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l If the compression pressure is low, pour 3 to

5 cc of clean engine oil into the cylinder through the
sparkplug hole and re-check the compression pressure. If
the compression pressure increases from the previous
value, then check the following.

- Leaking cylinder head gasket.

- Worn piston rings.
- Worn cylinder and piston.
- Piston ring stuck in the grooves.

l If the compression pressure is the same as the

previous value, check the valves for leakage and
carburettor piston valve opening.

CLUTCH - SERVICING

REMOVAL

Clutch assembly can be serviced with the engine mounted on

the vehicle itself. Normally clutch is serviced for:

- Loss of power / low pickup

- Jerking of vehicle
- Any abnormal noise from clutch
- Kick slip

l Drain engine cum transmission oil as explained

in chapter “Periodic maintenance” page no. 2-12. AB

l After draining always measure the oil quantity

using a measuring jar.

l Remove filter complete engine oil as explained

in chapter “Periodic maintenance” page no. 2
- 13 .

l Loosen lock nut (A) and adjusting nut (B) from

Fig. 3.2
the cable assembly clutch mounting. (Fig. 3.2)

12 mm spanner

l Using 20 mm open end spanner rotate the arm

clutch release towards front, in such a way that cable
assembly clutch can be dislocated from the arm clutch
release. (Fig. 3.3)

20 mm spanner

Fig. 3.3

3-2
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l Dislocate the cable assembly clutch from the

bracket clutch cable. (Fig. 3.4)

l Place a plastic tray under the engine to collect

the remaining oil in the engine while removing the cover
clutch.

Fig. 3.4

l Remove the hexagonal flange bolt (M6x25 -

1 no.) from the pipe complete outlet of engine oil cooler
and dislocate the pipe from the cover clutch casting. (Fig.
3.5)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 3.5
l Remove the hexagonal socket head cap screw
(M6x16 - 1 no.) from the cover clutch mounting. (Fig. 3.6)

4 mm allen key

Tightening torque 10 ± 2 Nm

Caution:
While reassembling, ensure to assemble the
hexagonal socket head cap screw without fail to
avoid leakage of oil.

l Remove the hexagonal flange bolts (M6x35 -

Fig. 3.6
11 nos.) from the cover clutch mounting. (Fig. 3.7)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Take out cover clutch by gently tapping at the

ends using nylon hammer.

Nylon hammer

l Take out gasket cover clutch and dowel pin

clutch cover (2 nos).
Fig. 3.7

3-3
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l Take out adopter pin clutch release from the

clutch assembly along with a ball (dia. 3/16). (Fig. 3.8)

Caution:
While reassembling ensure to assemble the ball
without fail.

Fig. 3.8

l Remove the hexagonal flange head bolts

(M6x25 - 4 nos.) from the plate clutch release mounting.
(Fig. 3.9)

10 mm spanner

Tightening torque 10 ± 2 Nm

Note:
Please follow the uniform loosening and tightening of
plate clutch release bolts to avoid uneven loading of
plate.

Fig. 3.9
l Take out plate clutch release.

l Take out the spring clutch (4 nos.). (Fig. 3.10)

Caution:
While reassembling, ensure all the four clutch
springs are having same colour grade.

l Using special tool hold the disc clutch pressure

and remove nut clutch shaft (slotted nut). (Fig. 3.11)

N231 001 0 Clutch holding tool

Fig. 3.10

N231 002 0 Clutch nut tightening tool

27 mm spanner

Tightening torque 60 ± 10 Nm

Caution:
Assemble all the four bolts of plate clutch release
with the clutch holding special tool. Do not
experiment with two bolts mounted diagonally as it
may damage the disc clutch pressure.

Fig. 3.11

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l Take out the spring disc from clutch shaft.

(Fig. 3.12)

Note:
While reassembling, locate the spring disc in such a
way that the concave face diameter of washer faces
towards outside.

Fig. 3.12

l Pull out disc clutch pressure along with the hub

clutch, plate clutch driven (5 nos.) and plate clutch drive (4
nos.) as a set. (Fig. 3.13)

Caution:
Please note that, one plate clutch drive (the top one)
is seated in next groove of the clutch housing as
shown. Care should be taken to reassemble the top
drive plate in the same position.

Fig. 3.13

l Separate the hub clutch, plate clutch driven

(5 nos.), plate clutch drive (4 nos.) and disc clutch
pressure. (Fig. 3.14)

Fig. 3.14
l Remove thrust washer clutch hub from the
shaft complete counter. (Fig. 3.15A)

l Pull out gear assembly primary driven along

with a clip primary driven gear from gear complete kick
starter. (Fig. 3.15B)

Note:
While reassembling, ensure the clip in the gear
assembly primary driven.

Also ensure to locate and lock the gear assembly

primary driven with gear complete kick starter driven.

Fig. 3.15A Fig. 3.15B

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TVS APACHE RTR 200 SERVICE MANUAL

INSPECTION

Plate clutch drive

l Inspect the thickness of plate clutch drive

using a vernier caliper. If the thickness is less than the
service limit, change the plate clutch drive as a set. (Fig.
3.16)

Vernier caliper

Service limit 2.600 mm (min)

Fig. 3.16
l Similarly, inspect the claw width of plate clutch
drive using a vernier caliper. (Fig. 3.17). If the claw width
is less than the service limit, change the plate clutch drive
as a set.

Vernier caliper

Service limit 15.300 mm (min)

l Check the plates for burning due to excessive

friction / contaminated or low oil level. Inspect plate clutch
drive claws for indents (cut marks) due to regular thrust
from the housing clutch. Found if any, replace the plates
as a set.
Fig. 3.17

Plate clutch driven

l Inspect the distortion of plate clutch driven

using a feeler gauge as shown. (Fig. 3.18)

l Check every individual plates. Hold the plates

with three fingers and insert the feeler gauge between the
surface plate and driven plate at 3 to 4 locations to
determine the distortion. If the distortion is more than the
service limit, change the plate clutch driven as a set.

Service limit 0.100 mm (max)

Fig. 3.18

Spring clutch

l Check the free length of springs clutch using a

vernier caliper. If the springs reaches service limit, replace
all the spring as a set. (Fig. 3.19)

Service limit 28.8 mm

Caution:
Clutch springs are graded and identified with
different colour codes. Whi le reassembling ensure
the springs of same colour codes are assembled.

Fig. 3.19

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Gear assembly primary driven (housing clutch)

l Inspect housing clutch for the indents / cuts

created by the plate clutch drive. (Fig. 3.20)

Note :
Check the primary drive gear play by rotating the
gear portion. The play should be lesser than 6° with
respect to the housing clutch (aluminum body). If it is
found more, replace the primary driven gear
assembly with a new.

Fig. 3.20

Hub clutch

l Inspect the hub clutch for wear. If any ridges or

cuts formed in the hub clutch by the clutch plates, replace
with a new one. Also check the lubrication holes for any
blockage. (Fig. 3.21)

REASSEMBLY

l Reassemble parts in the reverse order of

disassembly.
Fig. 3.21

l Before reassembling, inspect the bearing

clutch release plate for any abnormal noise and smooth
rotation. Replace bearing with a new one if found
defective.

l Ensure the clutch plates are held firmly

together by checking the play between the drive plates
after tightening the plate clutch release bolts. (Fig. 3.22)

l Before reassembling cover clutch, ensure the

assembly of a ball and pin clutch release inside the adopter
clutch release.
Fig. 3.22

l Replace the gasket cover clutch with a new

one.

l Reconnect the clutch cable and adjust clutch

play. Refer chapter “Periodic maintenance” page no. 2-25
for clutch adjustment procedure.

l Refill the engine cum transmission oil. Refer

chapter “Periodic maintenance” page no. 2-12 for oil filling
procedure.

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TVS APACHE RTR 200 SERVICE MANUAL

CYLINDER HEAD ASSEMBLY - SERVICING

REMOVAL

l Remove the cover frame R and L as explained

in the chapter “Periodic maintenance“ page no. 2-4.

l Remove the fuel tank complete as explained in

the chapter “Periodical maintenance“ page no. 2-5.

l Disconnect the HT card from the spark plug

and remove the spark plug. (Fig. 3.23)

Plug spanner

Fig. 3.23

l Loosen the hose clip (A) of tube air cleaner

outlet and hose clip (B) of pipe intake complete. (Fig. 3.24)

Phillips head screw driver

l Gently pull out the carburettor assembly along B

with the control cables and carefully hang it on the frame
itself.

Fig. 3.24

l Remove the plug (A) using small flat screw

driver from the adjuster assembly. (Fig. 3.25A)

l Using a small flat screw driver, lock the

adjuster plunger by rotating it in clockwise direction. (Fig. A
3.25B)

Small flat screw driver

Fig. 3.25A Fig. 3.25B

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l Remove the hexagonal flange bolts (M6x16 -

2 nos.) from the adjuster assembly mounting and take out
the adjuster assembly along with a gasket. (Fig. 3.26)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 3.26

l Remove the hose air cut valve of secondary air

injection assembly by dislocating the hose clip. (Fig. 3.27)

Nose plier

Fig. 3.27

l Remove the hexagonal bolt (M6x16 - 1 no.)

along with wave spring washer from the mounting of pipe
complete SAI (at cylinder block). (Fig. 3.28A)

l Remove the hexagonal bolt (M6x16 - 1no.)

from the mounting of pipe complete SAI (at magneto
cover) and dislocate the pipe complete SAI. (Fig. 3.28B)

8 mm spanner

Tightening torque 5.5 ± 0.5 Nm

Fig. 3.28A Fig. 3.28B

l Disconnect the wiring socket (A) of ignition coil

from the wiring harness. (Fig . 3.29)

l Remove the hexagonal flange bolt (M6x20 -

2 nos.) from the mounting of ignition coil assembly and take
out the ignition coil. (Fig. 3.29)

10 mm spanner

Tightening torque 5.5 ± 1 Nm AAA

Fig. 3.29

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l In-order to remove the muffler assembly, the

engine guard need to be removed.

l Remove the CRR pan head screw (M6x20 -

1 no.) along with plain washer from the top mounting of
engine guard. (Fig. 3.30)

Phillips head screw driver

Tightening torque 4.5 ± 1.5 Nm

Fig. 3.30

l Remove the CRR pan head screw (M6x20 -

2 nos.) along with plain washers from the LH and RH
mounting of engine guard. (Fig. 3.31)

Phillips head screw driver

Tightening torque 4.5 ± 1.5 Nm

l Gently takeout the engine guard as an

assembly.

Fig. 3.31

l Remove the hexagonal socket head cap screw

(M8x30 - 2 nos.) from the muffler assembly front
mounting. (Fig. 3.32A)

l Remove the hexagonal socket head cap screw

(M8x25 - 1 no.) from the center mounting of muffler
assembly with punched washer. (Fig. 3.32B)

6 mm allen key

Tightening torque 18.1 ± 1.3 Nm

Fig. 3.32A Fig. 3.32B

l Remove the hexagonal bolt (M8x60 - 1 no.)

from the muffler assembly rear mounting along with punched
washer and ‘U’ nut. (Fig. 3.33)

12 mm spanner

Tightening torque 19.6 ± 2 Nm

l Take out muffler assembly by dislocating form

the cylinder head assembly.

Fig. 3.33

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l Remove the hexagonal flange nuts (2 nos.)

fastening the cylinder head assembly with the cylinder
block. (Fig. 3. 34)

10 mm spanner

Tightening torque 7 ± 1 Nm

Fig. 3.34

l Remove the hexagonal flange bolt (M16x25 -

4 nos.) from the cover cylinder head mounting. (Fig. 3.35)

10 mm spanner

Tightening torque 10 ± 2 Nm

l Dislocate the cover cylinder from the left hand

side and take out.

Fig. 3.35
l Take out the packing seal cover cylinder head.
(Fig. 3.36)

Note:
While reassembling inspect the condition of the
packing seal. If any distortion / damage is found,
replace the packing with a new one.

l Slowly rotate the rear wheel and engage first

gear.

l Now, remove the hexagonal flange bolt

(M8x1.25 LH) from the cam shaft assembly. (Fig. 3.37)
Fig. 3.36

10 mm spanner

Tightening torque 18 ± 2 Nm

Caution:
Since left hand type thread is used in the bolt, it
should be loosened in the opposite direction.

Note:
Apply ANABOND 112 thread locker during reassembly
of the bolt.
Fig. 3.37

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l Gently pull out the sprocket cam shaft using

nose plier and dislocate the cam chain from cam sprocket.
(Fig. 3.38)

Caution:
Care should be taken not to drop the cam chain
inside the crankcase assembly while dislocating.

l Hold the cam chain using a good quality copper

wire to prevent the chain from falling into the crankcase
assembly and hang it on the head assembly itself.
Fig. 3.38

l Take out the washer camshaft sprocket from

the camshaft. (Fig. 3.39)

Nose plier

Fig. 3.39

l Take out the cam chain tensioner by removing

the bolt cam chain tensioner along with washer cam chain
tensioner. (Fig. 3.40)

12 mm spanner

Tightening torque 12 ± 2 Nm

Fig. 3.40

l Remove the bolt cylinder head (4 nos.) from

the mounting of cylinder head complete. (Fig. 3.41)

12 mm spanner

Tightening torque 24.5 ± 2.5 Nm

Note:
While reassembling, always tighten the cylinder
head assembly bolts in criss-cross pattern to have
uniform seating.

Fig. 3.41

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l Remove punched washers (3 nos.) and a

copper washer (A) from the mounting surface of bolt
cylinder head. (Fig. 3.42)

Caution:
While reassembling the bolt cylinder head at the right
hand front side of the cylinder head assembly, always
use copper washer to avoid oil leak.

Fig. 3.42

l Holding the cam chain, gently lift and take out

the cylinder head as an assembly. (Fig. 3.43)

l Take out the tubular dowels (A) either from

cylinder head assembly or from cylinder block. (Fig. 3.44) Fig. 3.43

l Take out the gasket cylinder head (B).

(Fig. 3.44)
A
Note:
While reassembling, check the gasket for any
damage, scoring, deformation or leakage marks. If
found replace the gasket with a new one. A
A

CYLINDER HEAD ASSEMBLY

Fig. 3.44
DISASSEMBLY

l Remove the REC CSK head screw (M6x16 -

2 nos.) from the pipe intake complete mounting and take
out the pipe intake along with a ‘O’ ring. (Fig. 3.45)

Phillips head screw driver

Tightening torque 10 ± 2 Nm

Note:
While reassembling replace the ‘O’ ring with new
one.
Fig. 3.45

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l Remove hexagonal flange bolt (A) (M6x25 -

4 nos.) from the mounting of cylinder head assembly. (Fig.3.46)

8 mm spanner

Tightening torque 7 ± 1 Nm

Fig. 3.46

l Remove the REC CSK head screw (M5x15 -

1 no.) from the stopper camshaft and dislocate and take out
the stopper camshaft. (Fig. 3.47)

Phillips head screw driver

Tightening torque 4 ± 1 Nm

l Take out the camshaft complete from the

cylinder head complete.

l Using a flat screw driver, gently push out both

Fig. 3.47
the shaft rocker arms. (Fig. 3.48)

Caution :
While removing the shaft rocker arm, the needle
bearing pins assembled inside the rocker arm may
fall inside the cylinder head. Ensure to re-collect all
the pins and fix it into the rocker arm without fail.

l Take out both intake and exhaust rocker arm

assemblies from the cylinder head assembly.

l Locate the special tool to remove the inlet

valve as the movable jaw of the tool rests on the retainer
Fig. 3.48
valve spring (Fig. 3.49A) and the other end (fixed jaw) to
rest at the center of the valve face. (Fig. 3.49B)

l Slowly tighten the special tool to compress the

valve springs.

Extractor assembly, inlet and

S131 002 0
exhaust valve

Caution:
Do not compress the spring more than required to
prevent the spring from loss of tension.

Fig. 3.49A Fig. 3.49B

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l Remove the cotter valves (2 nos.) from the

valve stem. (Fig. 3.50)

Nose plier

l Loosen and take out the special tool.

l Remove the cotters of other inlet valve in

similar manner.

Fig. 3.50

l Remove the retainer valve springs and spring

valves. (Fig. 3.51)

Fig. 3.51

l Gently push down the valves from the top and

remove it from the combustion chamber side. (Fig. 3.52)

Note:
While removing the valve, check for the free
movement of the valve. If there is no free movement,
check the valve for bend and runout. Replace the
valve incase of bend or runout.

Fig. 3.52

l Remove the seal valve stem oil from the valve

guides. (Fig. 3.53)

Nose plier

Note:
While reassembling, replace the seals valve stem oil
with a new one. Always use non metal cladding seal
valve stem oil.

Fig. 3.53

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l Remove seat valve spring. (Fig. 3.54)

Nose plier

l Repeat the same procedure for removing the

other side valves.

Fig. 3.54

l Using M6 nuts, remove stud bolt cylinder head

(2 nos.) from cyl inder head complete. (Fig. 3.55)

10 mm spanner

Tightening torque 7 ± 1 Nm

Note:
Remove the stud bolts only if necessary. Else it may
get spoiled.

Fig. 3.55

DECARBONISING

Cylinder head complete

l Carbon deposits on the combustion chamber

of the cylinder head complete will increase the compression
ratio which wi l l result in pre- igni t ion and overheat ing.
Carbon deposited at the exhaust manifold will prevent smooth
flow of exhaust, thereby reducing the engine power output.

l Decarbonise the combustion chamber of

cyl inder head complete using suitable decarbonising
spray. (Fig. 3.56)

Note:
Decarbonise the head complete cylinder combustion
chamber after removing both the valves. Use suitable
cleaning solvent.

Caution:
Care should be taken not to damage the surface of
the combustion chamber while decarbosnising.
Fig. 3.56

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Seat valve

l Carbon deposition on valve seating will cause

valves not to seat properly thereby causing leakage and
affects idling, pickup and mileage. Also leads to erratic
running and starting trouble.

Valve and valve guide

l Carbon deposits on the valve stem rubs

continuously on guide valve and results in increased
clearance between the stem and guide valve. Clean the
valve stem with suitable cleaning solvent. (Fig. 3.57)

l Clean the guide valve to remove any carbon

buildup by using carbon removers. Clean other parts of
head complete cylinder thoroughly with suitable cleaning
solvent.

INSPECTION
Fig. 3.57
Head complete cylinder

l After cleaning the liquid gasket from the

surface of the cylinder head complete, inspect the surface
for any scratches, high and low spots. If noticed, remove
them suing a fine emery paper (400 grade) placed over
the surface plate. (Fig. 3.58)

Surface plate

Fig. 3.58

l Using a feeler gauge, check for the distortion

of surfaces of the cylinder head complete. If the reading
exceeds the limit, replace the head complete cylinder with
a new one. (Fig. 3.59)

Feeler gauge

Surface plate

Service limit 0.050 mm (max)

Fig. 3.59

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Shaft valve rocker arm

l Inspect the shaft valve rocker arm for any

damage. Measure the outer diameter (OD) of shaft valve
rocker arm. If the OD is less than the service limit, replace
the shaft. (Fig. 3.60)

Outside micrometer

Service limit 8.000 ~ 7.991

Note:
The OD should be checked at the arm complete valve Fig. 3.60
rocker seating area.

Arm complete valve rocker

l The arm complete valve rocker has a roller

follower. The roller follower is a steel roller housed with a
needle bearing. This has been provided to decrease the
load exerted by the valve train on engine by reducing the
friction. (Fig. 3.61)

l Inspect this roller for its free rotation and for

any physical damage on its surface. Found if any replace
the arm.

l There are needle bearings assembled on both

the side of the arm at shaft seating area. Inspect these Fig. 3.61
bearings for any abnormality. Replace the arm if found any
abnormality.

Caution:
Each needle bearing of arm complete valve rocker
has 20 needles in it. Ensure the availability of all the
needles before reassembling the arm as the needles
may fall during removal of the arm from the cylinder
head assembly.

An additional care should be taken during

reassembly of the arm into the cylinder head because
the rollers may fall during reassembly also.

Camshaft assembly

l Check the camshaft assembly for runout, wear

of cam lobes and journals. Any of these could cause the
engine to produce abnormal noise, vibration or lack of
power output.

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l Measure the cam lobe height. If the lobe

height is less than the service limit, replace the camshaft
complete with a new one. (Fig. 3.62)

Outside micrometer

Service limit

Inlet 33.35 mm (min)

Exhaust 33.20 mm (min)

l Inspect the ball bearings of camshaft for

abnormal play, shake or pitting.
Fig. 3.62

l Measure the runout of the camshaft with a dial

gauge. Replace the camshaft with a new one if the runout
exceeds the limit. (Fig. 3.63)

V-block set (4”x3”x3”)

Dial gauge (1/100 mm) / Magnetic stand

Service limit 0.080 mm (max)

Valve intake and valve exhaust

Fig. 3.63
l Inspect each valve for trueness, burning,
scratches, abnormal wear or bend. Measure the outside
diameter of valve stem on the operational area. (Fig. 3.64)

Outside micrometer

Service limit

Inlet 4.470 ~ 4.455 mm (min)

Exhaust 4.485 ~ 4.470 mm (min)

l Using the special tools, measure the runout on

valve stem and valve head. Replace the valve with new
one if runout exceeds the service limit. (Fig. 3.65) Fig. 3.64

V-Block set (4”x3”x3”)

Dial gauge (1/100 mm) / Magnetic stand

Service limit

Runout on stem 0.050 mm (max)

Runout on head 0.075 mm (max)

l Check the valve for smooth movement in the

guide valve.
Fig. 3.65

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l Measure the thickness of valve head. If the

thickness is less than the service limit, replace the valve
with a new one. (Fig. 3.66)

Vernier caliper

Service limit
T
Inlet and exhaust 0.500 mm (min)

Fig. 3.66
Valve stem condition
A
l Inspect the valve stem end face (A) for pitting
and wear. If pitting or wear noticed, replace the valve with a
new one. (Fig. 3.67)

Fig. 3.67

Spring valve

l Measure the free length of the valve springs. If

the length is smaller than the service limit, replace the
springs. (Fig. 3.68)

Vernier caliper

Service limit

Spring length (inner) 38.75 mm (min)

Spring length (outer) 38.75 mm (min)

Fig. 3.68

Tensioner cam chain

l Inspect the tensioner cam chain for any

distortion / damage, cuts or crack. If found any of the
above, replace the tensioner with new one. (Fig. 3.69)

l After assembling the tensioner cam chain,

make sure it moves freely in the cylinder head assembly.

Fig. 3.69

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Cam chain

l Visually inspect the cam chain for loose pins,

twist / seized links etc. If found any replace the cam chain
with a new one.

l Count 21 pins on the cam chain and measure

the distance between 20 pitch. (Fig. 3.70) If the distance
measured exceeds the service limit, replace the cam chain
with a new.

Vernier caliper
Fig. 3.70
Service limit 128.20 mm (max)

REASSEMBLY

HEXAGONAL FLANGE BOLT (M6x25) - 4 Nos.

COVER CYLINDER HEAD

SCREW (M5x15)
PACKING SEAL COVER CYLINDER

WASHER CAM SHAFT SPROCKET REC. CSK.

BOLT CYLINDER HEAD - 4 Nos.
SPROCKET CAM SHAFT
PUNCHED WASHER 8.5x18x2.3 - 3 Nos.

HEXAGONAL FLANGE BOLT (M6x25) - 4 Nos.

STOPPER CAM SHAFT

ROCKER ARM ASSEMBLY

CAM SHAFT COMPLETE
INTAKE

CAM CHAIN

SPARK PLUG

REC. CSK. HD. SCREW (M6x16) - GASKET HEXAGONAL FLANGE BOLT

(M8x1.25 LH)
2 Nos.
BOLT CAM CHAIN TENSIONER

CLAMP PIPE
INTAKE
GASKET CYLINDER HEAD NUT
PIPE INTAKE
COTTER VALVE - 8 Nos.
COMPLETE O-RING

3750 240 RETAINER VALVE SPRING - 4 Nos.

CYLINDER HEAD COMPLETE SPRING VALVE - 4 Nos.

VALVE STEM OIL SEAL - 4 Nos.

VALVE SEAT SPRING - 4 Nos.

SHAFT ROCKER ARM - 2 Nos.

ROCKER ARM ASSEMBLY EXHAUST

VALVE EXHAUST - 2 Nos.
SCREW TAPPET ADJUSTING - 4 Nos.

NUT TAPPET ADJUSTING - 4 Nos.

VALVE INTAKE - 2 Nos.
STUD BOLT CYLINDER HEAD - 2
Nos.

GASKET CYLINDER HEAD NUT

HEX FLANGE BOLT (M8x15)

Fig. 3.71

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Head complete cylinder

l For reassembly, reverse the disassembly

procedure while taking care of the following instructions.
Refer exploded view of cylinder head assembly for
assembly details. (Fig. 3.71)

Note:
Use only new ‘O’ rings and oilseals. Do not use old
ones.

l Assemble the seat valve spring and a new seal

valve stem oil.

l While assembling the valves, insert smoothly

into the guide to avoid the damage to the seal valve stem
oil.

l Assemble the spring valve in such a way that

the smaller pitch of the spring valve facing downwards.
(Fig. 3.72)

CLOSED COIL
l Assemble the retainer valve spring.

l Using the special tool compress the spring and

assemble the cotter valves.

Fig. 3.72
Note:
The diameter of intake valves are larger than the
diameter of exhaust valves. Lubricate the valve stems
before installing.

Ensure proper seating of the cotter valves in its

groove by gently tapping on retainer valve spring.
(Fig. 3.73)

l After assembling the valves, pour petrol into

the intake port and look for leakage of the petrol around
valve intake seating. (Fig. 3.74)

l Similarly check the exhaust valves also.

Fig. 3.73

l If any leakage noticed, replace the defective

parts (valves or cylinder head assembly).

Note:
While checking the exhaust valves, close the
secondary air injection port opening to avoid petrol
leakage.

Fig. 3.74

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CYLINDER HEAD ASSEMBLY - RE-FIXING

l Reassemble the parts carefully in the reverse

A
order of removal.

l Remove plug TDC (A) along with the gasket.

(Fig. 3.75)
B

17 mm spanner

Tightening torque 27.5 ± 2.5 Nm

l Remove plug crankshaft hole (B). (Fig. 3.75) Fig. 3.75

10 mm allen key

Tightening torque 10 ± 2 Nm

l Ensure that the transmission is in neutral and

align the TDC mark (A) on rotor assembly with center of A
the inspection hole provided in the cover magneto by
rotating the rotor assembly. (
Fig. 3.76 )

17 mm tubular spanner

Fig. 3.76

l Assemble the sprocket camshaft along with

the cam chain in the camshaft complete while aligning the
sprocket camshaft mark (A) with the cylinder head surface
(B) towards exhaust side. (Fig. 3.77)

A
l Apply Anabond 112 thread locker to the
sprocket cam shaft mounting bolt and then assemble and
tighten the mounting bolt.
B

10 mm spanner

Tightening torque 18 ± 2 Nm
Fig. 3.77

Caution:
Since left hand type thread is used in the bolt, it
should be tightened in the opposite direction.

l Set the tappet clearance as explained in

chapter “Periodic maintenance” page no. 2-20.

l Reassemble the cover cylinder head, muffler

assembly, igni t ion coi l assembly and carburettor
assembly.

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 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l Assemble the spark plug and connect the

suppressor cap.

l Reconnect the pipe complete SAI to the

cylinder head assembly.

l Refill the engine cum transmission oil as

explained in chapter “Periodic maintenance” page no. 2-12
and ensure its level.

CYLINDER BLOCK, PISTON AND RINGS PISTON -

SERVICING

REMOVAL

l Remove the cylinder head assembly as

explained earlier.

l Disconnect the thermal sensor wiring socket

from the main wiring harness. (Fig. 3.78)

Fig. 3.78

l Pull out the guide cam chain (A) from the

cylinder block. (Fig. 3.79)

Fig. 3.79

l Remove the hexagonal flange nut (M6 - 2 nos.)

from the mounting cylinder block with the crankcase. (Fig.
3.80)

10 mm spanner

Tightening torque 7 ± 1 Nm

Fig. 3.80

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 SERVICING OF ENGINE
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l Gently pull out the cylinder block holding the

connecting rod by hand to avoid any damage to the piston
assembly and crankcase. (Fig. 3.81)

Fig. 3.81

l Remove the gasket cylinder (A) and tubular

dowel (B) (2 nos). (Fig. 3.82)

Nose plier

l Place a clean cloth in the crankcase assembly

bore to prevent the circlip pin piston from falling inside the
crankcase while removing. B

A
B

Fig. 3.82

l Remove the circlip pin piston from any one

side of the piston. (Fig. 3.83)

Nose plier

Fig. 3.83

l Gently push and take out the piston pin from

the piston and then take out the piston along with the rings.
(Fig. 3.84)

Fig. 3.84

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INSPECTION

Guide cam chain

l Inspect the guide cam chain for any distortion /

damage, cuts or crack. If found any of the above, replace the
guide with new one. (Fig. 3.85)

Fig. 3.85

Cylinder block

l Clean the gasket cylinder and adjuster

tensioner gasket seating areas if any gasket material is
stuck. Do not scrape the surfaces.

l Measure the cylinder block ID (bore) using the

bore gauge. Cylinder bore should be checked in two axis
with reference to the cylinder axis at three locations as
shown in the figure. (Fig. 3.86 & Fig. 3.87)

Bore gauge
Fig. 3.86

l If the wear exceeds the service limit, replace

the cylinder block or rework the cylinder to next oversize
by using a boring machine. The cylinder must be honed
after boring.

l The cylinder blocks are manufactured with

slightly increasing diameters which are all identified with 20 mm
their respective colour and codes as below:

Size Grade Standard Service Limit (in mm)

(in mm)

– A 66.000 ~ 66.005 Fig. 3.87

– B 66.005 ~ 66.010 66.

– C 66.010 ~ 66.015

1st OS PINK 66.256 –

2nd OS WHITE 66.506 –

Note:
Minor surface flaws on the cylinder wall due to
seizure or similar abnormalities may be corrected by
using fine emery paper (400 grade). If the flaws are
deep grooves, the cylinder must be reworked to the
next oversize or replaced.

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Piston
A
l Remove the ring piston top (1st) (A), piston ring B
2nd (B) and oil rings (C) along with separator oil ring (D). (Fig.
3.88) C
D
Caution:
Do not expand the rings more, it may lose it‘s
mechanical properties.

l Decarbonise the piston and piston ring Fig. 3.88

grooves. After cleaning the grooves, fit the rings and rotate
them in their respective grooves to make sure that they
rotate freely. (Fig. 3.89)

l Carbon in the grooves is liable to cause the

rings piston to stuck in the grooves, and this will lead to
reduced engine power output.

Note:
While cleaning the ring grooves of the piston, take
care not to damage the grooves. Use an old broken
ring to clean the grooves.

Fig. 3.89

l If a piston sliding surface is badly scored or

scuffed due to overheating, it must be replaced. Shallow
grooves or minor scuff can be removed by smoothening
with a fine emery paper (400 grade). (Fig. 3.90) Inspect
the piston for damage or crack. Replace if required.

l Measure the diameter at the right angle to the

pin piston and at a point which is 10 mm from the bottom to
check wear. If the diameter is lower than the service limit,
replace the piston. (Fig. 3.91)

Fig. 3.90
Outside micrometer

Size Grade Standard Service Limit (in mm)

(in mm)

– A 65.960 ~ 65.965

– B 65.965 ~ 65.970 65.00

– C 65.970 ~ 65.975

1st OS PINK 66.215 ~ 66.220 –

2nd OS WHITE 66.465 ~ 66.470 – 10 mm

l Cylinder to piston clearance is the difference

between piston diameter and bore diameter.
Fig. 3.91

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l Check the pin piston bore ID of piston for wear.

(Fig. 3.92)

Inside micrometer

Service limit 15.030 mm (max)

Dia.
l If the ID is more than the service limit, replace
the piston with a new.

Fig. 3.92

Piston pin

l Check the piston pin OD using a micrometer.

(Fig. 3.93) If the reading exceeds the service limit replace
the pin piston. Other wise the pin may create unwanted
noise.

Outside micrometer

Service limit 14.992 mm (min)

Fig. 3.93

Rings piston

l Inspect the piton rings for distortion, it will

cause the rings to stick or roll in the grooves. Replace the
distorted rings.

l As the rings wear out, its end gap increases

resulting in reduced engine power output.

l The rings (Top and 2nd) closed end gap should

be checked to assess the serviceability of the ring piston.

l Install the ring in the cylinder block, using the

piston, push the ring into the cylinder block bore at 20 mm PISTON RING FEELER GAUGE
from the bottom. This will make the ring to seat squarely in
the cylinder block. Using a feeler gauge measure the close
end gap. (Fig. 3.94)

l If the gap exceeds the limit, replace rings with

new ones.

Feeler gauge

Service limit 0.700 mm (max)

Fig. 3.94

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l To know the service condition of the ring check

the free end gap using a vernier caliper. (Fig. 3.95)

Vernier caliper

Service limit

Ring piston top 5.700 (max)

Ring piston 2nd 4.400 (max)

REASSEMBLY
Fig. 3.95

l Assemble the separator oil ring (3rd ring)

locating its end gap towards exhaust side (aero marked) of
the piston at 45 degree to the left from the center. (Fig.
3.96)

Note:
Assemble the separator oil ring in such away that its
triangle shaped end (Fig. 3.97) facing upward (triangle
facing towards piston top).

3rd & 4th 5th RING

l Assemble the oil ring (bottom - 5th ring) RINGS EXHAUST SIDE
locating its end gap towards exhaust side of the piston at
Fig. 3.96
45 degree to the right from the center. (Fig. 3.96)

l Assemble the oil ring (top - 4th ring) locating its TOWARDS UP
end gap towards exhaust side of the piston at 45 degree to
the left from the center.(Fig. 3.96)

SEPARATOR OIL RING (RAIL)

Fig. 3.97
l Assemble the ring piston 2nd, locating its end
gap towards the inlet side of the piston at 60 degree to the INLET SIDE
right from the center. (Fig. 3.98)

1st RING 2nd RING

l Assemble the ring piston top, locating its end

gap towards inlet side of the piston 60 degree to the left
from the center. (Fig. 3.98)

Fig. 3.98

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Note:
Avoid damage to the piston skirt surface and rings
piston during installation.

Before installing the piston, the rings should rotate

freely in their respective grooves.

Install the ring piston 1st and ring piston 2nd with the
marking on the ring ‘TOP1’ and ‘TOP2’ (Fig. 3.99)
facing up (mark facing towards piston top).

Fig. 3.99
Caution:
Always assemble the scrapper ring first. Because
this will accommodate the oil rails.
ARROW MARK

l Assemble the piston in such a way that the

arrow mark indicated in the piston crown should face
towards the exhaust port of the cylinder. (Fig. 3.100)

Note:
Carefully install the circlip pin piston in its groove.
Else it may come out from piston during engine
running and damage the cylinder block and piston
Fig. 3.100
assembly.

l While installing the cylinder block slightly

lubricate inner wall of the cylinder with fresh 4T oil.

l Reassemble the parts carefully in the reverse

order of removal.

l Align the TDC mark on the rotor assembly with

the crankcase mark by rotating the rotor assembly (refer
page no. 3-23).

l Set the tappet clearance as explained in

chapter “Periodic maintenance” page no. 2-20.

l Reassemble the cover cylinder head, muffler

assembly, igni t ion coi l assembly and carburettor
assembly. Assemble the spark plug and connect the
suppressor cap.

l Reconnect the pipe complete SAI to the

cylinder head assembly.

l Refill the engine cum transmission oil as

explained in chapter “Periodic maintenance” page no. 2-12
and ensure its level.

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GEAR BOX ASSEMBLY, CRANK SHAFT ASSEMBLY AND

BALANCER SHAFT ASSEMBLY- SERVICING

l Only to repair or replace gears, clutch shaft

assembly, drive shaft assembly, crankshaft assembly and
the balancer shaft assembly, the crankcases need to be
separated.

l Remove the clutch assembly as explained

earlier (refer page no. 3-2 for removal procedure).

l Remove the cylinder head assembly, cylinder

block and piston as explained earlier (refer page. 3-8 &
3-24 for removal procedure).

l Refer chapter “Fuel lubrication and exhaust

system” page no. 4-16 for SAI unit removal procedure.

REMOVAL OF ENGINE ASSEMBLY FROM THE VEHICLE

l Remove hexagonal screw (M6x20 - 1 no.) from

the arm gear shi fter lever mount ing. (Fig. 3.101)
Fig. 3.101

10 mm spanner

Tightening torque 10 ± 2 Nm

l Gently pull out the gear shift lever from the

shaft assembly gear shift.

l Remove CRR pan head screw (M6x20 - 2 nos.)

from the cover engine sprocket and take out cover engine
sprocket. (Fig. 3.102)

Philips head screw driver

Fig. 3.102

Tightening torque 10 ± 2 Nm

l Remove hexagonal screw (M5x10 - 2 nos.)

from the lock plate engine sprocket mounting. (Fig. 3.103)

8 mm spanner

Tightening torque 8 ± 1 Nm

l Take out the lock plate sprocket by rotating and

dislocating it from the shaft complete drive grooves.

Fig. 3.103

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l Pull out the sprocket engine along with drive

chain assembly from shaft drive. (Fig. 3.104)

l Dislocate sprocket from the drive chain. Hang

the drive chain in the frame itself.

Fig. 3.104

l Disconnect the speed sensor wiring socket

from the main wiring harness. (Fig. 3.105)

Fig. 3.105
l Remove hexagonal bolt (A) (M6x16 - 1 no.) and
dislocate the guide speed sensor (B). (Fig. 3.106A)
C
D

l Remove the hexagonal bolt (C) (M6x16 -

2 nos.) from the retainer oil seal drive shaft and take out the C
B
retainer (D). (Fig. 3.106B)

8 mm spanner
A
E
Tightening torque 10 ± 2 Nm

l Gently pull out the speed sensor (E) along with

guide speed sensor. (Fig. 3.106B) Fig. 3106A Fig. 3106B

Nose plier

l Remove the hexagonal flange bolt (M6x16 -

2 nos.) and take out the switch gear position (A). (Fig.
A
3.107)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 3.107

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l Remove the hexagonal bolt (M6x16 - 1 no.) (A)

and take out contact complete gear shift switch (B). (Fig.
3.108)

8 mm spanner
A B
Tightening torque 4 ± 1 Nm

Note:
While reassembling contact complete gear shift,
locate the projection of contact into the groove on
shaft for proper indication of gear positions.
Fig. 3.108

l Remove the circlip (12x1) from shaft complete

gear shift and take out the shim (12x26x1). (Fig. 3.109)

Snap ring plier - external

Fig. 3.109

l Disconnect all the wiring sockets from

magneto assembly connected to wiring harness. (Fig.
3.110)

Fig. 3.110

l Remove the hexagonal flange bolts (M6x40 -

9 nos.) from the cover magneto mounting. (Fig. 3.111)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Take out the cover magneto by gently tapping

with the nylon hammer along with starter assembly.

Nylon hammer
Fig. 3.111

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l Take out gasket magneto cover and dowel pin A

(A) (2 nos.). (Fig. 3.112)

Nose plier

Fig. 3.112

l Take out the spacer starter idle gear (A), pin

magneto cover (B) and gear starter idle (C) either from the
crankcase or from the cover magneto. (Fig. 3.113A)
C

Nose plier
BA
D
l Remove the stopper starter gear (D).
(Fig. 3.113B)

Note:
While reassembling the gear starter idle ensure to
assemble the stopper starter gear (D). (Fig. 3.113B) Fig. 3.113A Fig. 3.113B

l Remove bolt gear shift cam stopper and take

out stopper complete gear shift along with spring gear shift
cam stopper and shim. (Fig. 3.114)

10 mm spanner

Tightening torque 6 ± 1 Nm

Note:
While reassembling, ensure that shim is located
properly under the stopper complete gear shift, Fig. 3114
before tightening the bolt gear shi ft cam stopper.
After tightening check cam stopper for free
movement.

l Remove recessed CSK head screw (M6x20 -

1 no.) from the index star mounting and take out the index
star. (Fig. 3.115)

Philips head screw driver

Tightening torque 8 ± 2 Nm

Fig. 3.115

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l Carefully pull out the shaft complete gear shift.

(Fig. 3.116)

Fig. 3.116

l Take out the pin holder complete from the cam

gear shift. (Fig. 3.117)

Fig. 3.117

l Remove the E-ring from the oil pump shaft and

take out gear oil pump driven. (Fig. 3.118)

Small flat screw driver

l Remove the pin oil pump driven gear (A).

(Fig. 3.119)
Fig. 3.118

Nose plier

l Remove hexagonal flange bolt (3 nos.) from

the pump assembly oil and pull out pump assembly. (Fig. A
3.119)

8 mm spanner

Tightening torque 8 ± 2 Nm

Note:
While reassembling the oil pump ensure the
presence of pin oil pump.
Fig. 3.119

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l Disconnect both the thermel from the battery

assembly. (Fig. 3.120)

Fig. 3.120

l Dislocate the boot (A) from the starter motor

terminal. (Fig. 3.121A)
A B

l Remove the special screw (B) along with C

washer from the starter motor positive terminal and
disconnect positive terminal. (Fig. 3.121B)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Remove the hexagonal flange bolt (M6x25 - Fig. 3.121A Fig. 3.121B
1 no.) (C) from the starter motor mounting and remove the
negative terminal from the starter motor. (Fig. 3.121B)

8 mm spanner
A
Tightening torque 10 ± 2 Nm
B

l Dislocate the hose clip (A) and disconnect the

hose breather PCV (B) from the engine assembly. (Fig.
3.122)

Nose plier

Fig. 3.122

l Remove the hexagonal flange bolt (M6x25 -

1 no.) from pipe complete inlet of engine oil cooler and
dislocate the pipe complete inlet from the crank case
assembly R. (Fig. 3.123)

8 mm spanner

Tightening torque 10 ± 2 Nm

Note:
An ‘O’ ring is fitted on the pipe complete inlet end.
Ensure the condition and availability of ‘O’ ring
during reassembly.
Fig. 3.123

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l Remove the hexagonal flange bolt (M6x25 -

1 no.) from the starter motor and remove the motor
assembly starter along with a ‘O’ ring. (Fig. 3.124)

8 mm spanner

Tightening torque 10 ± 2 Nm

Note:
While reassembling the motor assembly starter,
make sure the presence of ‘O’ ring.
Fig. 3.124

l Unfold washer primary driven gear. (Fig. 3.125)

Chisel / metal hammer

Fig. 3.125

l Using the special tool, hold the rotor assembly

and remove hexagonal nut (M16 LH). (Fig. 3.126A & B)

N931 017 0 Magneto tool assembly

22 mm spanner

Tightening torque 60 ± 5 Nm

l Take out washer primary drive gear.

Note:
Fig. 3.126A Fig. 3.126B
While reassembling, replace the washer with a new
one.

l Remove gear oil pump drive (A). (Fig. 3.127) BA

l Remove gear primary drive (B). (Fig. 3.127)

Note:
While reassembling the primary drive gear, assemble
the primary gear in such a way that its stepped side
is facing towards crankshaft bearing.

Fig. 3.127

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l Take out key (4x4x15) from the crankshaft

assembly. (Fig. 3.128)

Nose plier

Fig. 3.128

l Using the special tool, hold the rotor assembly

as explained earlier and remove the hexagonal flange nut
(M12x1.25) from the balancer shaft assembly. (Fig. 3.129)

17 mm spanner

Tightening torque 30 ± 5 Nm

Note:
Apply ANABOND 112 thread locker during reassembly
of the nut.

Fig. 3.129

l Using the special tool, hold the rotor assembly

and remove the rotor assembly mounting hexagonal
flange nut (M12x1.25). (Fig. 3.130)

N931 017 0 Magneto tool assembly

17 mm spanner

Tightening torque 80 ± 5 Nm

Fig. 3.130

l Using the special tool, remove the rotor

assembly along with gear complete starter clutch. (Fig.
3.131)

M131 002 0 Puller assembly rotor

Note:
Always keep rotor assembly on a non metallic
surface with open side facing upwards.

Fig. 3.131

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l If required, separate the gear complete starter

clutch and remove the one way clutch from rotor assembly
by removing the hexagonal socket head cap screw
(M6x16 - 3 nos.) along with punched washers. (Fig. 3.132)

5 mm allen key

Tightening torque 12 ± 1 Nm

Note:
Do not separate the gear complete starter clutch from
one way clutch until it is necessary, to avoid falling of Fig. 3.132
rollers from one way clutch. Always keep them in
assembled condition.

l Take out the cam chain (A) and woodruff key A

(B) from the crankshaft complete. (Fig. 3.133)

Nose plier B

Fig. 3.133
l Remove the hexagonal flange bolt (A) (M8x25 -
2 nos.) along with spring washer from LH side top and
bottom mounting of crash guard. (Fig. 3.134) B
A

C
l Remove the hexagonal flange bolt (B) (M8x25 -
1 no.) along with spring washer from RH side top mounting
of crash guard and dislocate the cable guide (C). (Fig.
3.134)

A D
l Remove the hexagonal flange bolt (D) (M8x25 -
1 no.) along with spring washer from RH side bottom
mounting of crash guard and take out the crash guard.
(Fig. 3.134)
Fig. 3.134

12 mm spanner

Tightening torque 27 ± 3 Nm

l Remove the hexagonal flange bolt (M8x55 -

2 nos.) from the mounting of bracket crash guard RH and

take out the bracket. (Fig. 3.135) 12 mm spanner

Tightening torque 2 7 ± 3 Nm

Fig. 3.135

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l Remove the hexagonal flange bolt (M8x100 -

1 no.) and (M8x120 - 1 no.) from the mounting of bracket
engine mounting RH and take out the bracket. (Fig. 3.136)

12 mm spanner

Tightening torque 27 ± 3 Nm

l Remove the hexagonal flange bolt (M18x100 -

1 no.) and (M8x120 - 1 no.) from the rear mounting of the
engine assembly. (Fig. 3.137)
Fig. 3.136
12 mm spanner

Tightening torque 27 ± 3 Nm

Note:
While removing mounting bolts, always remove the
bottom bolt first.

Once the ‘U’ nuts are removed from its mounting, it

should be replaced with a new one.

l Gently lift the engine assembly with both the

hands and take out from the right hand side of the vehicle.
Fig. 3.137
Place the engine assembly on a engine rest.

ENGINE - DISASSEMBLY

l Remove the CRR pan head screw (M6x12 -

1 no.) from the retainer guide T/M oil and remove the
guide T/M oil. (Fig. 3.138)

Phillip head screw driver

Tightening torque 8 ± 2 Nm

Fig. 3.138

l Remove the hexagonal flange bolt (M6x55 -

1 no.) from the crankcase assembly mounting (RH side).
(Fig. 3.139)

8 mm spanner

Tightening torque 10 ± 2 Nm

l Turn the engine to the other side (magneto

side).

Fig. 3.139

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l Remove hexagonal flange bolts (M6x55 -

A
5 nos. (A), M6x40 - 4 nos. (B), M6x75 - 4 nos (C) and
A
M6x95 - 1 no. (D) from the crankcase mounting. (Fig.
3.140) D C

C
A
8 mm spanner B

Tightening torque 10 ± 2 Nm A
C B
B
Note:
While reassembling, insert all the bolts first and B A
C
check equal height of bolts from their respective
seating surfaces. Fig. 3.140

l Using special tool, separate the crankcase

assemblies by pulling the crankcase complete
L. (Fig. 3.141)

M131 011 0 Puller assembly

17 mm spanner

8 mm spanner

l Take out the tubular dowel (2 nos.).

Fig. 3.141

l Take out shim (15x27x0.5) (A) and retainer

spring (B) from the balancer shaft. (Fig. 3.142)

Fig. 3.142

l Take out the thrust washer (A) from the drive

shaft assembly. (Fig. 3.143)

l Take out the bearing kick starter driven gear (B)

along with thrust washer and shim from the counter
(clutch) shaft assembly. (Fig. 3.143)
A B

Fig. 3.143

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l Take out gear assembly balancer shaft driven

from the balancer shaft. (Fig. 3.144)

Caution:
While reassembling the gear assembly balancer shaft
driven, align the balancer drive and driven gears to
match the dot / punch marks in one line as shown in
the illustration without fail to avoid costly damages to
the engine. (Fig. 3.145)

Fig. 3.144

Fig. 3.145

l Remove the wood ruff key (A) from the

balancer shaft assembly. (Fig. 3.146)

Nose plier

l Take out the retainer spring (B) from the

balancer shaft assembly. (Fig. 3.146)
A
B

Fig. 3.146

l Pull out both the shaft shift forks from the fork
gear shifts. (Fig. 3.147)

Nose plier

Fig. 3.147

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 SERVICING OF ENGINE
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l Dislocate the fork gear shift no.1, fork gear

shift no. 2 and fork gear shift high speed from cam gear
shift and take out the cam gear shift (A). (Fig. 3.148)
A

Fig. 3.148

l Take out fork gear shift no.1, fork gear shift no.
2 and fork gear shift high speed from gears. (Fig. 3.149)

Fig. 3.149

l Take out drive shaft assembly and the counter

(clutch) shaft assembly along with the gears as a set. (Fig.
3.150)

Fig. 3.150

l Take out the gear 2nd driven. (Fig. 3.151)

Note:
Since the gear idler (speed sensor gear) locks the
2nd driven gear, it will not come along with the drive
shaft assembly during the shaft removal. Hence the
gear has to be taken separately.

Fig. 3.151

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l Take out thrust washer from the drive shaft

assembly gear 2nd driven seating area. (Fig. 3.152)

Fig. 3.152

l Pull out crankshaft assembly from the

crankcase assembly LH by gently tapping it from the other
side. (Fig. 3.153)

Note:
While removing the crankshaft assembly, ensure that
the balancer shaft is rotated to the other side and not
obstructing the crankshaft.

Fig. 3.153

l Take out the balancer shaft complete as an

assembly. (Fig. 3.154)

Fig. 3.154

l Remove hexagonal bolt (M6x16 - 1 no.) from

the bracket idler gear mounting and dislocate the bracket
idle gear. (Fig. 3.155)

8 mm spanner

Tightening torque 10 ± 2 Nm

Fig. 3.155

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l Take out the idler gear along with shims

(11.2x18.5x1 - 2 nos.). (Fig. 3.156)

Note:
While reassembling the idler gear ensure the
presence of shims on both side.

Fig. 3.156

l Using the special tool, remove the ball bearing

(6207) from the crankshaft assembly (in case if the bear ing
comes wi th crankshaf t ) . (Fig. 3.157)

S131 111 0 Extractor main bearing

17 mm spanner

Fig. 3.157

l Using the special tool (bearings installer set),

bearings and oil seals can be removed and reassembled.
(Fig. 3.158)

S131 050 0 Bearing installer set

Metal hammer

Note:
Remove the bearings, only if they need to be
replaced. Unnecessary removal of bearings should
be avoided, otherwise can damage the bearings and
can cause deterioration to the interference fit. It is
Fig. 3.158
sufficient to clean and lubricate the bearings in
assembled condition.

l Using the special tool (universal oil seal

remover) , the oi l seals can removed. (Fig. 3.159)

031 240 1 Universal oil seal remover

Fig. 3.159

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GEAR ASSEMBLY BALANCER SHAFT DRIVEN

l Gear balancer shaft driven can be separated A

from the race balancer gear driven by pushing it out.
B

Note: A
While reassembling the gear balancer shaft ensure
that the dots (A) on the race balancer gear driven and
gear balancer driven should be aligned and the pin
balancer shaft driven (B) should be placed opposite B
to each other. (Fig. 3.160)
Fig. 3.160

SHAFT COMPLETE DRIVE - DISASSEMBLY

l Take out the gear 4th driven. (Fig. 3.161)

Fig. 3.161

l Remove the circlip (20x1.2). (Fig. 3.162)

Snap ring plier - External

Fig. 3.162

l Take out the shim (A). (Fig. 3.163)

B
l Take out the gear 3rd driven (B). (Fig. 3.163)
A

Fig. 3.163

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l Take out the star bush. (Fig. 3.164)

Fig. 3.164

l Take out the gear 5th driven. (Fig. 3.165)

Fig. 3.165
INSPECTION

l Shaft complete drive / shaft complete counter

(assembly) / cam gear shift / drive gears and driven gears.

l Before inspection, clean all the components

thoroughly with cleaning solvent.

l Carefully inspect all the parts for any scoring

marks, breakage, wear of splined surfaces of shafts / gear
teeth. Replace damaged parts with the new ones.

l Using a feeler gauge, check the clearance

between fork gear shift and its seating groove on the gear.
(Fig. 3.166)

l If the measured clearance exceeds the service

limit, determine whether the gear or the fork gear shift
should be replaced with a new one.

Feeler gauge

Description Service limit

Fork gear shift to

0.300 mm (max)
groove clearance Fig. 3.166

3-47
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l Reverse the removal procedure of gears for re-

assembly.

l While reassembling the gears, attention must

be given to the locations and positions of washers and
circlips.

Caution:
Never reuse circlips after removing from the shaft.

While installing a new circlip, care should be taken

not to expand the end gap larger than the required to
slip over the shaft.

After installing a new circlip, always ensure that it is

completely seated in its groove and securely being
locked. The flat surface of the circlip should always
face towards the component being locked.

l The exploded view will serve as a reference for

correct mounting of the gears, washers and circlips. (Fig.
3.167)

GEAR 2nd DRIVEN

THRUST WASHER
STAR BUSH 1st DRIVEN

GEAR 5th DRIVEN

SHAFT COMPLETE DRIVE

GEAR 2nd DRIVE

GEAR COMPLETE KS IDLE GEAR 3rd DRIVEN
GEAR 3rd DRIVE
COMPLETE 1st DRIVEN
CIRCLIP 20x1.2 N
GEAR 4th DRIVEN GEAR

SHIM

SHIM GEAR 5th DRIVE

CIRCLIP 20x1.2 N GEAR 4th DRIVE

SHAFT COMPLETE COUNTER

THRUST WASHER SHIM

BEARING KS DRIVEN GEAR

GEAR COMPLETE KS DRIVEN THRUST WASHER

Fig. 3.167

3-48
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

ENGINE COMPONENTS - INSPECTION

PLAY PLAY

Bearings

l Wash bearings with a cleaning solvent and

lubricate them with engine oi l before inspecting.

l Inspect the play of each bearing before fixing it.

Hold inner race and rotate the outer race by hand and
observe for any abnormal noise and smooth rotation.
Replace bearing with a new one if found defective. (Fig.
3.168) Fig. 3.168

Note:
Do not use compressed air to clean the bearings.

Oilseal

A
l Damage to the oil seal lip (A) may result in
leakage of oil. Inspect the oilseals for the damage of lip
and always replace oilseals with the new ones during
reassembly. (Fig. 3.169)

Fig. 3.169
Crankshaft assembly - runout

l Support crankshaft assembly with ‘V’ blocks or

anvil. Mount the dial indicator at positions shown to read
the runout. Runout should be within the service limit. (Fig.
3.170)

l Excessive runout of crankshaft assembly

causes abnormal engine vibration and bearing noises.
Such vibration shortens the engine life.

V - block set (4“x3“x3“) Dial

gauge (1/100 mm) Magnetic

stand Fig. 3.170

Service limit 0.100 mm (max)

Condition of the big end bearing - crankshaft assembly

l Measure big end wear of connecting rod by the

deflection of small end. If deflection exceeds the limit,
replace the crankshaft assembly with a new one. (Fig.
3.171)

Service limit 3 mm (max) Fig. 3.171

3-49
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l Hold the crankshaft assembly in hand, shake

the connecting rod to find out the radial play. If any play is
noticed, then replace the crankshaft assembly with a new
one. (Fig. 3.172)

Fig. 3.172

l Measure connecting rod big end side

clearance with a feeler gauge. If the clearance exceeds the
service l imit, replace the crankshaft assembly with a new
one. (Fig. 3.173)

Feeler gauge

Service limit 0.650 mm (max)

Fig. 3.173

Connecting rod small end diameter

l Measure internal diameter (ID) of the

connecting rod small end. If ID is more than the service
limit, replace the crankshaft assembly with a new one. (Fig.
3.174)

Service limit 15.040 mm (max)

Fig. 3.174
Balancer shaft - Inspection

l Inspect the balancer shaft for any twist or

bend. If found any replace the balancer shaft assembly.

l Inspect the balancer shaft bearing for free

rotation and any abnormal noise. If found any replace the
bearing. (Fig. 3.175)

Note:
Replace both LH & RH bearings together (one bearing
is assembled on the shaft and the other one is on the
RH side crankcase).
Fig. 3.175

3-50
 SERVICING OF ENGINE
TVS APACHE RTR 200 SERVICE MANUAL

l Support the balancer shaft with ‘V’ blocks or

anvil. Mount the dial indicator at the position shown to
read the runout. Runout should should be within the limit.
(Fig. 3.176)

l Excessive runout of balancer shaft causes

abnormal engine vibration and bearing noises. Such
vibration shortens engine life.

V - block set (4“x3“x3“) Dial

gauge (1/100 mm) Magnetic

stand
Fig. 3.176

Service limit 0.100 mm (max)

ENGINE ASSEMBLY - REASSEMBLY

l Refer engine exploded view for assembly

details. (Fig. 3.177)

l Reassemble parts carefully in the reverse

order of disassembly.

l Never reuse gaskets, circlips, ‘O’ rings and

oilseals when the engine is overhauled.

l After installing a circlip, ensure that it is seated

properly in its groove by rotating it.

l Always use recommended special tools.

Bearings

For reassembling bearings use a special tool.

Note:
Whenever bearings are replaced it is recommended
that both LH & RH bearings are replaced as a set to
have better results. Make sure that the bearings are
not misaligned with the fitting.

Oil seals

While assembling the oilseals to the crankcase follow the

procedure given below:

l Apply grease to the lip of oilseal.

l Use only specified special tool for assembling

the oilseals.

3-51
3-52
TUBE INLET

CRPH. SCREW (M5x16) - 4 Nos. HEXAGONAL FLANGE BOLT (M6x25) - 4 Nos.

PUNCHED WASHER A5.5 - 4 Nos.

COVER CYLINDER HEAD
COVER FILTER ELEMENT
SCREW (M5x15)

SEAL AIR CLEANER WASHER CAM SHAFT SPROCKET REC. CSK.

PACKING SEAL COVER CYLINDER

RESONATOR INTAKE SPROCKET CAM SHAFT

FILTER HOLDER COMPLETE
BOLT CYLINDER HEAD - 4 Nos.

PUNCHED WASHER 8.5x18x2.3 - 3 Nos.

SEAL AIR CLEANER

HOSE CLIP DIA. 37

HEXAGONAL FLANGE BOLT (M6x25) - 4 Nos.
HEXAGONAL FLANGE BOLT (M8x1.25 LH) CAM CHAIN
STOPPER CAM SHAFT

CASE AIR CLEANER COMPLETE

CAM SHAFT COMPLETE

ROCKER ARM ASSEMBLY INTAKE

CARBURETTOR ASSEMBLY
SPARK PLUG

GASKET
2 Nos.
BOLT CAM CHAIN TENSIONER

CLAMP PIPE INTAKE REC. CSK. HD. SCREW (M6x16) -

GASKET CYLINDER HEAD NUT

DRAIN PIPE PIPE INTAKE COMPLETE COTTER VALVE - 8 Nos.

CLAMP TUBE OUTLET O-RING 3750 240 RETAINER VALVE SPRING - 4 Nos.

CYLINDER HEAD COMPLETE SPRING VALVE - 4 Nos.

SHAFT ROCKER ARM - 2 Nos. VALVE STEM OIL SEAL - 4 Nos.

BREATHER PCV VALVE SEAT SPRING - 4 Nos.

ROCKER ARM ASSEMBLY EXHAUST

HOSE CLIP - 3 Nos. HOSE
VALVE EXHAUST - 2 Nos.
SCREW TAPPET ADJUSTING - 4 Nos.
TENSIONER CAMCHAIN

NUT TAPPET ADJUSTING - 4 Nos.

VALVE INTAKE - 2 Nos.
SERVICING OF ENGINE

STUD BOLT CYLINDER HEAD - 2 Nos.

HEXAGONAL FLANGE BOLT (M6x16) - 2 Nos.

GASKET CYLINDER HEAD NUT
GASKET TENSIONER ADJUSTER
HEX FLANGE BOLT (M8x15)
TUBULAR DOWEL - 2 Nos.
ADJUSTER ASSEMBLY TENSIONER
GASKET MUFFLER

THERMAL SENSOR

MUFFLER ASSEMBLY

GUIDE CAMCHAIN
HEXAGONAL SOCKET HEAD CAP SCREW (M8x30) - 2 Nos.

CYLINDER BLOCK DAMPER 3 - 3 Nos. GASKET CYLINDER HEAD

HEXAGONAL FLANGE NUT M6 - 4 CONTACT GEAR SHIFT SWITCH COMPLETE

Nos
GEAR 5th DRIVEN STAR BUSH 1st DRIVEN SCREW (M6x16)

SHAFT COMPLETE DRIVE GEAR 2nd DRIVEN SWITCH GEAR POSITION CRPH.
GASKET CYLINDER
PIPE COMPLETE SAI
FORK GEAR SHIFT No. 2 THRUST WASHER HEXAGONAL FLANGE BOLT (M6x16) - 2 Nos.
CHAIN ASSEMBLY 116
TUBULAR DOWEL - 2 Nos.
FORK GEAR SHIFT No. 1
SPROCKET ENGINE 13T

SHAFT GEAR SHIFT FORK - 2 Nos.

PISTON RING TOP

RING 2nd

O-RING AIR INJECTION (M6x16) - 2 Nos.

FORK GEAR SHIFT HIGH PISTON RING OIL HEXAGONAL SCREW (M5x10) - 2 Nos.
Nos. GEAR 3rd DRIVEN DRIVE SHAFT HEXAGONAL FLANGE BOLT
SPEED
CAM GEAR SHIFT OILSEAL 20x40x6 RETAINER OIL SEAL LOCK PLATE SPROCKET
PISTON WAVE SPRING WASHER 6.5
GROMMET - 2 Nos. SHIM
GEAR 4th DRIVEN
DRIVE HEXAGONAL FLANGE BOLT (M6x16) PIN MAGNETO COVER WAVE SPRING WASHER 6.5 - 3 Nos.
OIL COOLER ASSEMBLY PISTON PIN
GEAR COMPLETE 1st DRIVEN SHIM
SPACER STARTER IDLE GEAR
HEXAGONAL FLANGE BOLT (M6x55) - 5 Nos. HEXAGONAL SOCKET HEAD CAP SCREW (M6x16) - 3 Nos.
GEAR COMPLETE KS IDLE
STUD BOLT CYLINDER HEAD - 2 Nos.
THRUST WASHER
OIL SEAL GEAR SHIFT SHAFT
CIRCLIP PIN HOLDER COMPLETE
CIRCLIP PISTON PIN - 2 Nos.
20x1.2 N GEAR 5th DRIVE GEAR 2nd SHIM 12x26x1
INDEX STAR
HEXAGONAL FLANGE BOLT (M6x16) - 4 Nos.
GEAR 3rd DRIVE HEX FLANGE NUT (M12x1.25)
REC. CSK. HEAD SCREW (M6x20) CIRCLIP 12x1.0 N

GUARD OIL COOLER CIRCLIP 20x1.2 N

ROD CLUTCH RELEASE COMPLETE
THRUST WASHER
GEAR 4th DRIVE
TUBULAR DOWEL - 2 Nos. HEXAGONAL FLANGE BOLT
GEAR COMPLETE KS DRIVEN
SHAFT COMPLETE COUNTER (M6x75) - 4 Nos.
MAGNETO ROTOR ASSEMBLY
SHIM
BALL BEARING 6201 RS1 C3 HEXAGONAL FLANGE BOLT
ONE WAY CLUTCH
PIPE COMPLETE OUTLET BEARING KS DRIVEN GEAR (M6x16)
BALL BEARING C3 6204 RS
GEAR STARTER IDLE GEAR COMPLETE STARTER CLUTCH
HEXAGONAL FLANGE BOLT (M6x25) - 2 Nos.
GAUGE OIL LEVEL HEXAGONAL FLANGE BOLT
PIPE COMPLETE INLET
(M6x95) STOPPER STARTER GEAR
SPRING DOWEL STARTER MOTOR
HEXAGONAL FLANGE BOLT (M6x25) - 2 Nos. CUP WASHER M6 - 4 HEXAGONAL FLANGE BOLT (M6x20) - 2
SPEED SENSOR
Nos.
OIL SEAL 12x18x4
HEXAGONAL FLANGE BOLT (M6x16) GEAR SHIFT LINKAGE ASSEMBLY
BEARING BUSH 12x15x10 O-RING 16.8x3.1
CRPH. SCREW (M6x16) -
SPRING GEAR SHIFT CAM STOPPER WOODRUFF KEY HEXAGONAL FLANGE BOLT (M6x40) - 4 Nos.
2 Nos.
SPRING CLUTCH CABLE RETURN HEXAGONAL FLANGE BOLT (M6x20) - 2 Nos.
SHIM 6x14x1 CRANKSHAFT COMPLETE
RETAINER COUNTER BEARING
GEAR IDLER
STOPPER COMPLETE GEAR SHIFT
BALL BEARING C3 6006 KEY 4x4x15
SHIM 11.2x18.5x0.5 - 2 Nos. BRACKET
BOLT GEAR SHIFT CAM STOPPER HEXAGONAL SCREW (M6x20)
O-RING AIR INJECTION - 4 Nos. NEEDLE BEARING NB 15x23x12
IDLER GEAR
CRANKCASE L
BALL BEARING 6207 PISTON
COVER ENGINE SPROCKET
CRANKSHAFT R
HEXAGONAL FLANGE BOLT (M6x55) WOODRUFF KEY
BRACKET CLUTCH CABLE STRAINER COMPLETE ENGINE OIL
GASKET BREATHER PLUG
CRPH. SCREW (M6x16)
GUIDE T/M OIL
HEXAGONAL FLANGE BOLT CRPH. SCREW (M5x12) - 2 Nos. PLUG TDC
(M6x35) - 11 Nos. T/M OIL GUIDE
RETAINER
O-RING 60.5x2.4
SCREW (M6x12) RETAINER

DOWEL PIN - 2 Nos. OIL SEAL CAP OIL STRAINER

SPRING GEAR SHIFT SHAFT RETURN BALL BEARING 15 42 13
SHIM 15x27x0.5 CLAMP MAGNETO LEAD

BALANCER SHAFT HEXAGONAL FLANGE BOLT (M6x20) - 3 Nos. CRPH. SCREW (M5x12) - 2 Nos.
O-RING 52.6x2.4 SHIFT COMPLETE PLUG CRANKSHAFT HOLE O-RING
RETAINER SPRING - 2 Nos.
FLANGE CLIP PRIMARY DRIVEN GEAR SHAFT GEAR SEALING WASHER 22.7x3.1
GASKET COVER CLUTCH
BOLT (M6x75) MAGNETO STATOR ASSEMBLY
GEAR ASSEMBLY PRIMARY DRIVEN GEAR BALANCER SHAFT DRIVEN PLUG COMPLETE OIL DRAIN
COVER CLUTCH
HEXAGONAL FLANGE BOLT (M6x30) - 3 Nos.
DISC PRESSURE CLUTCH SPRING BALANCER SHAFT - 4 Nos. PIN BALANCER
PUNCHED WASHER 6.5x11x1.6 O-RING 13x1.9 HEXAGONAL FLANGE BOLT (M6x40) - 9
CRPH. SCREW (M5x12) - 2 Nos.
SHAFT DRIVEN - 2 Nos. Nos.

RACE BALANCER GEAR DRIVEN COVER MAGNETO

HEXAGONAL SOCKET HEAD CAP SCREW (M6x16)
HEXAGONAL FLANGE BOLT
GEAR BALANCER SHAFT DRIVE DOWEL PIN - 2 Nos. GASKET
(M6x16) - 2 Nos. HEXAGONAL FILTER COMPLETE ENGINE OIL
CRANKCASE R BALL BEARING 6207 CLAMP MAGNETO LEAD MAGNETO COVER
CAP OIL FILTER SPRING OIL FILTER CAP
BALL BEARING 15 42 13 PULSAR COIL ASSEMBLY
NUT (M16) LH
HEXAGONAL FLANGE U NUT (M12x1.25)
HUB CLUTCH
WASHER CLUTCH WASHER PRIMARY DRIVE GEAR HEXAGONAL OIL PUMP ASSEMBLY
HUB
GEAR OIL PUMP DRIVE PIN CLUTCH SPRING

SPRING WASHER CLUTCH SHAFT

CIRCLIP (6.0x0.8) TYPE E HEXAGONAL FLANGE BOLT (M6x16) - 3 Nos.

NUT CLUTCH SHAFT

GEAR OIL PUMP DRIVEN GEAR PRIMARY DRIVE

BALL BEARING 6002 C3

TVS APACHE RTR 200 SERVICE MANUAL

PLATE CLUTCH DRIVEN - 5 Nos

ADAPTOR PIN CLUTCH RELEASE

PLATE CLUTCH DRIVE - 6 Nos

3/16 BALL

SPRING CLUTCH - 4 Nos.

PLATE CLUTCH RELEASE

PIN CLUTCH RELEASE HEXAGONAL FLANGE BOLT (M6x25) - 4 Nos.

 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

l Cuando se fija el los retenes sobre el cheque eje

que los asientos de labios sobre el eje perfectamente todo
alrededor de la circunferencia sin ninguna distorsión.

l Aplique aceite de motor en cada corriendo y arrastrando

parte antes de instalarlos durante el montaje.

Los sujetadores

l Apriete todos los tornillos con el par especificado

utilizando una llave de torsión (consulte el cuadro de apriete en la página no.

7-8 y 7-9 para la especificación de par).

CARTER ASAMBLEA LH & RH - MONTAJE

l Retire el material de la junta en el apareamiento

superficies de montaje de cárter L & R y completamente eliminar
manchas de aceite.

l Montar el engranaje intermedio en el cárter

conjunto de LH y seguro que con el engranaje loco soporte
con el perno de brida hexagonal (M6x16) y apriete con el par
especificado. (Fig. 3.178)
Fig. 3.178

8 mm llave

par de apriete 10 ± 2 Nm

l Montar el eje equilibrador completa como una

ensamblado en la LH conjunto de cárter. (Fig. 3.179)

Fig. 3.179

l Girar el eje equilibrador a otro lado como

se muestra y montar el conjunto de cigüeñal en el LH
​conjunto de cárter. (Fig. 3.180)

Nota:
Mientras que el montaje del cigüeñal tener un cuidado especial
para no causar ninguna abolladura, daños y arañazos en las
superficies mecanizadas.

Fig. 3.180

3-53
 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

l Montar el clip de retención en el equilibrador

eje y fijarlo con la tecla Ruff madera. (Fig. 3.181)

UNA

Fig. 3.181

l Montar el eje del engranaje de equilibrado, movido

montaje en el eje equilibrador. (Fig. 3.182)

Precaución:
UNA
Mientras que volver a montar, alinear de accionamiento de equilibrador
y engranajes accionados para que coincida con marcas de puntos / de
UNA
perforación (A) en una línea como se muestra en la figura.

Fig. 3.182

l Montar el muelle de retención (A) y la cuña

(B) en el eje equilibrador. (Fig. 3.183)

UNA UNA

Fig. 3.182

l Coloque una arandela de empuje en el cárter

LH montaje en el eje completa zona de estar de accionamiento (por
encima del cojinete de bolas). (Fig. 3.183A)

l Coloque el segundo engranaje impulsado en el cárter

LH montaje en el eje completa zona de estar de accionamiento (por encima
de la arandela de empuje). (Fig. 3.183B)

Fig. 3.183A Fig. 3.183B

3-54
 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

l Montar el conjunto de eje secundario (embrague

eje) y el eje de accionamiento de montaje tal como se establece en LH
conjunto de cárter. (Fig. 3.184)

Fig. 3.184

l Montar el cambio de engranajes no.1 tenedor, tenedor de engranajes

cambiar ninguna. 2 y el engranaje tenedor de conversión a elevada velocidad

en su respectiva posición. (Fig. 3.185)

Fig. 3.185

l Montar la leva de cambio de marchas (A) en el cárter

montaje. (Fig. 3.186) y localizar tanto los cambios de marcha de la
horquilla en sus respectivas ranuras en el cambio de velocidad completa
de la leva. UNA

Fig. 3.186

l Ensamble ambas las horquillas de cambio en el eje de

cárter LH montaje a través de cambios de marcha de la horquilla. (Fig.
3.187)

Fig. 3.187

3-55
 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

l Montar la cuña (A) en el eje completa

conducir. (Fig. 3.188)

l Montar teniendo engranaje de arranque accionado por arrancador

UNA
junto con cuña y la arandela de empuje (B) en el eje completo
mostrador. (Fig. 3.188) segundo

Nota:
Mientras que el montaje de la cuña y la arandela de empuje, montar
la cuña por debajo del engranaje accionado saque de cojinete de
arranque y la arandela de empuje en la parte superior.

Fig. 3.188
l Montar espiga tubular (2 nos) en el
cárter LH montaje y el cárter fix junta.

Nota:
Aplicar poco de grasa en el cárter junta para un mejor
asiento.

l Montar el conjunto de cárter a la RH

Montaje del cárter LH golpeando suavemente. (Fig. 3.189)

martillo de nylon

Fig. 3.189

l Montar y apretar pernos de la brida hexagonales

(M6x55 -. 5 nos, M6x40 -. 4 nos, M6x75 - 4 NOS y M6x95 -.
1 no.) En el cárter completa LH. (Fig. 3.190)

8 mm llave

par de apriete 10 ± 2 Nm

Nota:
Apriete los tornillos en forma cruzada.

Fig. 3.190

l Ensamble y apriete el perno de brida hexagonal

(M6x55 - 1 no.) En el cárter completa RH. (Fig. 3.191)

8 mm llave

par de apriete 10 ± 2 Nm

Fig. 3.192

3-56
 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

Nota:
Después de apretar los pernos del cárter, la verificación de la
rotación libre del árbol de accionamiento completo, y de eje
secundario completa y el conjunto de cigüeñal.

Si se siente gran resistencia, golpee suavemente en la unidad

completa del eje y el eje de los conjuntos de contador
completos con martillo de nylon.

EMBRAGUE

l Antes de montar la cubierta del embrague, garantizar

que la liberación de embrague adopta por y la bola son
assemb l ed en el cl Ly UTCH assemb. (Fig. 3.192A)

l También asegúrese de que la liberación de embrague pin es

montado en la cubierta del embrague. (Fig. 3.192B)

CALADO DE LA DISTRIBUCIÓN huelgos de válvulas y

de tiempo de válvula Fig. 3.192A Fig. 3.192B

l Mientras que volver a montar la rueda dentada del árbol de levas,

seguir los procedimientos dados a continuación:

l Girar conjunto de rotor y que coincida con el TDC UNA

do
marca (A) en el conjunto de rotor y la marca (B) en LH
conjunto de cárter. (Fig. 3.193A)
segundo

l En esta posición, asegurar que la marca (C) en re

eje de la rueda dentada de leva coincide con el borde de la superficie
de la cabeza completa inder cilindros (D). (Fig. 3.193B)

Fig. 3.193A Fig. 3.193B

el juego de válvulas

l Ajustar la holgura de válvula para el límite especificado

(Véase capítulo página “mantenimiento periódico” no. 2-19 para el
procedimiento y la especificación)

l Antes de arrancar el vehículo, se llenan cum motor

aceite de la transmisión y llevar a cabo todos los otros ajustes.
Ajustar el motor según lo prescrito en el capítulo página
“Mantenimiento periódico” no. 2-18.

3-57
 MANTENIMIENTO DE MOTOR
Televisores Apache RTR 200 MANUAL DE SERVICIO

RODAJE Después de reacondicionamiento

l El / motor reparado reconstruido debe someterse

rodaje.

l No sobrecargue el motor inmediatamente después

revisión, ya que puede resultar en un desgaste rápido de los componentes
debido a sobreesfuerzo, sobrecalentamiento y sobrecarga.

l Esto tendrá un impacto a través de la vida de

los componentes reconstruidos que resulta en un rendimiento bajo
de vehículo.

3-58
 CONTENIDO
Televisores Apache RTR 200 MANUAL DE SERVICIO

DESCRIPCIÓN PÁGINA NO
Capítulo 4
SISTEMA DE COMBUSTIBLE 1
COMPLETO DEL DEPÓSITO DE COMBUSTIBLE 1
ELIMINACIÓN 1
CLARO 2
MANGUERA DE COMBUSTIBLE 3
MONTAJE CARBURADOR 3
DESMONTAJE 6
MANTENIMIENTO 8
INSPECCIÓN 9
REENSAMBLAJE 9
AJUSTE DEL RALENTI 10
SISTEMA DE LUBRICACIÓN 10
Filtro de aceite (depurador) 12
La bomba de aceite 12
13

FUEL, LUBRICATION AND EXHAUST SYSTEM

MONTAJE ENFRIADOR DE ACEITE

FILTRO DE ACEITE DE MOTOR COMPLETO 13

CONTROL DE ESCAPE DE EMISIÓN 14
¿POR GASOLINA FALLO para quemar completamente? 14
CONTROL DE POLUCIÓN 14
SISTEMA DE ESCAPE 15
SECUNDARIA válvula de inyección AIRE 15
PRINCIPIO DE FUNCIONAMIENTO 15
FUNCIÓN dieciséis

ELIMINACIÓN dieciséis

MANTENIMIENTO PREVENTIVO (emisión) 17

MEDICIÓN DE CO NIVEL EN emisiones de escape 17
Para comprobar y SET LA CO% 17
 COMBUSTIBLE, lubricación y
SISTEMA DE ESCAPE Televisores Apache RTR 200 MANUAL DE SERVICIO

SISTEMA DE COMBUSTIBLE UNA

COMPLETO DEL DEPÓSITO DE COMBUSTIBLE

l La completa del depósito de combustible se encuentra en el bastidor

tubo cerca del pivote de dirección con un depósito de conjunto de tapa con

cierre de combustible (A) y el conjunto de llave de combustible de

accionamiento manual (B) en el lado inferior izquierdo del depósito. (Fig. 4.1)

l El depósito de combustible conjunto de tapa se puede abrir segundo

con la llave de encendido.

Fig. 4.1

l Una unidad de emisor de combustible está montado en la parte inferior

lado del tanque de combustible. (Fig. 4.2)

Capacidad del tanque

Principal 12 litros

reserva 2,5 litros

l Limpiar el depósito de combustible completo periódicamente.

Inspeccionar el tanque para cualquier fuga. Si se observa alguna fuga,
sustituir el depósito de combustible con una nueva.

Fig. 4.2
ELIMINACIÓN

l Drenar la gasolina por completo.

l Retire el conjunto del depósito de combustible como se explica en

capítulo página “Mantenimiento periódico” no. 2-5.

l Quitar los tornillos de brida hexagonales (M6x16 -

2 núms.), Junto con las juntas de la montaje del conjunto de grifo de
combustible y sacar el conjunto de llave de combustible. (Fig. 4.3)

10 mm llave
Fig. 4.3
par de apriete 7 ± 1 Nm

Nota:
Mientras que volver a montar la llave de combustible, asegurar la
presencia de embalaje articulación en el cuerpo del grifo de gasolina y
la junta en pernos hexagonales.

Precaución:
Cambie la empaquetadura conjunta con uno nuevo, mientras que
volver a montar si se encuentran daños.

Se debe tener cuidado de no dañar las superficies pintadas

del conjunto de depósito de combustible durante la retirada,
limpieza y nuevo montaje.

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l Dislocar la abrazadera de la manguera y desconecte el

Manguera de drenaje desde el conjunto de depósito de combustible. (Fig. 4.4)

alicate de nariz

Fig. 4.4

l Retire el perno de brida hexagonal (M5x14 -

4 núms.) De la unidad de montaje emisor de combustible. (Fig. 4.5)

8 mm llave

par de apriete 2,5 ± 0,5 Nm

l Retire cuidadosamente el sensor de nivel a lo largo de

con la junta.

Precaución:
Se debe tener cuidado de no dañar la uni emisor de combustible t
du rante la eliminación / reensamblado. De lo contrario puede
provocar un mal funcionamiento del indicador de combustible.

LIMPIEZA

Fig. 4.5
l Limpiar el conjunto del depósito de combustible a fondo con una

disolvente de limpieza adecuado.

Nota:
Antes de volver a montar el depósito de combustible completo, el
disolvente utilizado para la limpieza debe ser limpiado y secado
completamente.

el montaje del grifo de gasolina

l Un filtro de lápiz (A) se fija a la llave de combustible

UNA
montaje y se inserta en el interior del depósito de combustible. La llave de

combustible también tiene un filtro dentro de la cubeta de sedimentos llave de

combustible (B). (Fig. 4.6)

l En general las impurezas se consiguen recogidos en la gasolina.

Filtro lápiz ayuda a filtrar las impurezas finas en la gasolina

antes de entrar en la asamblea del grifo de gasolina.
segundo

Fig. 4.6

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l Limpiar el filtro periódicamente lápiz. Visualmente

inspeccionar los daños. Incase cualquier anormalidad se FILTRAR

encuentra el filtro, el conjunto de llave de combustible debe ser

reemplazado por uno nuevo.

ANILLO O'
l Los sedimentos filtrados por el filtro en el interior del combustible

vaso de decantación pene conseguirá depositado en el bol.

Por lo tanto el recipiente y el filtro interior del recipiente deben
ser retirados y limpiados periódicamente para evitar la entrada
de polvo en el conjunto del carburador. (Fig. 4.7)

10 mm llave Fig. 4.7

Precaución:
Reemplazar el anillo 'O' con uno nuevo, mientras que volver a
montar. (Fig. 4.7)

l Use aire comprimido para limpiar cualquier obstrucción en

el paso del conjunto de llave de combustible. Volver a montar
los componentes en el orden inverso de desmontaje.

MANGUERA DE COMBUSTIBLE

l inspeccionar visualmente la manguera para combustible grieta o

fugas en sus puntos de montaje. Si alguna grieta o fuga notaron

reemplazar el combustible manguera con una nueva.

MONTAJE CARBURADOR

La eliminación del vehículo

l El mantenimiento del conjunto de carburador

Descripción especificaciones del
requiere una limpieza periódica con el fin de evitar el bloqueo de
chorros, pasajes y el establecimiento de CO ralentí% carburador Especificación
recomendados por el fabricante. tipo de carburador Keihin CV 30VE

Nota: surtidor principal 112

Sé proa Remov i ng el conjunto tor carburet, gire el mando del difusor de la aguja N/A
grifo de gasolina a la posición 'OFF' y desconecte la manguera
aguja Jet NUQA
de combustible desde el conjunto de carburador.
posición del anillo E- N/A

Piloto de jet 38
l Retire el asiento y el marco embellecedor L y R por
refiriéndose la página del capítulo “Mantenimiento periódico” no. Válvula de pistón N/A

2-3 y 2-4. MCS tornillo vueltas 1 ~ 4 vueltas

rpm al ralentí 1500 ± 100

Ralentí CO% (con SAI) 1 ~ 3%

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Tapa de goma

placa STAY - 2 núms.

CABLE DE SOPORTE
PLACA STAY tornillo de la

SCREW cubierta del diafragma - 2 núms. CUERPO COMPLETO

DIAFRAGMA TAPA

MUELLE

TUBO DE CLIP

VALVULA DE ARRANQUE
MANGUERA DE SALIDA DE AIRE

MUELLE pistón de la válvula

CHOCK PALANCA

COLLAR
O' ANILLO tornillo piloto

piloto
SCREW CHOCK PALANCA
difusor de la aguja

del tornillo piloto LAVADORA tornillo

MUELLE MÍNIMO tornillo de ajuste

REGULADOR DE PILOTO tornillo

MUELLE difusor de la aguja

Porta-agujas JET
PILOTO DE JET
LAVADORA ACELERADOR PARADA

JET-agujas Porta Aguja surtidor principal

la aguja del flotador

FLOTADOR
FLOAT PIN

IDLE tornillo de regulación

JUNTA cámara del flotador

cámara del flotador

VÁLVULA DE PISTÓN

DRENAJE TORNILLO
SCREW cámara del flotador
O' DRENAJE ANILLO

MANGUERA CLIP TUBE

DRENAJE

Fig. 4.8

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l afloje completamente la tuerca de fijación del cable del acelerador (A) mientras

sosteniendo el ajustador (B). (Fig. 4.9)

segundo
10 mm llave

UNA

Fig. 4.9

l Dislocar la abrazadera de la manguera y tire de la salida de aire

manguera del conjunto del cabezal del cilindro. (Fig. 4.10)

alicate de nariz

Fig. 4.10

l Aflojar el tubo de salida de la abrazadera y dislocar la

tubo de salida del tubo de filtro de aire desde el conjunto de
carburador. (Fig. 4.11a)

destornillador de cabeza Phillips

par de apriete 1,75 ± 0,25 Nm

l Del mismo modo, afloje el tubo de admisión abrazadera y

tire suavemente a cabo el montaje del carburador del tubo de
admisión. (Fig. 4.11B)

par de apriete 2,25 ± 0,25 Nm

Fig. 4.11a Fig. 4.11a

l Retire la CRR. tornillo de cabeza troncocónica de la

ahogar montaje palanca y sacar la palanca junto con un collar
dislocando suavemente desde el arranque de la válvula
(émbolo cuña). (Fig. 4.12a) UNA

destornillador de cabeza Phillips

l Aflojar el soporte del cable (A) de la

cuerpo del carburador y sacar el motor de arranque de la válvula como un
conjunto (conjunto de émbolo estrangulador). (Fig. 4.12b)

13 mm llave
Fig. 4.12a Fig. 4.12b

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DESMONTAJE

l Tire de la salida de aire de la manguera (A) y la manguera de drenaje (B)

dislocando los clips. (Fig. 4.13)

alicate de nariz

UNA

segundo

Fig. 4.13

l Retire CRR. tornillos de cabeza plana (2 nn.) y

llevar a cabo el diafragma cubierta. (Fig. 4.14)

destornillador de cabeza Phillips

Fig. 4.14

l Sacar la válvula de pistón de resorte. (Fig. 4.15A)

l Retire el conjunto de válvula de pistón junto con el

diafragma. (Fig. 4.15b)

Fig. 4.15A Fig. 4.15b

l Retire el tornillo piloto ajustador (mezcla

tornillo de control) (A) a lo largo con el resorte, la arandela y el anillo
'O'. (Fig. 4.16A)

pequeño destornillador plano

l Aflojar y quitar el tornillo de ajuste de ralentí (B)

junto con el resorte y la arandela. (Fig. 4.16B)
UNA

Nota:
segundo
Mientras que volver a montar el tornillo piloto garantizar para
reemplazar el anillo 'O' con una nueva.

Fig. 4.16A Fig. 4.16B

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l Retire la CRR. tornillos de cabeza plana (4) nn.

desde el montaje cámara del flotador y sacar la cámara de
flotador junto con la junta. (Fig. 4.17)

destornillador de cabeza Phillips

Nota:
Mientras que volver a montar la cámara del flotador,
inspeccionar el estado de la cámara de flotador junta y
sustituir en caso necesario.

Fig. 4.17

l Retire el flotador alfiler. (Fig. 4.18)

alicate de nariz

l Sacar el flotador junto con la aguja del flotador

(Conjunto de válvula de aguja).

Fig. 4.18

l Usando un pequeño destornillador plano, con cuidado

eliminar jet piloto. (Fig. 4.19)

destornillador plano (pequeño)

Precaución:
Durante el montaje del surtidor auxiliar no apriete más
de lo necesario, ya que puede dañar la superficie de
asiento.

Fig. 4.19

l Eliminar chorro principal (A) mientras mantiene jet titular

aguja. (Fig. 4.20)
AB
Destornillador plano

l Eliminar chorro de soporte de aguja (B) y sacar

jet aguja.

7 mm llave

Nota:
El chorro de soporte de aguja y el chorro de aguja necesitan ser
eliminado sólo si es necesario.
Fig. 4.20

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válvula de pistón - desmontaje

l Retire la aguja del surtidor soporte utilizando una llave Allen y

sacar la aguja de inyección titular junto con un resorte. (Fig.
4.21)

llave allen 4 mm

Fig. 4.21

l Empuje aguja de inyección desde la parte inferior y quitar

la aguja de inyección. (Fig. 4.22)

l Inspeccionar la aguja de inyección, el conjunto de válvula de pistón

por cualquier daño / deformación. Encontrado si cualquier reemplazar

las partes respectivas con una nueva.

l Volver a montar la aguja de inyección en el orden inverso

de la eliminación.

l Tras el montaje, asegúrese de que el chorro

la aguja se mueve hacia arriba y hacia abajo en formas lado por la fuerza de

gran suavidad.
Fig. 4.22

MANTENIMIENTO

l El mantenimiento de un nivel completo de combustible en el tanque de combustible

no deje que se oxida y también reduce la deposición de

óxido en el montaje del carburador.

l Mientras que la palanca del obturador está en la posición 'ON', hacer

No abra el acelerador de lo contrario puede causar

inundaciones del carburador.

l Limpiar el filtro de aire completa filtro con regularidad,

desde el filtro de aire bloqueado o dañado tendrá efecto adverso
sobre el montaje del carburador y los resultados en el rendimiento
del motor reducida.

LIMPIEZA

l Pulverizar el limpiador de carburador en todos los pasajes de

el cuerpo del carburador (Fig. 4.23) para asegurar que no bloqueo
debido a polvo, suciedad, goma o depósito de carbono.

Fig. 4.23

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l Después de limpiar las páginas del carburador correctamente

usando el limpiador, soplar el aire comprimido para limpiar
los pasajes a fondo. (Fig. 4.24)

Precaución:
No utilice cables de limpiar los chorros.

Eliminar Al partes l de goma de la Asamblea

carburador antes de limpiarlo con una solución de
limpieza. Esto evitará daños o el deterioro de las
piezas de goma.

Fig. 4.24
No utilice comprimido ai r en un carburador
montado que puede causar daño al sistema de
flotador.

INSPECCIÓN

conjunto de válvula de aguja

l Cualquier partícula extraña sobre la aguja del flotador (aguja

conjunto de la válvula) y su asiento pueden causar sellado
inadecuada resultante en más de flujo de gasolina. el mismo tipo
de problema también ocurre en el caso de la aguja del flotador y
su zona de estar desgastado.

l Por el contrario si los pinchazos de aguja flotador, la gasolina

no fluye en la cámara de flotador.

l Si la aguja del flotador está completamente gastada como se muestra

(Fig. 4.25) reemplazarla con una nueva.

l Inspeccionar la válvula de pistón, jet de la aguja, aguja de inyección,

jet piloto, chorro principal, tornillo piloto y juntas tóricas para cualquier
desgaste o daño anormal. Si se observa cualquier daño, reemplazar
las piezas dañadas por otras nuevas.

Fig. 4.25
REENSAMBLAJE

l Volver a montar las piezas en el orden inverso de

desmontaje procedimiento garantizando al mismo tiempo la siguiente.

l Consulte montaje carburador explotó vista en

página no. 4-4 para los detalles de montaje.

Nota:
Asegúrese de que el chorro de piloto no se aprieta
demasiado, ya que esto puede causar daños a su cabeza.
Eliminación del cuerpo de mezcla se vuelve muy difícil.

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l Si bien volver a montar el carburador siempre

utilizar nuevos anillos 'O' y los anillos de sellado.

l Montar la válvula de pistón de tal manera que la

gancho como proyección de diafragma coincide con la ranura
del cuerpo de carburador. (Fig. 4.26)

l montaje del carburador Vuelva a montar en el vehículo

en el orden inverso de la extracción.

Nota:
Mientras que volver a montar, comprobar el movimiento suave de la
palanca del estrangulador y la válvula de pistón en el cuerpo del
Fig. 4.26
carburador.

l Después de volver a montar el carburador de montaje en

el vehículo, encaminar adecuadamente la salida de aire de la manguera de

drenaje y la manguera.

l Comprobar el funcionamiento suave del puño del acelerador y

ahogo. Comprobar y ajustar el acelerador jugar si es

necesario (referchapter página “Pe mantenimiento
periodicas” no. 2-26).

AJUSTE DEL RALENTI

l Después de volver a montar el carburador de montaje en

el vehículo, ajustar el carburador como se explica en detalle en el
capítulo de la página “Mantenimiento periódico” no. 2-18.

SISTEMA DE LUBRICACIÓN

l sistema de lubricación es muy importante para cualquier

motor que ayudan a que el motor se realice bien, incluso a
mayor velocidad y temperatura. Por ello, mantener el
sistema de lubricación es esencial para proteger el motor.

l En esta moto, el sistema de lubricación se llama como

sistema de lubricación positiva. Contiene una bomba de
aceite trocoidal que suministra aceite al circuito de lubricación
del sumidero.

l Tiene un filtro de aceite en el lado de entrada de la bomba.

También tiene filtro de papel a la salida de la bomba de aceite.
El aceite viaja a través de varios sistemas del motor se enfríe.

l El circuito de aceite se muestra en la ilustración. (Fig. 4.27)

l Siempre limpiar los conductos de aceite siempre que sea

el servicio o en el cárter de apertura.

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CONJUNTO DE MAGNETO

eje de LH CAM SPROCKET 16T,

cojinete de cigüeñal

CAM SPROCKET 32T,

eje LH TM cadena de levas

cojinete de accionamiento
BALANCÍN
Engranajes del

BIELA ​extremo pequeño, PISTON PIN

Pistón, Anillos de Pistón, la pared del cilindro contracojinete Lóbulos de leva, ejes
GUÍA de aceite del de las levas

CARTER LH ÁRBOL DE LEVAS

RODAMIENTO CIGÜEÑAL CIGÜEÑAL RH Refrigeración del cilindro

extremo grande COJINETE CABEZA DE CILINDRO cabeza de combustión
CÁMARA

PARTE INFERIOR
Al extremo del cigüeñal RH
PERNO CULATA RH

CARTER RH

FILTRO DE ACEITE tapa del embrague

FILTRO DE ACEITE
CARTER L ENFRIADOR DE ACEITE
(Filtro de sumidero)

SUMIDERO DE ACEITE

Fig. 4.27

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l Reemplazar o reponer el aceite lubricante según

el programa de mantenimiento periódico.

Filtro de aceite (depurador)

l El filtro de aceite es suministrado a la derecha del cárter lado

en la parte inferior dentro de la alcachofa de aceite tapa. (Fig. 4.28)

l Limpiar el filtro de aceite como se especifica en el periódico

programa de mantenimiento (véase capítulo “mantenimiento periódico”
página no. 2-12 para la eliminación y el procedimiento de limpieza).

La bomba de aceite Fig. 4.28

l El aceite conjunto de bomba está montado en la derecha

cárter lateral, justo debajo de la unidad principal de engranajes. (Fig.
4.29)

l La bomba de aceite es el miembro de primera que ofrece

aceite al sistema de lubricación del cárter. Es impulsado por un engranaje
separado (engranaje de accionamiento de bomba de aceite) a través de un
engranaje de plástico. Inspeccionar el engranaje accionado la bomba de
aceite y la superficie de la bomba de aceite de cualquier daño. Apretar la
bomba de aceite tornillos de montaje con el par IED f especí while volver a
montar.

Fig. 4.29
par de apriete 8 ± 2 Nm

l Para garantizar el suministro del aceite a la culata de cilindros

componentes, el flujo de aceite se pueden verificar en la cabeza del

cilindro siguiendo el procedimiento dado a continuación:

l Arranque el motor y una duración de pocos segundos.

l aflojar lentamente el perno de brida hexagonal

(M8x15 - 1 no.) Junto con la junta de cobre y buscar el flujo
de petróleo. (Fig. 4.30)

14 mm llave

par de apriete 12 ± 2 Nm

Nota:
No abrir el cerrojo de repente ya que el aceite puede
salpicar a través del agujero.

No mantener el agujero de la inspección del aceite abierta durante más

Fig. 4.30
tiempo, ya que puede conducir a una mayor cantidad de drenaje de
aceite.

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l Si no hay flujo de aceite a través de la inspección

agujero, comprobar el buen funcionamiento de la bomba de aceite, filtro de

aceite obstruido y para cualquier bloque en los pasos de flujo de aceite.

MONTAJE ENFRIADOR DE ACEITE

l El conjunto de radiador de aceite está montado en el

marco bramido el depósito de combustible cerca de la columna de
dirección. (Fig. 4.31)

l El aceite del motor se bombea a través de la

enfriador de aceite de montaje y se enfría de nuevo y enviar de
vuelta al motor.

l una inspección visual de las aletas del enfriador de aceite para cualquier

bloqueo. Si algún, limpiarlos usando una pequeña herramienta de

mezcla y aire comprimido.
Fig. 4.31

l Inspeccionar aletas del enfriador de aceite para cualquier deformación.

Si es así, enderezarlas con un destornillador delgado, de cabeza

plana.

l inspeccionar visualmente la entrada de conjunto del enfriador y

tubos de salida para cualquier crack, fugas, daños o

deformaciones. Si algún sustituirlos por unos nuevos.

l Consulte el capítulo página “Mantenimiento periódico”

no. 2-21 para la eliminación, inspeccione procedimiento de iones y
rectificación de refrigerador de aceite de montaje.

FILTRO DE ACEITE DE MOTOR COMPLETO

l El aceite filtro completo del motor debe estar

por iodical Ly inspeccionado y cambiado si es necesario
con una nueva. (Fig 4.32)

Nota:
Siempre que se sustituya el filtro de aceite completo del motor,
se recomienda que el aceite de motor es también ser
reemplazado.

l Th procedimiento e para el cambio de aceite y filtro de

aceite de motor completo se explica en detalle en el capítulo
página “Mantenimiento periódico” no. 2-12 y 2-13 .

Fig. 4.32

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CONTROL DE ESCAPE DE EMISIÓN

l Los contaminantes emitidos por los gases de escape

sistema son perjudiciales para el medio ambiente. Si la
combustión es absolutamente completa, no habría ningún
tipo de contaminación atmosférica del sistema de escape.
Agua y dióxido de carbono son los productos de la
combustión perfecta y completa. Sin embargo, la combustión
completa es difícil de lograr en motores de combustión
interna.

l Hay tres principales contaminantes en los gases de escape

emisión. Son:-

1. hidrocarburos no quemados (HC)

2. El monóxido de carbono (CO)

3. Los óxidos de nitrógeno (NO) X

¿Por qué el GASOLINA FALLO para quemar

completamente?

Hay varias razones para la combustión incompleta. Algunos

de ellos son:-

1. Chispa débil
2. proporción de la mezcla de aire-combustible incorrecto

3. gasolina adulterada

4. tiempo de encendido incorrecto

5. Compresión baja
6. Válvula excesiva sobre el regazo

7. ralentí incorrecto
8. sistema de escape incorrecta

CONTROL DE POLUCIÓN

l Con la aplicación de diversos vehículos de motor

reglas, se han establecido normas para el porcentaje permisible de CO
emitido desde los gases de escape tal como se muestra a continuación:

En masa Por debajo de 0,83 g / km

Por volumen Por debajo de 3,0%

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SISTEMA DE ESCAPE

l El sistema de escape consisten en partes derecha desde

la válvula de escape para silenciador de montaje a través de la
cual pasa el gas de escape.

l Normalmente en vehículo de cuatro tiempos, el silenciador

No estar sucio como dos vehículos Stoke menos que el
sistema está dañado debido al petróleo u otra cosa la
mezcla con gasolina sin saberlo. Pero cada vez que el
silenciador se retira del motor, la junta de escape debe ser
reemplazado para evitar fugas.

SECUNDARIA válvula de inyección AIRE

l válvula de inyección de aire secundario está montado en el

bastidor debajo del depósito de combustible cerca del conjunto del filtro de

aire. (Fig. 4.33)

PRINCIPIO DE FUNCIONAMIENTO

l Esta es la unidad que se utiliza en las emisiones de escape

sistema de control. El sistema de inyección de aire
secundario induce aire filtrado en el colector de escape. Fig 4.33
Siempre que hay impulsos de presión negativa en el
sistema de escape, se tomará el aire fresco en el tubo de
SECONDARYAIR
escape. Esta carga de aire fresco diluye considerable INJECTIONVALVE

cantidad de hidrocarburos (HC) y monóxido de carbono

(CO) en los gases de escape en dióxido de carbono (CO) y
agua (HO). (Fig. 4.34) AIRE

2 2 AIRE VACCUM

l Hay una válvula de lámina que actúa como un cheque

válvula, evita que el flujo de aire inverso de escape. Sólo se
permite aire fresco en el colector de escape.
FILTRO DE AIRE

l También hay un conjunto de diafragma en este . La Fig. 4.34

válvula. Bajo cierre repentino de la válvula reguladora, de alto
vacío se genera en el colector de admisión. Debido a este alto
vacío, el conjunto de diafragma se tira hacia arriba y la entrada
de aire fresco en el escape se corta.

l Bajo la condición de aceleración repentina cerrado,

una cierta cantidad de los gases no quemados de alta densidad se han
agotado. Estos gases no quemados cuando entran en contacto con el
aire fresco en el calor de escape, que se encienden y crean un sonido
de estallido (después de la quemadura).

4-15
 COMBUSTIBLE, lubricación y
SISTEMA DE ESCAPE Televisores Apache RTR 200 MANUAL DE SERVICIO

l Debido a esto tras la grabación, alta temperatura es

creado en este sistema y esta alta temperatura hace que la
pre-ignición en la cámara de combustión. Debido a esto la
preignición, el efecto de golpeteo es creado y por lo tanto
se reduce la eficiencia del motor. El aire fresco cortado en
la condición cerrada del acelerador, ayudará a evitar la
quemadura después.

FUNCIÓN

l El aire limpio desde el conjunto de filtro de aire es DIAFRAGMA INTAKEMANIFOLD

pasado a través del orificio de entrada (A). La salida (B) que
REED
tiene una válvula de láminas conectado a colector de escape. do
SOPORTE
Otra línea de colector de admisión está conectado a la cámara TAPÓN

(C). El puerto (D) tiene un pequeño orificio que los otros puertos.
El aire fresco y filtrado pasa desde el puerto (A) al puerto (B) a
segundo
través de este orificio. Cuando hay una succión en la cámara (C)
el diafragma es pul llevó hacia arriba, el cierre de la válvula en el
puerto (D). El flujo de aire desde el puerto (A) a (B) se detiene.
DA
Dependiendo de la cantidad de vacío creado en el colector de resorte de DE ESCAPE
COLECTOR
admisión, se controla la cantidad de flujo de aire desde por t (A) válvula
DE AirFilter
a (B). (Fig. 4.35)
Fig. 4.35

ELIMINACIÓN

l Dislocar la abrazadera de la manguera (A) de entrada de aire de la manguera

y desconectar la manguera de la válvula de inyección de aire UNA

secundario. (Fig. 4.36)

l Del mismo modo, dislocar la abrazadera de la manguera (B) de la manguera

salida de aire y desconecte la manguera de la válvula de inyección

de aire secundario. (Fig. 4.36)

alicate de nariz segundo

Fig. 4.36

l Retire el perno hexagonal (M6x30 -. 2 nos) de

montaje de la válvula de inyección de aire secundario y sacar la
válvula junto con las arandelas perforadas (2 nos.). (Fig. 4.37)

10 mm llave

par de apriete 7.5 ± 1 Nm

Nota:
Si bien volver a montar asegurar la disponibilidad de los
amortiguadores y separadores en el lugar de montaje de la
válvula.
Fig. 4.37

4-16
 COMBUSTIBLE, lubricación y
SISTEMA DE ESCAPE Televisores Apache RTR 200 MANUAL DE SERVICIO

l Dislocar el clip (A) de la válvula de corte de aire manguera

y desconectar la manguera de la válvula de inyección de aire
secundario. (Fig. 4.38) UNA

alicate de nariz

l Para el montaje, invertir la eliminación

secuencia.

MANTENIMIENTO PREVENTIVO (emisión)

l Mientras que todos los vehículos nuevos de salir de fábrica es Fig. 4.38
certificada y está cumpliendo con las normas de emisiones de
escape, el nivel de CO en los gases de escape puede quedar
alterado dependiendo de la altitud y también durante un periodo
de tiempo dependiendo del uso o la falta de mantenimiento. Por
tanto, es necesario cada vez que es atendida vehículo,
inspeccionar el nivel de CO y afinar el motor para mantener las
normas de emisión.

Precaución:
Aumento del nivel de CO en los gases de escape no sólo
contamina el aire mal, pero también afecta el rendimiento del
motor.

MEDICIÓN DE CO NIVEL EN emisiones de escape

l Cuando el rendimiento del motor es generalmente

buena, la sintonización de montaje del carburador mediante
el ajuste del tornillo piloto (tornillo control de la mezcla) y el
tornillo de ralentí ayudará a controlar el nivel de CO en los
gases de escape. Muchos equipos están disponibles para
medir el nivel de CO en los gases de escape. Antes de
medir la emisión, es importante entender el proceso de
medición, controles y aspectos mantenimiento de los
aparatos al referirse al manual del fabricante individual.

Comprobar y ajustar los co: -

l Utilice el kit de tuning de emisión (K310440)

suministrada por TVS-M y seguir las directrices que figuran a
continuación: -

l( Consulte manual de procedimiento operativo estándar,

que se suministra con la parte de kit de prueba de kilometraje no.
K310520. También el mismo procedimiento se puede hacer
referencia en la página “Manual de TVS Scooty Pep” capítulo “de
combustible, lubricación y sistema de escape” no. 4-20).

4-17
 COMBUSTIBLE, lubricación y
SISTEMA DE ESCAPE Televisores Apache RTR 200 MANUAL DE SERVICIO

directrices:

1. Calentar el vehículo haciendo funcionar el motor en régimen de ralentí

durante 5 - 8 minutos o ejecutar el vehículo durante 3 a 4 kms en 40
velocidad kmph.

2. Compruebe el número de revoluciones al ralentí con la ayuda del

tacómetro. Si es necesario ajustar ralentí rpm según la especificación
(véase capítulo página “mantenimiento periódico” no. 2-18 para más
detalles).

3. Funda de errático ralentí (variación más allá spec.), Situado

justo la misma antes de proceder para el ajuste del CO.

4. Fijar la extensión de tubo en el silenciador. Apriete las

abrazaderas para evitar cualquier fuga.

5. Inserte la sonda de analizador de gases de escape en el tubo de

extensión para la extensión de 30 a 60 cms.

ESCAPE DE GAS
ANALIZADOR
KIT DE EMISIÓN DE AJUSTE

SONDA

Fig. 4.36

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 COMBUSTIBLE, lubricación y
SISTEMA DE ESCAPE Televisores Apache RTR 200 MANUAL DE SERVICIO

6. Pulsar la tecla 'M' para Horiba o 'Enter Key' para analizador de

gases de escape Hermann para medir la emisión de CO.

7. Espere unos segundos hasta que se estabilice la lectura en la

pantalla.

8. Nota las lecturas de CO y HC se muestran en la pantalla.

Nota:
Al término de comprobación de CO, mantener el analizador
en 'modo de medición' durante aproximadamente 30
minutos para la circulación de aire fresco y después conecte
la alimentación 'OFF' la máquina.

4-19
 CONTENIDO
Televisores Apache RTR 200 MANUAL DE SERVICIO

DESCRIPCIÓN PÁGINA NO
Capítulo 5
CABLEADO CÓDIGO DE COLORES 1
PRECAUCIÓN 2
SISTEMA DE ENCENDIDO 3
Cerradura de encendido 4
El interruptor del motor MATANZA 4
VERIFICACIÓN DE PULSAR bobina con probador de bolsillo 5
VERIFICACIÓN conjunto del estator CON probador de bolsillo 5
VERIFICACIÓN bobina de encendido CON probador de bolsillo 6
BUJÍA 6
UNIDAD TCI 7
SENSOR TERMAL 7
SISTEMA DE ILUMINACIÓN 7
Interruptor de alumbrado 9
INTERRUPTOR DE CONTROL DEL HAZ 9
INTERRUPTOR DE PASO POR 9
SISTEMA DE REGULACIÓN 12V 10
REGULADOR DE CUM RECTIFICADOR 10
CARGA Y SISTEMA DC 10
Horn (12V DC) 11
La señal de vuelta LÁMPARAS delantero y trasero 12

ELECTRICAL SYSTEM
SENSOR DE POSICIÓN DE ENGRANAJES 12
APAGUE ASAMBLEA LUZ DE FRENO DELANTERO Y TRASERO 13
INDICADOR DE NIVEL DE COMBUSTIBLE 13
SENSOR DE VELOCIDAD 14
CARGA DE VERIFICACIÓN DE RENDIMIENTO dieciséis

SISTEMA arranque eléctrico 17

BOTÓN DE ARRANQUE ELÉCTRICO 18
INTERRUPTOR MONTAJE EMBRAGUE 18
RELAY arranque automático 19
SUSTITUCIÓN DE LÁMPARAS 19
Montaje de la lámpara INTERMITENTES BOMBILLA 19
CABEZA bombilla de la lámpara 20
POSICIÓN lámparas de repuesto 21
ASAMBLEA velocímetro digital 22
ASAMBLEA lámpara de cola 23
NÚMERO DE PLACA DE AVISO - BOMBILLA 23
AJUSTES 24
AJUSTE DE LA CABEZA faros o 24
Interruptor de ajuste de conjunto de tope luz trasera 24
BATERÍA 24
BATERIA CARGANDO 26
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

COLOR CABLE código de índice

[Link]. CÓDIGO COLOR CABLE

01 segundo NEGRO

02 BW NEGRO CON BLANCO TRACER

03 BBr NEGRO CON BROWN TRACER

04 POR NEGRO CON MARCAS AMARILLO

05 BI AZUL
06 BABERO AZUL CON NEGRO TRACER

07 BLG AZUL CON MARCAS VERDE

08 BLR ROJO AZUL CON TRAZADOR

09 blw AZUL CON BLANCO TRACER

10 br MARRÓN

11 BrBl BROWN CON AZUL TRACER

12 sol VERDE

13 GB VERDE CON NEGRO TRACER

14 GRAMO VERDE CON ROJO TRACER

15 GW VERDE CON BLANCO TRACER

dieciséis GY VERDE CON AMARILLO TRACER

17 Gramo GRIS
18 GrR GRIS CON ROJO TRACER

19 LBI AZUL CLARO

20 lg VERDE CLARO

21 O NARANJA

22 Orbe NARANJA CON NEGRO TRACER

23 OrGr NARANJA VERDE CON TRAZADOR

24 PAG ROSADO

25 R ROJO

26 RB ROJO CON NEGRO TRACER

27 RW ROJO CON BLANCO TRACER

28 RY ROJO CON AMARILLO TRACER

29 V VIOLETA

30 W BLANCO

31 WR BLANCO CON ROJO TRACER

32 WG BLANCO CON MARCAS VERDE

33 WB BLANCO CON NEGRO TRACER

34 Y AMARILLO

35 YBI AMARILLO CON TRAZADOR AZUL

36 YB AMARILLO CON NEGRO TRACER

37 Yor AMARILLO CON NARANJA TRACER

38 YR AMARILLO CON ROJO TRACER

39 YW AMARILLO CON MARCAS BLANCO

5-1
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

PRECAUCIÓN

CONECTOR
HACER CLIC

l Al conectar un conector, asegúrese de empujar

en hasta sentir un clic. (Fig. 5.1)

l Me nspectconnectorforcor corro-,
la contaminación y la rotura en su cubierta.

ACOPLADOR

Fig. 5.1
l Con un acoplador tipo de bloqueo, asegúrese de liberar el
bloquee antes de desconectarlo y empújelo completamente hasta que

consigue bloquear con un clic del tacto. (Fig 5.2A) Pulse para
liberar
l Al desconectar un acoplador, asegúrese de sujetar HACER CLIC
el acoplador de sí mismo y no tire de los cables conductores.
sello a prueba de

l Inspeccionar cada terminal en el acoplador por ser agua

suelto o doblada. Inspeccionar cada terminal para la corrosión y

la contaminación.

l acopladores a prueba de agua se proporcionan en el

conexiones importantes. (Fig. 5.2B) asegurar la presencia de juntas
a prueba de agua en los acopladores antes de volver a conectar Fig. 5.2A Fig. 5.2B
ellos.

FUSIBLE Fusible en buen estado Fusible quemado

l Cuando un fusible se funde, siempre investigar la

causa, corregirlo y luego vuelva a colocar el fusible. (Fig 5.3)

l No utilice un fusible con una capacidad diferente. No haga

usar alambre o cualquier otro sustituto para el fusible o puede
provocar la fusión / ardor de cables.

Fig. 5.3
SEMICONDUCTOR EQUIPADA PARTE

l Tenga cuidado de no dejar caer las piezas con una

semiconductor construido en tal como la unidad TCI, regulador
rectificador cum y otros. (Fig. 5.4)

l Al inspeccionar estas piezas, siga el

instrucción de inspección estricta. Despreciando el procedimiento
adecuado puede causar daño a estas partes.

Fig. 5.4

5-2
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

conexión de la batería

l Para el desmontaje de la batería o el mantenimiento, asegúrese

para desconectar el terminal negativo. Cuando se conecta

a los terminales de la batería, conecte el terminal negativo
al final.

l Si se encuentra que corroe cualquier terminal de la batería,

extraer la batería, se vierte agua caliente sobre ella y limpio, con
cepillo de alambre.

l Aplicar vaselina en los terminales después de

finalización de la conexión y cubre el terminal positivo con Fig. 5.5
la bota. (Fig. 5.5)

TVS Apache RTR 200 sistema eléctrico se divide en cuatro sistemas básicos (circuitos) con nombre:

1. circuito de encendido 2. circuito de iluminación 3. circuito de carga 4. circuito de arranque eléctrico

SISTEMA DE ENCENDIDO

El sistema de encendido de Apache RTR 200 consta de montaje magneto, el regulador de unidad cum rectificador (unidad RR), 15A fusible, la batería, la cerradura de encendido, el

interruptor de apagado del motor, la unidad de TCI, bobina de encendido y una bujía de encendido. (Fig. 5.6)

La salida de la bobina de pulsos de montaje magneto es directamente conectado a la unidad de TCI. La salida de corriente continua de la batería está conectado al interruptor de parada del

motor a través de un fusible de 15 amperios ya través de la cerradura de encendido. La salida del interruptor de parada del motor está conectado a la unidad TCI, bobina de encendido,

arranque del relé y el interruptor de auto arranque.

CONJUNTO DE MAGNETO
FUSIBLE 15A (DC)
12V - 200W RW
Y R R BW

RY
Y Y R
A Velocímetro
R
A relé de arranque 12V, 9Ah R
MOTOR
BBr
YY Y
Batería de

UNIDAD RR R
Cerradura de
PULSAR BOBINA 12V DC O
encendido
A otros circuitos
APAGADO

W ORB
EN
W BW A relé de arranque / AUTO
Br
START INTERRUPTOR
apagado del motor
O
br conmutador o
BW
Fusible de 10A
(FARO)

P RB
VELOCÍMETRO
ORB
GrR Orbe
A relé de arranque

GR
Licenciado en Derecho
Del interruptor de embrague UNIDAD TCI

BIB YB Licenciado en Derecho

DE ES INTERRUPTOR

WG
SENSOR BW
DE ENGRANAJE SENSOR DE POSICIÓN
BIR TERMAL BOBINA DE ENCENDIDO

A Velocímetro (TACHO DE
INDICACIÓN)

WB Yor WR CABLE HT
YB ybl

BUJÍA
OPERACIÓN DE FARO

Fig. 5.6

5-3
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

La bobina de pulsos produce las señales de voltaje cada vez que el

PIP en la periferia magneto pasa más cerca de él. Sobre la base de
estas señales, el microcontrolador equipado en la unidad de TCI
colapsa la tensión de devanado primario de la bobina de encendido
en la fracción de segundo. Esto a su vez-desarrolla un alto voltaje a
través del devanado de la bobina de encendido secundario debido a
la inducción mutua. Esta alta tensión se da a través de cable de la
bujía HT.

Cuando la cerradura de encendido se encuentra en estado 'OFF' o el interruptor

de parada del motor está encendido 'OFF' habrá que no haya ningún flujo de

corriente a la unidad y la bobina de encendido TCI por lo tanto el motor no arranca.

Cerradura de encendido

l El i gn ITI en l ock oca ISL ted en el

conjunto de velocímetro. (Fig. 5.7)

l Desconectar el acoplador de bloqueo de encendido de

mazo de cables principal y de bloqueo para inspeccionar la continuidad
con el probador de bolsillo (multímetro).

probador de bolsillo

posición LOCK R O

APAGADO

EN O O
Fig 5.7

l Vuelva a colocar la cerradura de encendido si no hay

continuidad se encuentra .

El interruptor del motor MATANZA

l interruptor de apagado del motor se encuentra en el lado derecho de

manejar el conjunto de barra en la RH manilla del conjunto del interruptor.

(Fig. 5.8)

l Desconectar el mango conjunto de interruptor de RH

acoplador de cableado principal e inspeccione el interruptor de
continuidad con el probador de bolsillo.

probador de bolsillo

posición LOCK R O

PULSE ARRIBA ( )
. La Fig. 5.8
Pulse hacia abajo ( ) O O

5-4
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

COMPROBACIÓN DE LA BOBINA PULSAR CON probador de bolsillo

(MULTÍMETRO)

probador de bolsillo

l probador de bolsillo fijado en la posición 2.000 ohmios.

l Desconectar la bobina de pulsar forma socket cableado

aprovechar.

l Conecte probador de bolsillo '' + ve conducir al marrón

alambre (Br) de la bobina de pulsar y '-ve' conducen a cable blanco (W) de la

bobina de pulsar. (Fig. 5.9)

l Medir la resistencia. Si la resistencia

410
medido no está dentro del límite especificado, sustituir la bobina W V

de pulsos con una nueva.

bobina Pulsar (Br - W) 360 ~ 440 ohmios UNA

COM MAV W

!
FUSED FUSED

CONTROL DE LA conjunto del estator CON probador de

bolsillo
Fig. 5.9

l Dado que no hay un conjunto de magneto 3 fase es

utilizado en este vehículo, el procedimiento de comprobación
conjunto de estator es completamente diferente a otros vehículos de
formulario. (Fig. 5.10) La resistencia del conjunto de estator va a ser
comprobado entre todas las tres caras. Siga el procedimiento dado a
continuación:
1.0
W VV ~

l Desconectar la forma socket conjunto de estator

mazo de cables principal.
V~

Un 10A
3
10 A COM MAV W

l Ajuste el mando probador de bolsillo a 200 ohmios !

posición .
FUSED FUSED

2 1

probador de bolsillo
Fig. 5.10

l Hay tres cables amarillo (Y) que salen de

el conjunto de estator. Conectar el probador de bolsillo (+ ve)
conducen a la primera cable amarillo (Y) y (-ve) conducen a
segundo cable amarillo (Y) y medir la resistencia. (Fig. 5.10)

l Del mismo modo, comprobando la resistencia entre

cables amarillo segunda y tercera. También el tercer y primer
cables amarillo. Si cualquier resistencia de una fase no está
dentro del límite, sustituir el conjunto de magneto estator con
una nueva.

resistencia a través
0,2 ~ 1,2 ohms
cualquier dos fases

5-5
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

INSPECCIÓN DEL CONJUNTO CON bobina de encendido

probador de bolsillo

l La bobina de encendido está montado en el lado derecho de

el bastidor debajo del conjunto de depósito de combustible, cerca del

conjunto de cabeza de cilindro. (Fig. 5.11)

l Desconectar la toma de cableado de conexión TCI

unidad y la bobina de encendido. Asimismo, desconecte el cable de
encendido de la bujía.

probador de bolsillo

Fig. 5.11
l Probador de bolsillo fijado en la posición 200 ohmios.

l Conecte el probador de bolsillo '+ ve' y '-ve'

conducir a los terminales del acoplador de la bobina de encendido
como se muestra para medir la resistencia del devanado primario. 4.54
(Fig. 5.12) Si la resistencia no está dentro del límite especificado,
sustituir el conjunto de bobina de encendido con una nueva. W VV

V~

Un 10A

La resistencia primaria 4.05 ~ 4.95 ohmios COM MAV W

!
FUSED FUSED

l Si la resistencia del devanado primario está bien, a continuación, comprobar

la resistencia del devanado secundario.

Fig. 5.12
l probador de bolsillo fijado en la posición 20 k ohmios.

l Retire la tapa de la tarjeta supresor de HT.

Conectar el probador de bolsillo '+ ve' conducir al cable de
HT y '-ve' conducir a cualquier terminal de la l acoplador de 12.14
encendido coi y medir la resistencia. (Fig. 5.13)
W VV

resistencia secundaria 10.8 ~ 12.32 k ohmios V~

Un 10A

COM MAV W

!
l Si la resistencia de los devanados no están dentro del FUSED FUSED

limitar, reemplace el conjunto de bobina de encendido con una nueva.

BUJÍA
Fig. 5.13

l El descuido de la bujía conduce a una mala

rendimiento del motor. Si se utiliza la bujía para un período
más largo, el electrodo se quema poco a poco y el carbono
se acumula a lo largo del i ns i de par te (véase el capítulo
“Per i OD mantenimiento ic” página sin
. 2-14 para la limpieza y
mantenimiento de la bujía).

Precaución:
Siempre use maquillaje recomendada y el tipo de
bujía única.

Bujía BOSCH UR4KE

5-6
 SISTEMA ELÉCTRICO
Televisores Apache RTR 200 MANUAL DE SERVICIO

UNIDAD TCI

l TCI (unidad de control de transistor) unidad se coloca debajo

el montaje del depósito de combustible cerca de la batería. unidad de
TCI se puede comprobar haciendo un buen (o) mal análisis (en
sustitución existente por uno nuevo). (Fig.5.14 )

Fig. 5.14

SENSOR TERMAL

l Un sensor térmico fijada en el bloque de cilindros para

detectar la temperatura del motor y dar entrada a la unidad
TCI en forma de resistencia. (Fig. 5.15) Verificar la
resistencia del sensor térmico de la siguiente manera:

l Establecer el probador de bolsillo en la posición 20 k ohmios.

probador de bolsillo

l Desconectar el acoplador del sensor térmico de

Fig. 5.15
mazo de cables principal. Conectar han + 'alambre del
probador de bolsillo conducir al rojo amarillo (YR) y '-ve'
conducir al rojo blanco (WR) del acoplador sensor térmico y
medir la resistencia cuando el motor en frío. (Fig. 5.16)

Resistencia 3.0 ~ 14 k ohmios

l Si la resistencia medida no está dentro del

límite especificado, sustituir el sensor térmico con una nueva.

Fig. 5.16

SISTEMA DE ILUMINACIÓN

El sistema de iluminación se compone de montaje magneto, el regulador de unidad cum rectificador (unidad RR), la batería, la cerradura de encendido, 10A fusible (lámpara de cabeza), la

unidad de TCI y los interruptores de control. El funcionamiento del sistema de iluminación de la TVS Apache RTR 200 4V son como sigue. (Fig. 5.17)

Una salida de CC desde la batería está conectada a un fusible 10A (lámpara de cabeza) a través de la cerradura de encendido. La salida del fusible 10A está conectado a la unidad de
TCI. Cuando el bloqueo de encendido en la posición 'ON', uno más de salida de CC de la cerradura se suministra a la unidad de TCI, iluminación interruptor, control del haz del
interruptor y el paso de los switch.

Cuando el mando de iluminación interruptor se desplaza a la posición 'PO', la corriente continua de salida del interruptor se suministra a las luces de posición y la lámpara de
cola.

5-7
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

Similarly, when the switch lighting knob is slid to the ‘HL’ (head lamp ‘ON’) position, the output DC current from the switch is supplied to the TCI
unit along with the position lamps and the tail lamp. Upon receiving the input from the switch lighting the TCI unit checks for the input from the
pulsar coil to determine the engine running condition (head lamp works only for 10 seconds when the engine is in ‘OFF’ condition) and the switch
beam control to determine the head lamp beam (‘High’ or ‘Low’).

If the beam control switch is in ‘High’ position, the TCI unit will not get any input signal from switch beam control and supplies the power to the
head lamp ‘High beam’ and the head lamp high beam glows. If the beam control switch is in ‘Low’ position, the TCI gets an input signal from the
switch and supplies power to the head lamp ‘Low beam’ and the head lamp low beam glows.

When the pass-by switch is pressed, a DC signal is sent to the TCI unit. Now, the TCI unit checks for the input from the switch lighting to
determine the head lamp condition (‘ON’ or ‘OFF’). If the head lamp is in ‘OFF’ condition the TCI unit supplies the power to the head lamp ‘high
beam’ and makes it to glow. If the head lamp is in ‘ON’ and glowing in ‘low beam’, the TCI unit cuts ‘OFF’ the power supply to the ‘low beam’
and supplies to the ’high beam’ (toggles). If the head lamp is glowing in ‘high beam’ the TCI unit does it in vice-versa. If the pass-by switch is
pressed when the engine is not running, the head lamp glows only with 50% illumination.

If the head lamp is turned ‘ON, when the engine is not running, the TCI unit checks for the input from switch beam control to determine the
head lamp beam (‘High’ or ‘Low’). Based on the switch beam controls position the head lamp glows for 10 seconds with only 50% intensity. If
the self start switch is pressed within this 10 seconds the head lamp goes ‘OFF’ and gets ‘ON’ after the engine starting with 100% intensity. If
the vehicle is kept in engine idling condition for more than 20 seconds with the head lamp ‘ON’, the head lamp reduces the illumination by 50%
and gains it back to 100% once the vehicle is moved or the throttle is opened.

MAGNETO ASSEMBLY
12V - 200W FUSE 15A (DC)
RW BW
Y Y R R

RY
Y Y R
TO SPEEDOMETER
R
TO RELAY 12V, 9Ah R
STARTER MOTOR
BBr
Y Y
BATTERY
Or
TO OTHER

RR UNIT R CIRCUITS

PULSAR COIL IGNITION

12V, DC Or
LOCK
OFF

W OrB
ON
W BW
Br

ENGINE KILL TO RELAY STARTER / SELF

Or
Br SWITCH Or START SWITCH / IGNITION
BW COIL

FUSE 10A
(HEAD LAMP)

P RB OrB
SPEEDOMETER
Or
GrR OrB
RELAY

GR Bl Gr
FROM CLUTCH SWITCH FROM TCI UNIT TO IGNITION COIL
TAIL LAMP TO SPEEDOMETER (FOR BACK
ILLUMINATION)
SENSOR TO STARTER 12V LED
BIB YB
FROM ES SWITCH FROM THERMAL SENSOR Gr
SWITCH
WG BIR BW LIGHTING
FROM GEAR POSITION
TO SPEEDOMETER Or

Gr PO
Or

NUMBER PLATE LAMP

WB 12V, 5W

HEAD LAMP 12V, 60/55W YB HL

SWITCH
Or
WB YBl BW Gr BEAM
BW CONTROL
YB WR HI

YBl
Or
YBl
YOr
LOW
TO SPEEDOMETER (FOR HIGH
BEAM INDICATION) WR

YOr Or

PASS BY SWITCH

Fig. 5.17

5-8
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

SWITCH LIGHTING

l Switch lighting is provided on the switch

assembly RH at the right hand side of the handle bar. (Fig.
5.18)

l Check the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION Or Gr

OFF ( ) Fig. 5.18

PO ( ) O O

SWITCH POSITION Or YBl

OFF ( )

ON ( ) O O

SWITCH BEAM CONTROL

l Switch beam control is provided on the switch

assembly LH at the left hand side of the handle bar. (Fig.
5.19)

l Check the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION Or WR

PRESS UP ( ) - HIGH

PRESS DOWN ( ) - LOW O O Fig. 5.19

PASS-BY SWITCH

l Pass-by switch is provided on the switch

assembly handle LH at the left side of the handle bar. (Fig.
5.20)

l Check the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION YW YBI

PRESS - ON O O

RELEASE - OFF
Fig. 5.20

5-9
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

12V REGULATION SYSTEM

REGULATOR CUM RECTIFIER (RR UNIT)

l The RR unit (regulator cum rectifier) is fitted

below the rear seat assembly near the tail lamp assembly.
(Fig. 5.21)

l The RR unit consists as the name implies,

regulator which regulates the voltage between 12V to 14V
constantly, and rectifier used for converting AC current to
DC for charging and other purpose.
Fig. 5.21

CHARGING AND DC SYSTEM

The DC system consists of magneto assembly, regulator cum rectifier unit (RR unit), battery, ignition lock, fuse 15A (main fuse) and the
control switches. A DC output from the battery is directly connected to the speedometer through a 15A fuse for the memory and other
functions of speedometer. Another DC output from the battery is connected to the ignition lock through the same 15A fuse. When the ignition
lock is turned ‘ON’ the DC output from the ignition lock is supplied to the position lamps, smart phone charger, brake lamp switches front and
rear, horns, speedometer assembly and other DC operated components. (Fig. 5.22)

MAGNETO ASSEMBLY
12V - 200W FUSE 15A (DC)
RW BW
Y Y R R

RY R
Y Y R
R
TO RELAY
STARTER MOTOR
BBr
Y Y
BATTERY
12V, 9Ah
R TO OTHER
R IGNITION CIRCUITS
RR UNIT LOCK
12V, DC
OFF
POSITION LAMPS
12V LED
ON Or Or

Or Or
BW

WG
FUEL SENDER UNIT TO TCI UNIT
Or

GY GEAR POSITION SENSOR

HORN
R Or
ELECTRONIC Or
BW WG
FLASHER
5

SWITCH HORN
1

UNIT
N

Or
4

GY
3

HORN GG
FROM TCI UNIT (FOR HIGH BEAM BW
INDICATION)
Lbl
BlR YB
FROM TCI (FOR TACHO TO TCI UNIT (FOR NEUTRAL
INDICATION)
Lbl
OPERATION)
BRAKE SWITCH FRONT
SPEEDOMETER
GP
FROM SWITCH LIGHTING W
L R Or BRAKE LAMP
12V LED
12V, 10W 12V, 10W W
BW BRAKE SWITCH REAR
BW
BW BW W

SOCKET FOR MOBILE

OrGr
V Lg CHARGING
TURN SIGNAL TURN SIGNAL Or
BY LAMPS L LAMPS R
V
V
12V, 10W 12V, 10W Lg BW
GW
Lg
BW BW

Or
TO FUSE HEAD LAMP
BY

V TO PASS BY SWITCH Or Or
SPEED
TO SWITCH LIGHTING
SENSOR GW

Lg Or
TO ENGINE KILL SWITCH Or
TO BEAM CONTROL SWITCH

Fig. 5.22

5-10
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

A negative input from the common earth junction is directly connected to the position lamps. On switching ‘ON’ the ignition lock the lamps
glows directly. Similarly, the smart phone charger also gets the negative input from the common earth junction and it will be ready for charging
the smart phones.

When the brake lamp switch front or rear is operated (brake applied), the DC current from either of the switch is supplied to the brake lamp. A
negative earth connection from the common earth junction is connected to the lamp and hence the lamp glows. Similarly, when the horn button
is pressed, the negative input from the common junction is connected to the horns. Since the horns are connected to the ignition lock’s DC
output directly, on pressing the switch the horns blows.

A DC output from the ignition lock is connected to the speedometer assembly for its operation. A input signal from the gear position sensor is
connected to the speedometer and the TCI unit for gear position sensing. A neutral indication signal is connected to the TCI unit from the
speedometer for electric start operation. The fuel level indicator in the speedometer gets an input signal in the from of variable resistance from
the fuel sender unit. Based on these signals the fuel level indicator shows the fuel level indication.

An input voltage and a negative supply are given to the speed sensor from the speedometer. The output signal from the speed sensor is
connected to the speedometer. Based on these signals the speed indication is shown. Speedometer shows engine rpm based on the engine
speed signal received from the TCI unit.

A DC output from the ignition lock is connected to the electronic flasher unit. The output from the flasher unit is connected to the switch turn
signal. When the switch is slid to the ‘right’ or ‘left’ the respective front and rear turn signal lamps glows along with the turn signal indicator on
the speedometer .

HORNS (12V DC)

l The horns are mounted on the frame at the

front side of the vehicle below the fuel tank. (Fig. 5.23)

l The DC output orange wire (Or) from the

ignition lock is connected to the horns directly and the
negative green wire (G) from the horns is connected to
earth through the horn switch.

Fig. 5.23

l The horn switch is located on the switch

assembly handle LH. (Fig. 5.24)

l Check the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION G BW

PRESS - ON O O

RELEASE - OFF

Fig. 5.24

5-11
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

TURN SIGNAL LAMPS FRONT AND REAR

l The DC output from the ignition lock is

connected to the switch turn signal through a electronic
flasher unit mounted below the seat assembly near the
battery. (Fig. 5.25)

l The DC output wire orange (Or) from the

ignition lock is connected to the flasher unit and the output
from the flasher unit is connected to the switch turn signal
through a light blue wire (Lbl).

Fig. 5.25

l The switch turn signal is located on the switch

assembly handle LH. (Fig. 5.26)

l Inspect the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION V LbI Lg

TO LEFT ( ) O O

PRESS RELEASE O

TO RIGHT( ) O O Fig. 5.26

GEAR POSITION SENSOR

l The gear position sensor is mounted on the

crankcase assembly LH below the cover engine sprocket.
(Fig. 5.27)

l Gear position sensor senses the exact

position of the gear and generates the resistance
accordingly. These resistance are sent to the digital
speedometer and the TCI unit through a white green wire
(WG). To measure the resistance level of gear position
sensor at various position follow the procedure given Fig. 5.27
below:

l Set the pocket tester at 20k ohms position.

Pocket tester

l Disconnect the gear position sensor’s socket

form wiring harness.

l Connect pocket tester’s ‘+ve‘ lead to the

green white wire (GW) of gear position sensor and ‘–ve‘
lead to body earth. (Fig. 5.28)
Fig. 5.28

5-12
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l The resistance of gear position sensor at

various position are as follows:

GEAR POSITION RESISTANCE

First gear 0.3 kilo ohms

Neutral 0.75 kilo ohms

Second gear 1.5 kilo ohms

Third gear 2.7 kilo ohms

Fourth gear 5.6 kilo ohms

Fifth gear 15 kilo ohms

SWITCH ASSEMBLY STOP LAMP FRONT AND REAR

(BRAKE SWITCHES)

l The DC output from ignition lock is connected

to the stop lamp through switch assembly stop lamp front
and rear. Stop lamp switch front is fitted on the lever bracket
assembly RH. (Fig. 5.29)

l Switch assembly stop lamp rear is fitted on the

frame below the battery assembly near the mounting of
the swing arm complete and operated by the brake pedal.
(Fig. 5.30)
Fig. 5.29

l Inspect the switch for continuity with the

pocket tester.

Pocket tester

SWITCH POSITION G BW

APPLY BRAKE - ON O O

RELEASE - OFF

FUEL LEVEL INDICATOR

l Fuel level indicator and fuel warning lamp are Fig. 5.30
provided in the digital speedometer.

l Fuel level indicator and the warning lamp

works based on the variable resistance signal received
from the fuel sender unit. Fuel sender unit resistance
alters the resistance in accordance with the amount of fuel
available in the fuel tank.

l The fuel sender unit is fitted on the bottom of

the fuel tank. (Fig. 5.31)

Fig. 5.31

5-13
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l To inspect the fuel sender unit, fuel tank FULL

complete must be removed (refer chapter “Fuel,
lubrication and exhaust system” page no. 4-1 for removal
procedure).

l Inspect the fuel sender unit for continuity with

pocket tester by connecting ‘+ve' lead of pocket tester to
green yellow wire (GY) and ’-ve' lead to the black white wire
(BW). EMPTY

Pocket tester

l Set pocket tester at 200 ohms position and Fig. 5.32

check the resistance of fuel sender unit. If the resistance
value is not within the specified limit, replace the sender
unit with new one. (Fig. 5.
32 )

Full 4 ~ 6 ohms
Resistance
Empty 108 ~ 112 ohms

SPEED SENSOR

l Speed sensor is mounted on the crank case LH

near engine sprocket. (Fig. 5.33)

To check the speed sensor:

l Set pocket tester at DC 20 V range.

Pocket tester

l Check and ensure the battery voltage is within

the specifications.

Battery voltage 12.9 volts Fig. 5.33

l If the battery voltage is found less than the

specified voltage, recharge the battery as explained in
page no. 5-26.

l Disconnect the speed sensor coupler from the

main wiring harness. (Fig. 5.34)

Fig. 5.34

5-14
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Turn ‘ON’ the ignition.

l Connect the pocket tester’s ‘+ve‘ lead to the

orange grey wire (OrGr) of speed sensor coupler at the
wiring harness side and ‘–ve‘ lead to the black yellow wire
(BY) of speed sensor coupler at the wiring harness side
and measure the voltage. (Fig. 5.35)

The voltage should be:

Voltage 9 ± 1 Volt
Fig. 5.35
l Then connect the pocket tester’s ‘+ve‘ lead to
the white green wire (WG) of speed sensor coupler at the
wiring harness side and ‘–ve‘ lead to the black yellow wire
(BY) of speed sensor coupler at the wiring harness side
and measure the voltage. (Fig. 5.36)

The voltage should be:

Voltage 5 ± 1 Volt

l If there is no voltage output found in the speed

sensor coupler. Then check the continuity of wiring
harness between speed sensor coupler and speedometer Fig. 5.36
coupler .

WIRE SPEEDO SPEED SENSOR

COLOUR COUPLER COUPLER

OrGr O O

BY O O

GW O O

l If there is no continuity in the wiring harness,

replace the wiring harness and check for speed indication in
the speedometer.

l If the continuity is found OK, replace the

speedometer and check for speed indication in the
speedometer.

l If the voltage is found OK while checking with

the pocket tester, then check speed senor in the following
manner:

l Reconnect the speed sensor coupler.

l Set pocket tester knob at DC 20 V range.

5-15
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Connect the pocket tester’s ‘+ve‘ lead to the

orange grey wire (OrGr) and ‘–ve‘ lead to the black yellow
wire (BY) of speed sensor coupler and measure the
voltage. (Fig. 5.37)

The voltage should be:

Voltage 9 ± 1 Volt

l Then connect pocket tester’s ‘+ve‘ lead to the

white green wire (WG) and ‘–ve‘ lead to the black yellow
wire (BY) of speed sensor coupler and measure the
voltage. (Fig. 5.38) Fig. 5.37

The voltage should be either level A or level B.

LEVEL VOLTAGE LEVEL

A 5 ± 0.5 Volt

B 0.1 ± 0.5 Volt

l Now slowly rotate the rear wheel. If the

voltage indicated in the pocket tester is at
level A then it should change to level B or vice versa.

l Now rotate the rear wheel little faster. If the Fig. 5.38
voltage indicated in the pocket tester is not as per the
specification. Then replace the speed sensor and check
the speedometer for proper speed indication.

Voltage 2.5 ± 0.5 Volt

CHARGING PERFORMANCE CHECK

l Set the pocket tester at DC 200 V range.

l Remove the cover frame RH (refer chapter

“Periodic maintenance” page no. 2.4 for
removal procedure).

l Connect the pocket tester’s ‘+ve‘ lead of

pocket tester to positive terminal of the battery and ‘–ve‘
lead of pocket tester to the negative terminal of the battery.
(Fig. 5.39)

l Start and warm up the engine. Switch on the

head lamp high beam.

Fig. 5.39

5-16
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Gradually increase the throttle while observing

the rpm indicator of speedometer. Once the rpm reaches
4000, check the pocket tester reading. The reading should
be

Charging 14.5 ± 0.3V at 2500 rpm and

performance above

Note:
While checking the charging current, switch on the
head lamp high beam to know the correct reading.

l If the reading measured is not within the limit,

check the stator coil resistance as explained in page no. 5-5
.

l If the stator coil resistance found OK, then

replace the RR unit with a new and re-check.

l Reassemble the cover frame RH.

ELECTRIC STARTER SYSTEM

MAGNETO ASSEMBLY
12V - 200W FUSE 15A (DC)
RW BW
Y Y R R

RY
Y Y R
TO SPEEDOMETER
R

BBr OrB
Y Y
IGNITION COIL BATTERY
PULSAR COIL
12V, 9Ah

RR UNIT R
IGNITION
12V, DC Or
LOCK
W TO OTHER CIRCUITS TO

Br W OFF

Br ON
OrB
BW R

W ENGINE KILL
Or
SWITCH Or
BW
FUSE 10A
(HEAD LAMP) OrB
P
FROM SPEEDOMETER FOR
NEUTRAL POSITION RB
WG
FROM GEAR POSITION
SENSOR
OrB

RELAY STARTER
BW GR
Bl MOTOR
TCI UNIT
COIL
GrR YB SENSOR TO IGNITION
CLUTCH SWITCH
FROM THERMAL
TACHO INDICATION) OrB
BIB GrR
TO SPEEDOMETER (FOR

BIR
OrB
R R

BIB WB YOr WR
GrR
YB Ybl
GrR

FOR HEAD LAMP OPERATION

STARTER SWITCH
OrB
M STARTER MOTOR

BIB BW
GrR

Fig. 5.40

5-17
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

Electric starter system consists of battery, ignition lock, engine kill switch, electric starter switch, neutral switch, clutch switch, speedometer
assembly, TCI unit, relay starter motor and the starter motor assembly. (Fig. 5.40)

A DC output from the battery is connected to the ignition lock through a 15A fuse. When the ignition lock is turned ‘ON’, this DC output is
connected to the TCI unit, electric starter switch and relay starter motor through the engine kill switch.

A DC output from the battery is directly connected to the relay starter motor and the output of the relay is connected to the starter motor
through thick wires. A negative is connected to the starter motor from the common earth junction. When the relay energies, the battery output
is supplied to the starter motor and the motor works.

Based on the resistance input from the gear position sensor, the neutral position is sensed by the speedometer and the speedometer supplies a
negative input to the TCI unit for activating the electric start circuit. A negative output from the clutch switch is supplied to the TCI unit when the
switch is operated. In the absence of neutral indication from the speedometer, this negative input is taken by the TCI unit for activating the self
start circuit.

While pressing the electric starter switch, the DC supply from the electric starter switch flows to the TCI unit. On receipt of this DC input signal,
the TCI unit checks the availability of negative input either from the speedometer or from the clutch switch. If any one of these input is
available, the TCI unit connects a negative supply to the relay starter motor and energies the relay. Even though all the above conditions are
met by the TCI unit, if the engine is in running condition (if there is a pulsar coil input to the TCI unit), the TCI unit cuts ‘OFF’ the negative
supply to the starter relay to avoid the cranking of motor during engine running condition and protects the motor from damage.

If the electric start switch is pressed continuously either in neutral or in clutch applied condition, the TCI unit energies the starter relay for 3
seconds and switches ‘OFF’ it automatically and energies again after 3 seconds for battery saving.

E LECTRIC STARTER SWITCH

l Electric starter switch is located at the bottom

side of switch assembly RH on the right hand side of the
handle bar. (Fig. 5.41)

l Inspect switch for continuity using pocket

tester with the engine kill switch is in ‘ON’.

SWITCH POSITION Or BIB

PRESS - ON O O

RELEASE - OFF Fig. 5.41

SWITCH ASSEMBLY CLUTCH

l Switch assembly clutch is located at the

bracket clutch lever which is mounted in handle bar LH.
(Fig. 5.42)

l Inspect the switch for continuity with the

pocket tester.

SWITCH POSITION GR BIB

PRESS - ON O O

RELEASE - OFF
Fig. 5.42

5-18
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

RELAY SELF STARTER (STARTER RELAY)

l Relay self starter is located on the right side of

the vehicle on top of the air cleaner assembly. (Fig. 5.43)

l Inspect relay by checking the continuity using

pocket tester.

RELAY CONDITION Gr R

NOT ENERGIZED

ENERGIZED O O Fig. 5.43

(To energise the starter relay keep the vehicle in neutral

condition, press and hold the starter switch with the ignition
lock and engine kill switch ‘ON’ condition.)

l If there is no continuity found, replace the

starter relay and once again check for continuity. Again
problem persists, then replace the TCI unit and check.

BULBS REPLACEMENT

LAMP ASSEMBLY TURN SIGNAL - BULB

l Remove the self tapping screw from turn

signal lamp housing and take off lens along with the holder
assembly and bulb. (Fig. 5.44)

Phillips head screw driver

Fig. 5.44

l Rotate and pullout the bulb holder from the

housing and replace the bulb with a new one. (Fig. 5.45)

Turn signal lamp 12V, 10W

l Reassemble the parts and tighten the self

tapping screw.

l Same procedure can be followed for replacing

the turn signal lamps bulbs.

Fig. 5.45

5-19
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

HEAD LAMP ASSEMBLY - BULB

l Remove the CRR pan head screw (M5x16 -

2 nos.) from the housing speedometer rear moun t i ng
and r emove t he hous i ng speedometer rear. (Fig. 5.46)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 5.46

l Remove the CRR pan head screw (M6x25 -

2 nos.) housing head lamp front top mounting. (Fig. 5.47)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 5.47

l Loosen the hexagonal flange bolt (M6x16 -

2 nos.) from the bottom mounting housing head lamp
(both LH and RH) and tilt the housing head lamp forward.
(Fig. 5.48)

10 mm spanner

Tightening torque 3 ± 1 Nm

Fig. 5.48

l Pullout the socket head lamp (A) from head

lamp bulb and dislocate the dust cap (B) of head lamp
assembly. (Fig. 5.49)

A B

Fig. 5.49

5-20
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Take out head lamp bulb by snapping out the

clip (A) and replace with a new one. (Fig 5.50)

A
Head lamp bulb 12V, 60/55W H4

l Reassemble the parts in the reverse order of

removal.

Note:
After reassembling head lamp, readjust the head lamp
beam as explained in chapter “Periodic maintenanc e”
page 2-38)
Fig. 5.50

Do not touch the halogen bulb at it will reduces its

life and performance.

POSITION LAMPS - REPLACEMENT

l Remove the housing head lamp mounting

bolts and tilt the housing head lamp as explained in the
pervious page.

l Remove the hexagonal nuts (M6 - 4 nos.)

from the bracket housing head lamp along with the punched
washer. (Fig. 5.51)
Fig. 5.51

10 mm spanner

Tightening torque 3 ± 1 Nm

l Remove the CRR pan head tap screw (M6x16 -

2 nos.) from the bracket housing head lamp. (Fig. 5.52)

Phillips head screw driver

Tightening torque 1.5 ± 0.5 Nm

l Gently pull out the turn signal lamp by

Fig. 5.52
dislocating it from the lugs and separate the housing head
lamp front and rear.

l Disconnect the position lamp assembly

connector. (Fig. 5.53)

Fig. 5.53

5-21
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 3 nos.) and takeout the position lamp
assembly LH. (Fig. 5.54)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Position lamp LED lamp (2W)

l Replace the position lamp with a new one and

reassemble housing lamp front.
Fig. 5.54
l In similar manner the position lamp RH can be
removed and replaced.

l Reassemble the parts in the reverse order of

removal.

Note:
After reassembling head lamp assembly, readjust the
head lamp beam as explained in chapter “Periodic
maintenance” page 2-38).

DIGITAL SPEEDOMETER ASSEMBLY

Since the digital speedometer is provided with LED indicators,

it is not possible to replace t h e m individually. Recommended
to replace the entire speedometer assembly, incase of any
failure.

REMOVAL

l Remove the CRR pan head screw (M5x16 -

2 nos.) from the mounting of housing speedometer rear
and take out the housing speedometer. (Fig. 5.55)

Phillips head screw driver

Fig. 5.55

Tightening torque 3 ± 1 Nm

l Remove the hexagonal nut (M6 - 3 nos.) along

with plain washers from the mounting of speedometer
assembly. ( Fig. 5.56 )

10 mm spanner

Tightening torque 3 ± 1 Nm

Fig. 5.56

5-22
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Disconnect coupler from the speedometer

assembly by gently pressing the lock and take out the
digital speedometer. (Fig. 5.57)

l Replace the new speedometer.

l Reassemble the parts in the reverse order of

removal procedure.

Note:
After reassembling the head lamp, readjust the head
lamp bea m as explained in chapter “Periodic
maintenance” page 2-38). Fig. 5.57

TAIL LAMP ASSEMBLY

l Refer the chapter “Periodic maintenance”

page 2-10 for tail cover assembly rem oval procedure.

l Remove the hexagonal flange nut (M6 - 2 nos.).

(Fig. 5.58)

10 mm spanner

Fig. 5.58
Tightening torque 2.5 ± 0.5 Nm

l Remove the CRR pan head screw (M6x16 -

2 nos.) from the tail assembly mounting. (Fig. 5.59)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Replace lamp assembly with new one.

l Reassemble the parts in the reverse order of

dismantling.
Fig. 5.59

NUMBER PLATE ILLUMINATOR - BULB

l Remove the rear seat assembly.

l Disconnect the number plate lamp couplers

from the main wiring harness. (Fig. 5.60)

Fig. 5.60

5-23
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Remove mounting nuts (M6 - 2 nos.) and take

out the number plate illuminator as an assembly and pull
out the rubber grommet. (Fig. 5.61A)

10 mm spanner

Tightening torque 3 ± 1 Nm

l Pull out bulb holder along with the bulb.

(Fig. 5.61B)

l Remove bulb from the holder and replace with Fig. 5.61A Fig. 5.61B
a new one.

Note:
While reassembling ensure that the presence of the
grommet in the tail cover.

ADJUSTMENTS

HEAD LAMP BEAM ADJUSTMENT

l Adjust the head lam p beam as per the

specification by referring procedure given in chapter
“Periodic maintenance” page no. 2-38 for the adjustment
procedures.

SWITCH ASSEMBLY STOP LAMP - REAR

l The switch assembly stop lamp rear can be A

adjusted by turning the adjuster nut (A) in or out, so that
the brake lamp glows when the rear brake is applied. (Fig.
A
5.62)

Note :
While adjusting the switch assembly, do not turn the
body switch assembly (B) holding the adjuster nut
(A). Fig. 5.62

BATTERY
B
A
l Remove the cover frame RH (refer chapter
”Periodic maintenance” page no. 2-4)

l Disconnect the battery’s negative terminal (A)

first and then positive terminal (B). (Fig. 5.63)

10 mm spanner

Tightening torque 3 ± 1 Nm
Fig. 5.63

5-24
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the clamp by removal of the CRR pan

head screw (M6x16 - 1 no.) (A) and take out the battery
assembly. (Fig. 5.64)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Remove the battery from the vehicle and clean

it thoroughly.

l Visually inspect the surface of the battery

assembly for any sign of cracking or electrolyte leakage. If Fig. 5.64
any sign of cracking or electrolyte leakage from side walls
of the battery is noticed, replace the battery with a new
one.

l Measure the open circuit voltage of battery

using pocket tester. (Fig. 5.65)

Open circuit voltage 12.9 Volts

l If the voltage measured is less than 12 volts,

then charge the battery using constant current battery
charger as explained below:

l If the battery lead terminals are rusty or an Fig. 5.65

acidic white powdery substance, then clean them with
sand paper / warm water.
Maximum
l The electrolyte level must be between the
minium level and maximum level mark provided on the
battery case. (Fig. 5.66)

l Add distilled water as necessary, to ensure the

electrolyte is above the minimum level line but not above Minimum
the maximum level line. (Fig. 5.66)

Caution:
Add only distilled water for tapping up the electrolyte
level. Fig. 5.66

l Check the electrolyte specific gravity reading

using the hydrometer. (Fig. 5.67) If the reading is not within
the specified limit, it indicates that the battery needs
charging. HYDROMETER
1.25
Hydrometer

Electrolyte specific gravity at 20 C

Battery type Normal Under charged

12V, 9.0 Ah 1.28 1.25

Fig. 5.67

5-25
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

Note:
To read the specific gravity on the hydrometer, bring HYDROMETER
the electrolyte in the hydrometer to eye level (Fig.
5.68) and read the graduations on the float scale
bordering on the lower meniscus.

Fig. 5.68

BATTERY CHARGING

l Constant current battery charger having the

current output of 0.9 amps must be used for charging the
12V, 9 AH battery.

Caution:
Use only constant current battery charger. Do not
use constant voltage battery charger.

l If the battery charger has multiple battery

charging facility (0.25A/0.5A/0.9A), then select the output
current according to the battery connected for charging at
each bay.

Charging procedure

l Remove the filler cover strip of battery and

connect the positive lead of the battery charger (red
colour) to the positive terminal (+) of the battery and the
negative lead of the charger (black colour) to the negative
terminal (-) of the battery as shown in the figure. (Fig.
5.69)

Caution:
Care should be taken not to connect the battery
charger in reverse order ie. positive lead to negative
terminal and vice versa.

Incase, if the battery is connected in the reverse

Fig. 5.69
order, the reverse polarity indicator of the charger (if
available in the charger) glows and the protection
fuse (if available in the charger) blows.

Correct the connection and replace the fuse before

charging. Otherwise the battery may not get
charged.

5-26
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

l Turn the selector knob (A) of the charger to the

0.9 amps position incase of multiple battery charger. (Fig.
5.70)

Caution:
Ensure to select the charging current based the
battery amphere only. If more or less current is A
selected the battery may get damaged.

l Connect the battery charger to the power

supply and switch on the power.
Fig. 5.70

l Switch on the ‘MAINS ON-OFF’ switch (A) and

ensure that the ‘MAINS-ON’ LED indicator (B) is glowing.
(Fig. 5.71) If this indicator is not glowing, then check the
main fuse of the charger and replace the fuse if required.
A

Fig. 5.71

l Now, the ‘CHARGING’ LED indicator (A) glows

and indicates the battery is getting charged. If this
indicator is not glowing, check whether ‘LO-BATTERY’
LED indicator (B) is glowing. (Fig. 5.72)

A
l If the ‘LO-BATTERY’ LED indicator is glowing,
it indicates that the battery voltage is very less and it can’t B
be charged further. Replace the battery with a new one.

Fig. 5.72

l After charging the battery for few hours (time

may vary based on the battery voltage and capacity)
‘CHARGED’ LED indicator (A) of charger glows and
indicates that the battery is charged. (Fig. 5.73)

Fig. 5.73

5-27
 ELECTRICAL SYSTEM
TVS APACHE RTR 200 SERVICE MANUAL

Indication of full charge

l The following are the indication of full charge.

HYDROMETER
1.28
l Battery can be considered to be fully charged
when three consecutive specific gravity (SG) readings
taken at intervals of 30 minutes each, indicating a reading
of 1.28. (Fig. 5.74)

l Free gassing of electrolyte.

Fig. 5.74

l The stable consecutive readings showing 12.8

volt or more with 30 minutes of interval. (Fig. 5.75)

Note:
If the battery voltage is less than 11 volt, irrespective 12.74
of correct specific gravity reading, then the battery
needs to be replaced with a new one.

l After charging re-fix the battery assembly and

connect the positive terminal first followed by the negative
terminal.
Fig. 5.75

l Apply petroleum gelly to the terminals to avoid

corrosion.

l Reassemble the parts in the reverse order of

removal.

5-28
 CONTENTS
TVS APACHE RTR 200 SERVICE MANUAL

DESCRIPTION PAGE NO
Chapter 6
WHEEL ASSEMBLY FRONT 1
DISC PLATE REPLACEMENT 1
REMOVAL 1
INSPECTION 2
REASSEMBLY 3
DISC BRAKE SYSTEM FRONT 5
BRAKE PADS 5
BRAKE FLUID AND ITS HANDLING 6
INSPECTION OF BRAKE FLUID LEVEL 6
AIR BLEEDING FROM BRAKE SYSTEM 7
BRAKE FLUID REPLACEMENT 8
HOSE COMPLETE FRONT BRAKE 8
CALIPER ASSEMBLY - REMOVAL AND DISASSEMBLY 9
DISC PLATE - SERVICING 12
MASTER CYLINDER - REMOVAL AND DISASSEMBLY 13
REASSEMBLY 15
FORK ASSEMBLY FRONT 17
OIL CHANGE 17
LEG ASSEMBLY FRONT FORK - DISASSEMBLY 21
INSPECTION 22
REASSEMBLY 22
LOWER BRACKET COMPLETE - DISASSEMBLY 23
INSPECTION 25
REASSEMBLY 26
WHEEL ASSEMBLY REAR - REMOVAL 28

CHASSIS
DISC REPLACEMENT 28
SPROCKET DRUM ASSEMBLY - DISASSEMBLY 30
INSPECTION 31
REASSEMBLY 32
TUBELESS TYRE 33
PUNCTURE REPAIR 33
REPLACEMENT OF VALVE TUBELESS TYRE 34
DISC BRAKE SYSTEM REAR 36
BRAKE PADS 36
BRAKE FLUID 37
HOSE COMPLETE REAR BRAKE 37
CALIPER ASSEMBLY - REMOVAL AND DISASSEMBLY 38
DISC PLATE - SERVICING 42
MASTER CYLINDER REAR - REMOVAL AND DISASSEMBLY 42
INSPECTION 44
REASSEMBLY 45
REAR SHOCK ABSORBER - REMOVAL 46
SWING ARM COMPLETE 48
REMOVAL 48
INSPECTION 50
REASSEMBLY 51
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

WHEEL ASSEMBLY FRONT

REMOVAL

l Support the motorcycle by center stand and

place a jack or block to keep the front wheel off the ground.

l Remove the front wheel axle nut along with

punched washer. (Fig. 6.1)

22 mm spanner
Fig. 6.1

Tightening torque 76 ± 18 Nm

l Draw out the axle front along with punched

washer. (Fig. 6.2)

l Take out the wheel assembly front along with

disc plate and spacer complete LH.

Note:
While taking out the front wheel keep some cushion
in between the brake pads, to avoid binding.

Disc replacement Fig. 6.2

l Remove special screw (M8 - 6 nos.) from the

disc plate mounting and take out disc plate from the alloy
wheel front. (Fig. 6.3)

6 mm allen key
A
Tightening torque 31 ± 3 Nm

l Remove oil seal (A) using the special tool.

031 240 1 Universal oil seal remover

Note: Fig. 6.3

While reassembling the mounting bolts apply thread
locker without fail.

Removal of bearings

Warning:
Bearings should be removed only in case of
replacement.

l Heat the wheel assembly front upto 125° C by

placing the wheel on a hot plate. (Fig. 6.4)

Hot plate

Fig. 6.4

6-1
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Gently tap out bearing left and right and spacer

complete front hub with a suitable mandrel. (Fig. 6.5)

Nylon hammer

Drift

INSPECTION

Before inspection, clean all necessary components

with suitable cleaning solvent and lubricate them. Fig. 6.5

Wheel bearings PLAY PLAY

l Inspect the wheel bearings inner race for play

by hand while fixing it in the hub complete front wheel. (Fig.
6.6)

l Rotate the inner race by hand to inspect

whether abnormal noise occurs or rotating smoothly.
Replace bearing if found defective.

Axle front

Fig. 6.6
l Using the special tools, check the axle front for
run out (straightness) and replace the axle with a new one if
run out exceeds the limit. (Fig. 6.7)

Dial gauge (0.01mm)

Magnetic stand

V - block - 4“x3“x3“

Service limit 0.25 / 100 mm

Warning:
Do not attempt to straighten a bent axle.
Fig. 6.7

Alloy wheel front

l Using the special tools, measure the alloy

wheel front’s run-out. Excessive run-out is usually due to a
bent alloy wheel. (Fig. 6.8)

Dial gauge (0.01mm)

Magnetic stand

Service limit 0.6 mm

l Replace the alloy wheel if found defective.

Fig. 6.8

6-2
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

Tyre front

l Using the vehicle with excessively worn tyres

will decrease riding stability and consequently invite a
dangerous situation due to loss of control. It is highly
recommended to replace the tyre with a new one when
the groove depth of tyre from tread surface reaches the
following specifications: (Fig. 6.9)

Tyre depth gauge / Vernier caliper

Service limit 1.5 mm Fig. 6.9

Note:
Tyre depth can also be checked by tyre wear
indicator (TWI). (Fig. 6.10)

TW
I
Tyre inflation pressure

Fig. 6.10
l Inflation pressure affects the tyre life to a
greater extent. So it is necessary to maintain proper
inflation pressure. (Fig. 6.11)

Tyre pressure gauge

Pressure:

Single and dual 1.75 kg/cm² (25 PSI)

Note:
Tyre pressure should be checked when the tyre is
cold.

Fig. 6.11

Tubeless tyre

l Refer page no 6-34 for puncture repairing

procedure and replacement of valve tubeless tyre.

REASSEMBLY

l Reassemble the wheel assembly front in the

reverse order of disassembly and removal. Before
assembling front wheel assembly, lubricate the axle front
and bearings.

6-3
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Before tightening axle nut, stroke the fork

assembly front several times to check for proper fork
action. Tighten the axle nut only after ensuring the fork
action.

Note:
While remounting front wheel assembly locate the
disc in between the brake pads after removing
cushion.

l Refer the explode view for details. (Fig. 6.12)

AXLE DIA. 15x250

PUNCHED WASHER 15.5x26x2.3 (2 nos.)

SPACER AXLE FRONT - 2 Nos.

TYRE TUBELESS FRONT 90/90 - 17

SPACER COMPLETE DISC FRONT BRAKE

BALL BEARING (6302Z C3) - 2 Nos.

DUST SEAL 1 - 2 Nos.

ALLOY WHEEL FRONT

VALVE TUBELESS TYRE HEXAGONAL FLANGED U’

NUT M14x1.5

SCREW SPECIAL M8 (6 nos.)

Fig. 6.12

6-4
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

DISC BRAKE SYSTEM - FRONT

BRAKE PADS

l Take out lever RH (front brake lever) by

removing the mounting bolt and flange nut. (Fig. 6.13)

10 mm spanner

Tightening torque 11 ± 0.5 Nm

Fig. 6.13

l Remove the caliper assembly mounting bolts

(M8x27 - 2 nos.) and take off the caliper assembly. (Fig.
6.14)

12 mm spanner

Tightening torque 23 ± 5 Nm

Note:
Wash mud and dust off around the front wheel
assembly and caliper assembly before dismantling
them.

Fig. 6.14

l Remove the plug pin (2 nos.) from the caliper

body. (Fig. 6.15)

Flat head screw driver

Tightening torque 2.5 ± 0.5 Nm

Fig. 6.15

l Remove pin hanger (2 nos.). (Fig. 6.16)

5 mm allen key

Tightening torque 17.5 ± 2.5 Nm

Fig. 6.16

6-5
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Pull out the pad complete inner and pad

complete outer by hand. (Fig. 6.17)

Fig. 6.17

Inspection of brake pads

l Observe the wear limit line marked on the pad

and check the wear condition of brake pads. (Fig. 6.18)
When the wear exceeds the limit line, replace the pad with
WEAR LIMIT
new ones .

BRAKE FLUID AND ITS HANDLING

Fig. 6.18
Inspecting brake fluid level

l Before inspecting the brake fluid level, place

your motorcycle firmly on the centre stand with the
handlebar kept straight.

l Inspect the brake fluid level in the reservoir, If

the oil level is found to be lower than the ‘Lower level’
mark provided on the reservoir, replenish the reservoir
with the brake fluid graded below. (Fig. 6.19)

TVS Grilling DOT 3 or DOT 4

Caution:
Since the brake system of this motorcycle has glycol
based brake fluid, do not use or mix different types of
brake fluid such as silicon based and
petroleum-based fluid for refilling the system,
Fig. 6.19
otherwise damage sustained will be serious.

Do not use any brake fluid taken from old or used or

unsealed containers.

Do not squeeze the brake lever while the reservoir

cap is removed. Otherwise brake fluid will sometimes
spout out.

6-6
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

Caution:
Do not place the removed reservoir cap on the
speedometer or on any other painted surfaces.
Brake fluid will damage the instrument cluster
lenses and painted parts.

Ensure no water enters the brake fluid container.

Because brake fluid has hygroscopic property, and
its boiling point falls excessively if water is mixed
with it.

Check the brake hose for cracks and hose joints for
leakage. If found any, replace the hose.

Air bleeding from the brake system

l If the front brake lever travel becomes more or

if any soft or spongy feel is observed in the lever, you
must carry out the air bleeding from the brake system.
Follow the procedure given below for bleeding the air:

Note:
It is best, if two persons perform air bleeding. Keep
the fluid level in the reservoir just above the ‘Lower
level’ mark during the bleeding procedure.

1. Dislocate the bleeder cap and attach a bleeder tube to the

bleeder screw as shown in figure (Fig. 6.20). A transparent
tube is useful in finding air bubble expelled from the
system. The tube must be submerged in a clean container
partially filled with brake fluid.

2. Fill the reservoir with the brake fluid. Fix back the reservoir
cap to prevent a spout of brake fluid and entry of dust.

Fig. 6.20
3. Allow the pressure in the hydraulic system by stroking the
brake lever rapidly several times and then hold the lever
tight.

4. Unscrew (open) the bleeder by half a turn and depress the

lever all the way down. Do not release the lever until the
bleeder valve is screwed in (tighten) again. (Fig. 6.21)

10 mm spanner

5. Repeat steps 5 and 6 until air bubbles disappear from the

bleeder tube or container. Tighten the bleeder securely.

Fig. 6.21

6-7
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

6. Remove the bleeder tube and install the cap bleeder.

7. After completing the bleeding operation, check the fluid

level in the reservoir and replenish if necessary.

Caution:
Do not reuse the brake fluid drained from the system.

Brake fluid replacement

l Boiling point of brake fluid falls considerably

with absorption of moisture which may take place during a
long period of use. Therefore, it is recommended to
replace old brake fluid with new one periodically.

Replace brake fl uid every 21000 km

l On changing brake fluid, extreme attention

should be paid so as not to mix any foreign materials
because they would block the return port of the master
cylinder resulting in the brake dragging or squeaking.

Perform the following procedure to change the brake fluid:

1. Attach a bleeder tube to the bleeder. Drain out the old brake
fluid by squeezing the brake lever with bleeder opened
until the brake fluid disappears in the bleeder tube.

2. After old brake fluid is drained out from the system

completely, carry out the same procedure as described in
‘air bleeding‘ from the brake system.

HOSE COMPLETE BRAKE (BRAKE HOSE)

l Inspect the hose complete brake for any crack

or leakage. If leakages found, replace the hose as below:

l Flush the brake fluid out by opening the

bleeder at caliper assembly with a tube on the bleeder
head to a clean container (refer brake bleeding).

6-8
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the banjo bolt (2 nos.) along with

gaskets (2 nos. on each side) from both the ends of the
hose complete brake. (Fig. 6.22)

12 mm spanner

Tightening torque 30 ± 2 Nm

Note:
Ensure the reassembly of new gaskets while
reconnecting the hose without fail to avoid leakage.

Fig. 6.22

l Dislocate the hose complete brake from the

clamp hose under bracket (Fig. 6.23A) and clamp brake
hose. (Fig. 6.23B)

l Dislocate and take out the brake hose from the

vehicle.

Caution:
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid
reacts chemically with paint, plastics, rubber
materials etc., and will damage them severely.

Fig. 6.23A Fig. 6.23B

l Reassemble the new brake hose in the reverse

order of dismantling.

l Assemble and tighten the banjo bolts at both

the ends of the hose along with gaskets.

Caution:
Assemble only new gaskets with the banjo bolts
during reassembly. Do not use old ones.

l Bleed the air from the brake circuit after

reassembly of brake hose (refer air bleeding procedure on
page no. 6-7).

Replace brake hose every 3 year

CALIPER ASSEMBLY - REMOVAL AND DISASSEMBLY

l Remove banjo bolt along with gaskets and

take off the hose from the caliper assembly. (Fig. 6.24)

12 mm spanner

Tightening torque 30 ± 2 Nm
Fig. 6.24

6-9
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove caliper assembly mounting bolts and

brake pads as explained in page no. 6-5.

l Remove the spring pad from the caliper

housing. (Fig. 6.25)

Nose plier

Fig. 6.25

l Dislocating the boot-B and bush boot pin from

the pin grooves and slide out the bracket complete front.
(Fig. 6. 26 )

Fig. 6.26

l Carefully pull out the boots from the caliper

assembly housing. (Fig. 6.27)

l Insert a spacer in between the piston caliper

and the caliper body (at pad position) and then apply
compressed air through inlet port of the caliper to slide both
the pistons out. (Fig. 6.28)
Fig. 6.27

Caution:
Be careful while applying compressed air as it
pushes the pistons forcefully. Do not use high
pressure air which may damage to pistons.

Note:
Do not try to pull out single piston as the
compressed air cannot push the second piston.

Do not use nose plier to pull out the pistons as it

damages the piston.
Fig. 6.28

6-10
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the dust seals 1 and 2 with a bent

plastic / brass tool to avoid scratches in the caliper bore.
(Fig. 6.29)

1
2

Fig. 6.29

l Remove the bleeder screw. (Fig. 6.30)

10 mm spanner

Tightening torque 5.5 ± 1.5 Nm

l Clean parts thoroughly with the fresh brake

fluid.

Caution:
Never use kerosene, petrol or other solvents for
cleaning the brake system. Otherwise rubber parts
will be damaged. Do not wash the pads and also take
Fig. 6.30
care that brake fluid is not splashed on pads.

Caliper assembly inspection

Inspect the following parts:

- Pin hangers for any bend.

- Bracket complete front for loose lugs.
- Piston and caliper bore for any scratches.
- Piston and dust seals for any damage.

Replace
l inspection. the defective parts after necessary

Caliper assembly - reassembly

Insert
l caliper the
body dust seal
seal - 1 and
grooves anddust sealperfect
ensure - 2 into the

seating without any twist (refer exploded view

on page no. 6-16 for assembly details).

l or Smear
DOT the piston
4 brake fluid with
and fresh
slowlyTVS Girling
insert into DOT
the 3

bore of caliper body without tapering. Ensure the piston is

sliding easily into the bore.

6-11
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Assemble the spring pad in the caliper body

and fix back the boot-B and bush boot pin.

l Apply little grease on the pin bolts of bracket

complete front and assemble the bracket into the caliper
body while ensuring the proper seating of both boots in the
pin bolt grooves.

l Assemble the pad inner and pad outer. Locate

the pin hangers properly into the holes of pad inner and
pad outer and assemble it. Fix back plug pin and bleeder
screw.

l Remount the caliper assembly into the fork leg

and reconnect the brake hose along with gaskets. Bleed
the system thoroughly.

DISC PLATE SERVICING

Inspection (with disc mounted on wheels)

l Face out of the disc plate should not be more

than the limit specified below. Measure disc plate face out
on the largest periphery of the disc plate with a dial
indicator. (Fig. 6.31)

l If the face out exceeds the limits, check

whether the cause lies in the front wheel bearing or the
disc plate itself. Replace defective parts.

Magnetic stand

Dial gauge (0.01)

Fig. 6.31

Standard 0.05 mm

Service limit 0.10 mm

Note:
Wipe out disc plate surface with a dry soft cloth
before inspection.

l Measure thickness of the disc plate at the

worn-out portion as shown. (Fig. 6.32)

l If the thickness measured is less than the

limits, replace the disc plate (refer page no. 6-1 for disc
plate removal procedure).

Micrometer

Standard 4.5 mm

Service limit 4.0 mm

Fig. 6.32

6-12
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

MASTER CYLINDER - REMOVAL AND DISASSEMBLY

l Dislocate the dust cap (A) and loosen the lock A

nut of rear view mirror. Now, remove the rear view mirror
gently. (Fig. 6.33)

14 mm spanner

Tightening torque 28.5 ± 6.5 Nm

Caution:
While reassembling the mirror care should be taken Fig. 6.33
not to damage the mounting threads of the master
cylinder.

l Bleed out brake system completely as

explained earlier.

l Remove the banjo bolt and brake hose from

the master cylinder assembly along with the gaskets (2
nos.). (Fig. 6.34)

14 mm spanner

Tightening torque 30 ± 2 Nm

Fig. 6.34

l Disconnect the wiring harness of the stop

lamp switch from the switch terminal. (Fig. 6.35)

Fig. 6.35

l Take out the lever RH (front brake lever) by

removing the mounting bolt and flange nut. (Fig. 6.36)

10 mm spanner

Tightening torque 30 ± 2 Nm

Fig. 6.36

6-13
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the master cylinder fluid reservoir cap

by unscrewing screws (2 nos.). (Fig. 6.37)

Phillips head screw driver

Tightening torque 1.5 ± 0.5 Nm

l Take out plate diaphragm and diaphragm from

the reservoir.

Fig. 6.37

l Take out the master cylinder by unscrewing

the mounting bolts (2 nos.) of holder master cylinder. (Fig.
6.38)

10 mm spanner

Tightening torque 10 ± 2 Nm

Note:
Hold the master cylinder while removing the holder
mounting bolts in-order to avoid falling.

Fig. 6.38

l Remove the mounting screw of stop lamp

switch and take out the stop lamp switch. (Fig. 6.39)

Phillips screw driver

Fig. 6.39

l Remove the dust boot from the master

cylinder using a blunt tool. (Fig. 6.40)

Note:
While removing boot, care must be taken not to
damage it.

Fig. 6.40

6-14
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Holding the master cylinder by hand slightly

press the piston with thumb finger and remove the circlip
from the master cylinder using a circlip plier without
damaging the piston and cylinder. (Fig. 6.41)

Circlip plier

Note:
Ensure that the circlip is seated properly in its position
after installation.

Fig. 6.41

l Slowly pull out the piston along with the

P - cup, S - cup and spring. (Fig. 6.42) Clean the system
thoroughly using fresh brake fluid.

Caution:
Never use kerosene, petrol or other solvents for
cleaning the brake system. Otherwise rubber parts
will get damaged.

Do not wash the brake pads. Ensure that the brake

fluid is not in contact with the pads surface.

Fig. 6.42
Inspection of master cylinder

Inspect the following parts:

- Master cylinder for any scratches or any other

damages.
- Piston and cup surface for scratches or other
damages.
- Piston boot and other components for wear and
damages.
- Master cylinder recuperation and feed port for any
blockage, if so clear the block using compressed air.

Afterthe
l replace therespective
above inspection,
parts. if any defect found

REASSEMBLY

l Reassemble the master cylinder in the reverse

order of dismantling. Refer Fig. 6.43 for assembly details.

Caution:
Apply the brake fluid to the cylinder bore and all
internal parts before inserting piston assembly into
the bore.

6-15
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

SCREW RESERVOIR CAP (2 Nos)

ASSEMBLY RESERVOIR CAP

HAND LEVER BOLT

PLATE DIAPHRAGM
SNAP RING BOOTS

CUP
S CUP
DIAPHRAGM

PISTON

HOLDER BOLT (2 Nos)

SPRING P

HOLDER

MASTER CYLINDER

NUT
GASKET (4 Nos.)

WAVE SPRING WASHER BANJO BOLTS (2 Nos.)

HEX FL BOLT M6x16

HOSE DISC BRAKE FRONT

CLAMP BRAKE HOSE

PLUG PIN (2 Nos.)

BLEEDER SCREW

BOOT B

PIN HANGER (2 Nos.)

SPRING PAD

PAD COMPLETE OUTER

CALIPER ASSEMBLY

BUSH BOOT PIN

PISTON CALIPER (2 Nos.)

PAD COMPLETE INNER

HEX FLANGED BOLT M8x27 (2 Nos.)

BRACKET COMPLETE FRONT

Fig. 6.43

6-16
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remount the master cylinder to the handle bar

and fix the holder in ‘UP’ direction. (Fig. 6.44)

10 mm spanner

Tightening torque 10 ± 2 Nm

Note:
Always tighten the top bolt first and then the bottom
one.

Mount master cylinder to the handle bar such that

reservoir becomes horizontal when the bike is Fig. 6.44
placed on centre stand and steering is kept straight.

l Fix the brake hose to the master cylinder outlet

port along with the banjo bolt and gaskets.

l Fill the reservoir with fresh TVS Girling DOT3 or

DOT4 brake fluid above the level ‘LOWER’ mark on the
reservoir and bleed the system thoroughly. (Fig. 6.45)

l Fix the reservoir cap along with diaphragm and

plate diaphragm and tighten screws. Connect the wiring
harness to the brake light switch.
Fig. 6.45

l Replace the following parts every 21,000 km

- Piston along with P-cup, S-cup, spring and boot.

- Reservoir cap and diaphragm.

- Caliper dust seal - 1 and dust seal - 2.

FORK ASSEMBLY FRONT

OIL CHANGE

l Dismantle the wheel assembly front (refer

page no 6-1 for dismantling procedure).

l Remove caliper assembly along with hose

complete brake. Keep some cushion in between the brake
pads, to avoid binding.

l Remove the CRR pan head screws (M6x16 -

2 nos.) from the fender front L & R.(Fig. 6.46)

Phillips screw driver

Fig. 6.46
Tightening torque 3 ± 1 Nm

6-17
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove hexagonal screws (M8x20 - 4 nos.)

along with wave spring washer (4 nos) from the fender
front mounting. (Fig. 6.47)

13 mm spanner

Tightening torque 18 ± 3 Nm

l Take out brace front fender along with spacer

front fender (4 nos.).

Fig. 6.47

l Loosen hexagonal socket head screws (A)

(M8x30 - 2 nos.) from the handle bar assembly mounting.
(Fig. 6.48)

6 mm allen key
B A A B

Tightening torque 16 ± 2 Nm

l Loosen hexagonal socket head screws (B)

(M8x45 - 2 nos.) from the upper bracket complete
mounting (fork upper mounting). (Fig. 6.48)

Fig. 6.48
6 mm allen key

Tightening torque 19 ± 2 Nm

l Loosen the hexagonal screws (M10x40 -

2 nos.) of lower bracket complete (fork lower mounting).
(Fig. 6.49)

14 mm spanner

Tightening torque 36 ± 4 Nm

Note:
Hold the fork leg assembly while loosening the
bottom mounting bolts. Else it may fall.

Fig. 6.49

6-18
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l the Slightly pull outtill

under bracket thethe
fork
topleg
nutassembly RH from
is accessible

and tighten the lower bracket hexagonal bolt again. (Fig.

6.50A)

Caution:
Do not over tight the lower mounting screw, as it may
damage the inner tube assembly of fork leg.

l of Using
front anleg
fork 17 assembly
mm spanner, loosen the
to facilitate lock nut
easy

dismantling of fork leg. (Fig. 6.50B) Fig. 6.50A Fig. 6.50B

17 mm spanner

Tightening torque 24 ± 2 Nm

Now,
l screw andonce
pull again
out theloosen the
fork leg lower mounting
assembly RH.

l the Remove the lock

leg assembly frontnut along
fork. ([Link] ‘O’
6.51) ring from

Caution:
Remove the lock nut with constant handgrip on nut.
The nut is subject to spring load and may jump out
Fig. 6.51
incase of loose handling.

l forkInleg
similar manner,
assembly LH. remove and dismantle the

l Take out the washer, spacer front fork, washer

spring seat and spring front fork. (Fig. 6.52)

Fig. 6.52

l Turn the leg assembly front fork upside down,

holding outer tube by hand, pump inner tube ‘in’ and ‘out’ to
drain the oil completely. (Fig. 6.53)

Note:
Hold the leg assembly front fork inverted for few
minutes to drain the oil completely.

l Clean leg assembly front fork with kerosene

and drain completely.

Fig. 6.53

6-19
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Fill little more then the specified amount of

fresh fork oil . (Fig. 6.54)

Oil quantity 325 ± 2 cc per leg

Oil specification KYB G10

Fig. 6.54

l Adjust the special tool (oil level gauge) to the

specified height. Hold the front fork vertically and take out
the excess oil from the front fork using the special tool as
shown. (Fig. 6.55)

Note :
When adjusting the oil level, Compress the inner tube
fully.

031 180 0 Fork oil level gauge

Oil level 114 mm

Fig. 6.55
l Check spring front fork length (refer page no.
6-22 for checking procedure).

l Install spring front fork with its smaller pitch

end facing upward. (Fig. 6.56)

l Assemble washer spring seat, spacer front

fork and washer.

l Before installing cap nut front fork, lightly apply

grease to the ‘O’ ring. Remount for leg assembly LH & RH.

lT i ghten top mount i ng sc rews ( for k

Fig. 6.56
upper mounting) to the specified torque (refer chapter ”Service
information page no. 7-9 for
torque sheet).

l Tighten hexagonal bolts of lower bracket (fork

bottom mounting) to the specified torque (refer chapter ”Service
information page no. 7-9 for torque sheet)..

l Reassemble front fender and front wheel

assembly in the reverse order of removal.

l Re-fix the caliper assembly front fork and

ensure the proper working of brake.

6-20
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

LEG ASSEMBLY FRONT FORK- DISASSEMBLY

l Remove both the leg assembly front fork LH

and RH (refer page no. 6- 17 ) .

l Drain out the front fork oil as explained earlier.

l Remove the seal dust front fork (dust seal)

from the outer tube while ensuring no damage to the dust
seal, inner surface of outer tube and outer surface of inner
tube. (Fig. 6.57A)

l Remove the snap ring from the outer tube 6.57A Fig. 6.57B
while ensuring no damage to the inner surface of outer
tube and outer surface of inner tube. (Fig. 6.57B)

Flat screw driver

Caution:
While reassembling, replace the dust seal incase
found damaged.

l Us ing the special tool, holding the piston,

remove hexagonal allen screw connecting fork outer tube
and inner tube. (Fig. 6.58)

Fig. 6.58
N931 011 0 Tool front cylinder holder

8mm allen key

Tightening torque 23 ± 3 Nm

Note:
Please remember to replace the gasket with a new
one reassembling.

l Hold the inner and outer tube using both the

hands. Pull out the tube inner (inner tube) from the tube
outer (outer tube) along with cylinder front fork (piston
front fork), DU bush and oil seal.
Fig. 6.59

l Remove spindle tapper from the bottom of the

piston front fork. If it does not come out with piston, remove it
from the fork outer tube. (Fig. 6.59)

l Remove piston front fork and spring front fork

from the inner tube assembly. (Fig. 6.60)

Fig. 6.60 Fig.

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 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

INSPECTION

l Before inspection clean all the components

with a cleaning solvent.

l Inspect piston front fork and ring damper

piston for wear and any damage. (Fig.6.61) Replace with
new one if any damage is noticed.

Inspect
l sliding the outer
surface (innersurface
surface)ofofinner
outertube
tubeand
for

any scuffing, scratches, dents, plating peel off etc.. Fig. 6.61
Replace the inner tube or outer tube if it has surface
defects / flaws. If the inner tube has damage / dent on
surface, replace the oil seal and inner tube together.

l or Similarly,
wear. inspect
Replace the DU
if found bush for any damage
any.

Spring front fork

A

l Measure the free length (A) of the spring front

fork. If the length is shorter than service limit or
deformation of spring, replace it with a new one. (Fig.
6.62) Fig. 6.62

Service limit length (A) 428 mm

REASSEMBLY

Reassemble and remount the leg assemblies front fork in the

reverse order of disassembly while carrying out the following
steps.

l Refer leg assembly front fork exploded view

(Fig. 6.63) for assembly details.

l Make sure al l components are clean.

Lubricate the inner surface of the outer tube and outer
surface of the inner tube.

l Insert the fork piston along with the rebound

spring slowly, so that it slides down into the tube inner
and protrudes from the bottom.

l Assemble spindle tapper in the piston. now

insert the outer tube in the inner tube along with DU bush.

l Apply thread lock to the allen screw of the

piston before assembly.
Fig. 6.63

6-22
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Assemble the washer spring seat, spacer front

fork and washer .

l( Install
Fig. the new oil seal using the special tool.
6.64A)

N931 009 0 Tool fork oil seal

Note:
Before installing the oil seal, apply little grease (MOS
) on the lip of oil2 seal.

l Reassemble the snap ring.

Fig. 6.64A Fig. 6.64B

l( Reassemble
Fig. 6.64B) the dust seal using special tool.

N931 009 0 Tool fork oil seal

l Fill up the fork oil as per specification.

Note:
After filling up, slowly pump the leg assembly front
fork up and down to remove air lock / gaps. Install the
spring with its smaller pitch up-ward. Before
installing the lock nut, apply grease to the ‘O’ ring.

l Remount the front fork assembly.

L OWER BRACKET COMP L ETE (STEERING

STEM) - DISASSEMBLY

l Remove the CRR pan head screw (M5x16 -

2 nos.) from the housing speedometer rear moun t i ng
and r emove t he hous i ng speedometer rear. (Fig. 6.65)

Phillips head screw driver Fig. 6.65

Tightening torque 3 ± 1 Nm

l Di sconnec t wi r i ng socket f rom the

speedometer assembly.

l Remove the CRR pan head screw (M6x25 -

2 nos.) housing head lamp front top mounting. (Fig. 6.66)

Phillips head screw driver

Tightening torque 3 ± 1 Nm
Fig. 6.66

6-23
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the hexagonal flange bolt (M6x16 -

2 nos.) from the bottom mounting housing head lamp
(both LH and RH) while holding the housing by one hand.
(Fig. 6.67)

10 mm spanner

Tightening torque 3 ± 1 Nm

l Take out the housing head lamp by gently

disconnecting and dislocating the wiring sockets of main
wiring harness.
Fig. 6.67
l Remove both the leg assembly front fork (refer
page no. 6-17).

l Take out cap lock nut (A) and remove lock nut
steering along with the special washer. (Fig. 6.68)

32 mm spanner A

Tightening torque 80 ± 20 Nm

l Gently lift the handle bar assembly, support

and hang it at the side of the fuel tank complete while taking
care of painted surface of the tank. Fig. 6.68

Note:
Ensure that the control cables are not stretched too
much or bent.

l Unlock the lock washer arrester steering using

a blunt tool. (Fig. 6.69A)

l Remove the arrester steering stem top using a

special tool. (Fig. 6.69B)

N931 014 0 Tool steering nut

Fig. 6.69A Fig. 6.69B

l Take out the lock washer arrester steering.

(Fig. 6.70A)

l Remove the arrester steering stem using the

special tool while holding the lower bracket complete and
draw out bracket. (Fig. 6.70B)

N931 014 0 Tool steering nut

Note:
Steering balls tend to fall during bracket removal,
hence they should be collected carefully.

Fig. 6.70A Fig. 6.70B

6-24
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the dust seal steering upper.

(Fig. 6.71A)

l Remove cone top. (Fig. 6.71B)

l Remove upper and lower steering balls.

Position Qty Size

Upper 18 nos 6.35 mm

Lower 18 nos 6.35 mm

Fig. 6.71A Fig. 6.71B

l Assembly the special tool on the frame and

slowly draw out cup top from the steering pivot pipe (frame).
(Fig. 6.72)

M931 016 0 Remover steering cup

Note:
While fixing the special tool, ensure that the tool is
seated properly on the steering pivot tube and the
lock plate of the tool is locked with the steering
stopper properly.

l In similar manner, remove the cup bottom

Fig. 6.72
from the frame.

l Remove the cone bottom and dust seal

steering lower fitted on the lower bracket complete. (Fig.
6.73)

Chisel / metal hammer

INSPECTION

Before inspection clean all the components with kerosene.

Inspect the removed parts for the following abnormalities and
replace the defective with new.
Fig. 6.73

- Handle bar distortion.

- Races and cones for wear, pitting, rusting and
indentation. (Fig. 6.74)
- Worn or damaged steel balls / ball cage and rusting.
(Fig. 6.74)

Note:
Always replace cup, cone and races as a set only.

Fig. 6.74

6-25
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l Reassemble the lower bracket complete, leg

assembly front fork LH & RH, handle bar assembly and
wheel assembly front in the reverse order of disassembly
while carrying out the following steps:

l Refer lower bracket complete exploded view

(Fig. 6.75) for assembly details.

ARRESTER STEERING STEM TOP

LOCK WASHER ARRESTER STEERING

DUST SEAL UPPER ARRESTER STEERING STEM

LOWER BRACKET COMPLETE

TOP

BALL STEERING UPPER (18 Nos.) CONE

CUP TOP

CUP BOTTOM

BOTTOM BALL STEERING LOWER (18 Nos.)

DUST SEAL STEERING LOWER CONE

Fig. 6.75

Cup bottom and cup top

l Assemble cup bottom and cup top by using a

special tool. (Fig. 6.76)

NB31 004 0 Sleeve steering cup

Note:
Always replace the cup, cone and races as a set.

Fig. 6.76

6-26
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

Steering balls

l Apply grease to the cup top and cup bottom.

(Fig. 6.77)

Bechem premium grade 3

l Install specified quantity of steering balls at

cup top and cup bottom (refer page no. 6-25 for the
specified quantity).

Fig. 6.77 A Fig. 6.77 B

Cone bottom

l Install cone bottom to the lower bracket

complete (steering stem) by using the special tool and
apply grease. (Fig. 6.78)

N931 013 0 Tool cone bottom installer

Reassemble
l with thedust
cone top and lower bracket
seal upper complete
in the along

reverse order of disassembly. Assemble and tighten the

arrester steering stem to 30 ~ 35 Nm.

Fig. 6.78

N931 014 0 Tool steering nut

Loosen
l loosen) andthe arrester
re-tight it to steering
6 ~ 8 [Link] 0 Nm (fully

l andTurn
left, the
five under
or six bracket
times forcomplete to the right
proper seating of

steering ball (Fig. 6.79) and re-tight the arrester to 6 ~ 8 Nm

torque again.

Now assemble
l steering the lock
and Assemble washer
steering arrester
arrester top

and tighten it till it touches lock washer.

Fig. 6.79

Now loosen
l grooves steering
till it matches arrester
with top tab
the next andinalign
the the

lock washer.

l withFold
the the lock washer
grooves tabs upside
in the arrester andtop
steering match

l barAssemble
[Link] upper
Finally bracket
tighten thealong with
locknut handle

steering to the specified torque (60 ~ 100 Nm).

6-27
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

Warning:
Steering should be adjusted correctly for smooth
movement of handlebar and safe riding. Stiff steering
prevents smooth movement of handlebar resulting in
poor directional stability and too loose steering will
cause vibration and damage to the steering races .

Note:
After adjustment, ensure the handlebar moves
smoothly without any jerk or sticky. When slowly
moved by hand it moves freely from center position
to either left or right with its own weight.

WHEEL ASSEMBLY REAR - REMOVAL

l Remove the chain (refer chapter “Periodic

maintenance” page no. 2-32 for chain removal procedure).

l Loosen the chain adjusting screw from chain

adjuster complete LH and RH. (Fig. 6.80)

Fig. 6.80
12 mm spanner

l Remove ‘U’ nut (M14x1.50) from the axle

complete rear along with washer. (Fig. 6.81A)

22 mm spanner

Tightening torque 78 ± 18 Nm

l Pull out the axle complete rear by gently

tapping at other end. (Fig. 6.81B)

l Dislocate the caliper assembly from the slot

provided on swing arm complete by pulling it towards rear
side. Fig. 6.81A Fig. 6.81B

l Take out wheel assembly rear.

l Remove the sprocket drum assembly along

with spacer rear axle LH from the alloy wheel rear.

DISC REPLACEMENT

l Remove spacer rear axle R. (Fig. 6.82)

Fig. 6.82

6-28
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the screw special (M8 - 3 nos) from

the disc plate mounting and take out disc plate from the
alloy wheel rear. (Fig. 6.83)

6 mm allen key

Tightening torque 31 ± 3 Nm

Fig. 6.83

Wheel bearing removal

Warning:
It is recommended to remove the bearings only in
case of replacement.

Note:
Before heating the wheel assembly rear it is
recommended to remove the absorber rear wheel hub
shock. (Fig. 6.84)

Fig. 6.84

l Remove oil seal using the special tool.

(Fig. 6.85)

031 240 1 Universal oil seal remover

Fig. 6.85

l Place the wheel assembly rear (brake drum) on

a hot plate and heat to approximately 125°C. (Fig. 6.86)

Hot plate

Fig. 6.86

6-29
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Draw out the bearing from the wheel

assembly rear. (Fig. 6.87)

Drift

Nylon hammer

Fig. 6.87

S P R O C K E T D R U M A S S E M B L Y - DISASSEMBLY

l Take out the spacer rear axle LH from the

sprocket drum assembly. (Fig. 6.88)

Fig. 6.88

l Remove the dust seal using special tool.

(Fig. 6.89)

031 240 1 Universal oil seal remover

Fig. 6.89

l Remove the ‘U’ nut flanged (M10 - 4 nos.).

(Fig. 6.90)

12 mm spanner

Tightening torque 48 ± 2 Nm

l Take out the sprocket rear and bolt rear

sprocket (4 nos.).

Fig. 6.90

6-30
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Heat the drum rear sprocket on a hot plate to

approximately 125° C. (Fig. 6.91A)

Hot plate

l Draw out ball bearing, from drum rear sprocket

along with the shaft rear sprocket. (Fig. 6.91B)

Drift

Nylon hammer

Fig. 6.91A Fig. 6.91B

INSPECTION

Before inspection, clean all the components with kerosene

and lubricate the bearings immediately after cleaning. NORMAL WORN-OUT

l Inspect wheel bearings, axle complete rear

and alloy wheel rear (refer page no. 6-2 for checking
procedure).

l Clean and inspect the drive chain as explained

in chapter ”Periodic maintenance” page 2-32.

Sprocket rear
Fig. 6.92

l Inspect sprocket rear teeth for wear. If they are

worn-out as illustrated (Fig. 6.92), replace the sprocket
with a new one.

Absorber rear wheel hub shock

l Inspect the absorber rear wheel hub shock for

wear, deformation or damage and replace with new if
required. (Fig. 6.93)

Tyre inflation pressure

l Tyre inflation pressure affects the tyre life to a

Fig. 6.93
great extent. So it is necessary to maintain the proper tyre
pressure. (Fig. 6.94)

Tyre pressure gauge

Tyre pressure
2
Solo riding 2.00 kg/cm (28 PSI)
2
Dual riding 2.25 kg/cm (32 PSI)

Note:
Tyre pressure should be checked when the tyre is
cold. Low tyre pressure consumes more fuel.

Fig. 6.94

6-31
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l Reassemble and remount the wheel assembly

rear in the reverse order of disassembly. Also carry out the
following steps. Refer wheel assembly exploded view (Fig.
6.95) for assembly details.

l Before assembling rear wheel assembly,

lubricate the axle rear and bearings.

COVER DISC REAR

U’ NUT M14x1.5

BALL BEARING 15x42x13

SPACER COMPLETE
SCREW SPECIAL M8 (3
Nos.)

TYRE TUBELESS REAR

VALVE TUBELESS TYRE

CALIPER DISC BRAKE REAR

DISC PLATE

DUST SEAL 1

BALL BEARING

HEX. BOLT M10x1.25x35 (4 Nos.)

SHAFT REAR SPROCKET DRUM

BALL BEARING
ALLOY WHEEL REAR

ABSORBER REAR WHEEL HUB SHOCK

U’ NUT FLANGED 10x1.25 (4 Nos.)

DUST SEAL SPRING WASHER - 2 Nos.

DRUM REAR SPROCKET

SCREW M8x45 - 2 Nos.

CLAMP CHAIN ADJUSTOR - 2 Nos. WAVE

SPROCKET REAR WHEEL
SPACER AXLE REAR LH CHAIN

ADJUSTER COMPLETE - 2 Nos.

WASHER 14.5x32x3.2 - 2 Nos.

REAR AXLE

Fig. 6.95

6-32
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Make sure that the slot (A) in the bracket

complete caliper assembly fits over the stopper (B) on the
swing arm assembly. (Fig. 6.96)

Note:
While reassembling the disc plate apply specified
thread lock to the disc plate mounting bolts.
B

After remounting the wheel assembly rear, readjust A

the chain slackness (refer chapter “Periodic
maintenance” page no. 2-32). Fig. 6.96

TUBELESS TYRE

PUNCTURE REPAIR

Tubeless tyre provides the benefit of easy repairing the

punctured tyre without removing the wheel assembly. Hence
repairing can be performed in vehicle stand still condition and
repairing procedure is as follows:

l Keep the bike firmly on center stand.

l Identify the punctured location and make a

visible mark. (Fig. 6.97A)

l Pull out nail or puncture causing object from

the tyre using a combination plier. (Fig. 6.97B)

Combination plier

Fig. 6.97A Fig. 6.97B

l Insert the reaming tool exactly into the

punctured point and carefully ream the punctured hole.
(Fig. 6.98)

Fig. 6.98

6-33
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Take a cold mending strip and insert it

between the strip holding jaws of strip inserting tool. (Fig.
6.99)

Note:
After inserting the strip, ensure that strip is held at the
middle point of strip length. (Fig. 6.99)

Fig. 6.99

l Insert the strip inserting tool along with strip

into the reamed hole till the strip goes inside at least more
than half of its folded length. (Fig. 6.100)

l Leaving the strip in that position, gently pull out

the strip inserting tool.

Note:
While pulling out the strip inserting tool, ensure that
the strip does not come out along with the tool.

Fig. 6.100

l Take out the tool completely and cut remaining

strip leaving 5 mm from surface of tyre. (Fig. 6.101)

l Fill air to the specified limit and checkout for

any leakage.

Caution: 5 mm
Ensure, the wheel assembly is checked for proper
balancing after every tyre puncture repair or tyre
replacement for better vehicle stability (refer chapter
“Periodic maintenance” page no. 2-48 for detailed
procedure of wheel balancing).
Fig. 6.101

REPLACEMENT OF VALVE TUBELESS TYRE

Valve tubeless tyre in RTR 200 alloy wheel can be replaced by

following below given procedure:

l Remove wheel assembly from the vehicle

(refer page no. 6-1 & 6-28 for wheel assembly removal
procedure)

6-34
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the tyre from the alloy wheel.

Caution:
Use of normal tyre levers for removal of tubeless
tyre by any puncture repair shop may cause severe
damage to the tyre seating area of alloy wheel, which
leads to improper sealing and loss of air. Hence it is
recommended that removal of tubeless tyre is
performed by using a tyre removal machine.

l Keep the alloy wheel on a level surface.

l Applying gentle load on valve tail, cut the valve

tubeless tyre at the alloy wheel neck area and take out
separated piece . (Fig. 6.102A)

Hand knife

l Push out remaining part of valve from the alloy

wheel using a suitable tool. (Fig. 6.102B)

l Locate and seat new valve tubeless tyre to the

Fig. 6.102A Fig. 6.102B
valve mounting hole from outer periphery of alloy wheel.
(Fig. 6.103A)

l Using a suitable mandrel, gently tap the valve

head and ensure that valve is seated properly. (Fig.6.103B)

l Reassemble parts in reverse order of

disassembly.

Note:
While reassembling the tyre, ensure that the arrow
mark (A) on the tyre faces the direction of wheel
rotation. (Fig. 6.104)
Fig. 6.103A Fig. 6.103B

It is recommended to apply a little amount of soap

solution over the alloy wheel at the tyre seating area
for ease of tyre assembly.

Caution:
Ensure, the wheel assembly is checked for proper
balancing after every tyre puncture repair or tyre
replacement for better vehicle stability (refer chapter A
“Periodic maintenance” page no. 2-48 for detailed
procedure of wheel balancing).

Fig. 6.104

6-35
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

DISC BRAKE SYSTEM REAR

BRAKE PADS

l Remove wheel assy rear along with the disc

plate (refer page no. 6-28 for wheel assy rear removal
procedure).

l Take out the bracket complete along with the

caliper assembly and take out the caliper cover.

Fig. 6.105
l Remove the plug pin from the caliper housing.
(Fig. 6.105)

Flat head screw driver

Tightening torque 2.5 ± 5 Nm

l Remove the pin hanger. (Fig.6.106)

5 mm spanner

Tightening torque 17.5 ± 2.5 Nm

Fig. 6.106
l Take out the pad complete inner and pad
complete outer. (Fig. 6.107)

Fig. 6.107
Inspection of brake pads

l Observe the wear limit line marked on the pad

and check the wear condition of brake pads. (Fig. 6.108)
When the wear exceeds the limit line, replace the pad with
new ones. Wear limit

Fig. 6.108

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 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

BRAKE FLUID

Inspection of brake fluid level

l Remove cover frame R (refer chapter MAXIMUM

“Periodic maintenance” page 2-4 for removal procedure).
MINIMUM
Place the vehicle in center stand. Inspect the brake fluid
level in the reservoir.

l The brake fluid level in the reservoir should be

at the maximum mark provided in the reservoir. Fig. 6.109)
(

Fig. 6.109
l If the level is below lower level mark, replenish
the level up to the maximum level.

l Remove the cap and take out the diaphragm

and fill fresh brake fluid of recommended grade. (Fig.
6.110)

Brake fluid TVS Griling DOT3 / DOT4

Air bleeding

l If the rear brake pedal travel becomes more or

if any soft or spongy feel is observed in the lever, you
Fig. 6.110
must carry out the air bleeding from the brake system.

Brake fluid replacement

l Boiling point of brake fluid falls considerably

with absorption of moisture which may take place during a
long period of use. Therefore, it is recommended to
replace old brake fluid with new one periodically.

Replace brake fl uid every 21000 km

l Refer page 6-6, 6-7 & 6-8 for brake fluid

handling, air bleeding from the brake system and brake
fluid replacement procedure.

HOSE COMPLETE BRAKE REAR

l Inspect the hose complete brake for any crack

or leakage. If leakages found, replace the hose as
described below:

l Flush the brake fluid out by opening the

bleeder at caliper assembly with a tube on the bleeder
head to a clean container (refer brake bleeding).

6-37
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the banjo bolt (2 nos.) along with

gaskets (2 nos. on each side) from both the ends of the
hose complete brake. (Fig. 6.111)

12 mm spanner

Tightening torque 33 ± 5 Nm

Note:
Ensure the reassembly of new gaskets while
reconnecting the hose without fail to avoid leakage.

Fig. 6.111
l Dislocate the hose complete brake rear from
the clamps of swing arm assembly and care fully take out.

Caution:
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid
reacts chemically with paint, plastics, rubber
materials etc., and will damage them severely.

l Reassemble the new brake hose in the reverse

order of dismantling.

l Assemble and tighten the banjo bolts at both

the ends of the hose along with gaskets.

Caution:
Assemble only new gaskets with the banjo bolts
during reassembly. Do not use old ones.

l Bleed the air from the brake circuit after

reassembly of brake hose (refer air bleeding procedure on
page no. 6-7).

Replace brake hose every 3 year

CALIPER ASSEMBLY - REMOVAL AND DISASSEMBLY

l Bleed out brake fluid from the brake system.

l Remove banjo bolt and take out the gaskets.

(Fig. 6.112)

12 mm spanner

Tightening torque 30 ± 2 Nm

Fig. 6.112

6-38
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove wheel assy rear along with the disc

plate (refer page no. 6-28 for wheel assy rear removal).

l Take out bracket complete along with the

caliper assembly.

l Remove plug pin from the caliper housing.

(Fig. 6.113)

Flat head screw driver

Tightening torque 2.5 ± 5 Nm Fig. 6.113

l Remove the pin hanger. (Fig.6.114)

5 mm spanner

Tightening torque 17.5 ± 2.5 Nm

Fig. 6.114

l Take out the pad complete inner and pad

complete outer. (Fig. 6.115)

Fig. 6.115

l Remove spring pad from the caliper housing.

(Fig. 6.116)

Fig. 6.116

6-39
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the bracket complete rear caliper by

sliding out after dislocating boot-B and bush boot pin from
the pin grooves. (Fig. 6.117)

Fig. 6.117

l Carefully pull out the cap piston (A) and boots

(B)from the cal iper assembly housing. (Fig. 6.118)
B

Fig. 6.118

l Insert a spacer between piston caliper and the

caliper housing (at pad position) and then apply
compressed air through the inlet port of the caliper to slide
pistons out. (Fig. 6.119)

Caution:
Be careful while applying compressed air as it will
shoot the piston forcefully. Do not use high pressure
air to prevent damage to the piston.

Do not use nose plier to pull out the piston as it may

cause scratches.
Fig. 6.119

l Remove the dust seals with a bent plastic /

brass tool to avoid scratches on the caliper bore. (Fig.
6.120)

Fig. 6.120

6-40
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Unplug cap bleeder and remove bleeder

screw. (Fig. 6.121)

8 mm spanner

Tightening torque 5.5 ± 1.5 Nm

l Clean the parts thoroughly with fresh brake

fluid.

Caution:
Never use kerosene, petrol or other solvents for
cleaning the brake system. Otherwise rubber parts Fig. 6.121
will be damaged. Do not wash the pads and also take
care that brake fluid is not splashed on pads.

Caliper assembly inspection

Inspect the following parts:

- Pin hangers for any bend.

- Bracket complete front for loose lugs.
- Piston and caliper bore for any scratches.
- Piston and dust seals for any damage.

l After completion of above inspection, replace

the defective parts as required.

Caliper assembly - reassembly

l Insert the dust seals in the caliper housing

grooves and ensure perfect seating without any twist of the
seals (refer exploded view on
page no. 6-43 for details).

l or Smear
DOT the piston
4 brake fluid with
and fresh
slowlyTVS Girling
insert into DOT
the 3

bore of caliper body without tapering. Ensure the piston is

sliding easily into the bore.

l Assemble the spring pad in he caliper housing.

l Assemble boot-B and bush boot pin in the

caliper housing.

l Apply little grease to the pin bolts of bracket

complete caliper and assemble the bracket by ensuring
proper seating of both the boots in their respective
grooves.

l Assemble pad inner and pad outer.

6-41
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Assemble the pin hangers by locating it

properly in the holes of the pad inner and outer.

l Fix the plug pin, bleeder screw and cap

bleeder.

l Remount wheel assembly rear along with

spacer RH.

l Remount caliper assembly rear by locating the

slot provided on bracket comp caliper with the stopper
provided on swing arm complete. Assemble the axle and
tighten ‘U’ nut of rear axle.

l Remount brake hose along with gaskets and

bleed the system by referring the procedure explained on
page no. 6-7.

DISC PLATE - SERVICING

Inspection (with disc mounted on wheels)

l Inspect the disc plate as explained in front disc

plate servicing (refer page 6-12 for disc plate inspection).

Disc plate replacement

l Replace the disc plate if found to be defective

(refer page no. 6-28 for removal procedure).

MASTER CYLINDER REAR (REAR DISC BRAKE)

- REMOVAL AND DISASSEMBLY

l Remove the cover frame RH (refer chapter

“Periodic maintenance” page no 2-4 for cover frame R
removal procedure).

l Bleed the brake system completely.

l Remove the banjo bolt along with gasket

(2 nos. on each side) from the master cylinder rear. (Fig.
6.122)

12 mm spanner

Tightening torque 30 ± 2 Nm

Fig. 6.112

6-42
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the split pin and take out cotter pin

from the rear master cylinder. (Fig. 6.123)

Nose plier

Fig. 6.123

l Remove clip hose (A) and take out hose oil (B).
(Fig. 6. 124)

B
Nose plier

Fig. 6.124

l Remove the hexagonal screws (M6x40 -

2 nos.) along with punched washers. (Fig. 6.125)

13 mm spanner

Tightening torque 30 ± 2 Nm

l Take out master cylinder assembly from the

pillion footrest assembly RH.

Fig. 6.125

l By firmly holding master cylinder housing,

remove the circlip (A) by using circlip plier. (Fig. 6.126) B

Circlip plier

l Take out insert (B) from the master cylinder

assembly. (Fig. 6.126) A

Fig. 6.126

6-43
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Take out the ‘O’ ring from the master cylinder

assembly. (Fig. 6.127)

Fig. 6.127
l Carefully lift the boot from the cylinder by using
a blunt tool. (Fig. 6.128A)

Note:
While removing the boot care should be taken not to
damage it.

l By firmly holding the master cylinder by hand

slightly press the push rod and remove circlip from the
master cylinder by using circlip plier without damaging the
cylinder. (Fig. 6.128B)

Circlip plier

Fig. 6.128A Fig. 6.128B

l Slowly pull out piston along with P - cup, S - cup
and spring. (Fig. 6.129)

l Clean the system thoroughly using fresh brake

fluid.

Caution:
Never use kerosene, petrol or other solvents for
cleaning the brake system. Otherwise rubber parts
get damaged.

INSPECTION

Fig. 6.129
Inspect the following parts:

- Master cylinder for any scratches or other damage.

- Piston and cup surface for scratches or other damage.

- Piston boot and other components for wear and

damage.
- Master cylinder recuperation and feed port for any
blockage, if so clear the blockage using compressed
air.

l After completion of above inspection, replace

defective parts as required.

6-44
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l Reassemble master cylinder in the reverse

order of dismantling. Refer exploded view for assembly
details. (Fig. 6.130)

CAP OIL RESERVOIR HOSE DISC BRAKE REAR

COVER DISC REAR

BANJO BOLT (2 Nos.)

DIAPHRAGM

GASKET (4 Nos.)

DIAPHRAGM PLATE
SCREW

CAP BLEEDER

BLEEDER BODY CALIPER REAR

OIL RESERVOIR

CRR PAN HEAD MASTER CYLINDER ASSY REAR

SPRING WASHER
CIRCLIP PISTON CALIPER
HEXAGONAL SCREW M8x40 WAVE
PIN HANGER
PLUG PIN

INSERT SEAL PISTON

P CUP SPRING PAD
HOSE OIL O’ RING DUST SEAL 2

PISTON MASTER CYLINDER REAR

HOSE CLIP (2 Nos.)
DAMPER PSITON

STOP PLATE CUP

PAD COMPLETE INNER

CIRCLIP S PAD COMPLETE OUTER

BOOT COMPLETE PIN BOLT B PLATE BRACKET

BUSH BOOT PIN

SWITCH ASSY STOP LAMP

BOOT B
PUSH ROD

NUT ROD (2 Nos.)

PIN BOLT A
JOINT ROD
SPRING STOP
COTTER LAMP SWITCH

PIN

BRACKET COMPLETE REAR CALIPER

O’ RING

BRAKE RETURN SPRING DISC

BRAKE PEDAL ASSY SHAFT COMPLETE BRAKE PEDAL

Fig. 6.130

6-45
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

Caution:
Apply brake fluid to the cylinder bore and all internal
parts before inserting the piston into the bore.

l Fix the hose complete brake rear to the master

cylinder outlet port along with the banjo bolt and gaskets.

l Fill the reservoir with DOT3 or DOT4 brake

fluid upto the level ‘MAXIMUM’ marked on the reservoir.

l Fix the reservoir cap along with plate

diaphragm and diaphragm.

l Bleed the system thoroughly by referring the

bleeding procedure on page no. 6-7.

l Once again inspect and if required top-up the

brake fluid and tighten reservoir mounting screw.

Replace following parts at every 21,000 km.

- Piston along with P-cup, S-cup, spring and boot

assembly.
- Diaphragm plate and diaphragm.
- Caliper seal piston and dust seal-2.

REAR SHOCK ABSORBER - REMOVAL

l Remove the rear wheel assembly as explained

in page no. 6-28.

l Dislocate the starter relay from the air filter

assembly. (Fig. 6.131)

l Loosen the clamp tube outlet screw and Fig. 6.131

dislocate the tube outlet from the carburettor assembly.
(Fig. 6.132)

Philips head screw driver

A
l Remove hose clip (A) from hose air inlet and
pull out the hose from air cleaner assembly. (Fig. 6.132)

B
l Remove hose clip (B) from hose engine
breather and pull out the hose from air filter cleaner
assembly. (Fig. 6.132)

Nose plier Fig. 6.132

6-46
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the CRR pan head screw (M6x16 -

2 nos.) along with the punched washers and take out the
air celaner assembly. (Fig. 6.133)

Philips head screw driver

Tightening torque 5 ± 1 Nm

Fig. 6.133

l Remove the hexagonal bolts (M6x20 - 4 nos.)

along with the washers from the chain guard assembly and
gently dislocate the chain guard. (Fig. 6.134 & 6.135)

10 mm spanner

Tightening torque 8 ± 2 Nm

Fig. 6.134

Fig. 6.135

l Remove the hexagonal bolt (M12x55) from the

shockabsorber mounting top along with the punched
washer. (Fig. 6.136)

17 mm spanner

Tightening torque 40 ± 4 Nm

Fig. 6.136

6-47
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the hexagonal bolt (M12x55) along

with punched washer from the bottom mounting of
shockabsorber rear shock absorber. (Fig. 6.137)

l Dislocate and take out the rear shock absorber.

17mm spanner

Tightening torque 40 ± 4 Nm

l Reassemble the rear shock absorber and other

parts in the reverse order of removal. Fig. 6.137

SWING ARM COMPLETE

REMOVAL

l Remove the rear wheel assembly along with

disc plate and dislocate the caliper assembly rear. Refer
page no. 6-28.

l Remove the CRR pan head screw from the

reservoir mounting and take out the reservoir.
(Fig. 6.138)
Fig. 6.138
Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Remove CRR pan head screw from the rider

foot rest disc assembly RH and dislocate the rider foot rest
disc assembly RH. (Fig. 6.139)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 6.139
l Loosen the shock absorber rear top mounting
hexagonal bolt (M12x55). (Fig. 6.140)

17 mm spanner

Tightening torque 40 ± 4 Nm

Fig. 6.140

6-48
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove hexagonal flange bolt (M12x55 -

1 no.) of shockabsorber rear lower mounting from swing
arm complete. (Fig. 6.141)

17 mm spanner

Tightening torque 40 ± 4 Nm

Fig. 6.141

l Remove ‘U’ nut (M12) rear swing arm pivot

mounting. (Fig. 6.142)

17 mm spanner

Tightening torque 40 ± 4 Nm

l Take out nut and the punched washer.

Fig. 6.142

l Draw out the shaft complete swing arm along

with punched washer by gently tapping at the other side.
(Fig. 6.143)

Nylon hammer

l Dislocate the brake hose from the swing arm

complete.

l Take out swing arm complete from the frame

assembly.

Fig. 6.143

l Remove CRR pan head screw (M6x16 - 1 no.)

(A) along with punched washer and take out buffer chain
(B) from the swing arm assembly. (Fig . 6.144)

l Draw out both the bush swinging arm

(Fig. 6.144) and check the needle bearing for any damage
or abnormality. If found any replace the needle bearing as
set. Follow the bellow procedure described below:

A B

Fig. 6.144

6-49
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

l Remove the dust seal (2 nos.) from swing arm

assembly. (Fig. 6.145)

Fig. 6.145

l Using the special tool remove the needle

bearing (2 nos.) from the swing arm assembly. (Fig. 6.146)

N931 015 0 Tool swing arm service

Note:
Swing arm needle bearing should be removed only in
case of replacement.

Fig. 6.146

l Reassemble the needle bearing using the

special tool. (Fig. 6.147)

N931 015 0 Tool swing arm service

INSPECTION
Fig. 6.147

Shaft complete swing arm

l Using the special tools, check shaft complete

swing arm for run-out and replace it with a new one if
run-out exceeds the limit. (Fig. 6.148)

Dial gauge (0.01mm)

Magnetic stand

V - block

Service limit 0.06 mm

Fig. 6.148

6-50
 CHASSIS
TVS APACHE RTR 200 SERVICE MANUAL

REASSEMBLY

l Reassemble and remount swing arm

complete in the reverse order of removal. Refer exploded
view for assembly details. (Fig. 6.149)

AXLE SWING ARM

SWING ARM COMPLETE

SLEEVE SWING ARM - 2 Nos.

DUST SEAL SWING ARM (2 Nos.)

NEEDLE BEARING (2 Nos.)

CRR. PAN HEAD SCREW (M6x16)

BUFFER CHAIN
PUNCHED WASHER

PUNCHED WASHER

DUST CAP SWING ARM (2 Nos.)

NUT REAR SWING ARM PIVOT

Fig. 6.149

6-51
 CONTENTS
TVS APACHE RTR 200 SERVICE MANUAL

DESCRIPTION PAGE NO. Chapter 7

SERVICE DATA 1
VALVE AND VALVE GUIDE 1
CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER 1
CYLINDER, PISTON AND RINGS PISTON 2
CRANKSHAFT COMPLETE AND BALANCER SHAFT 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
FUEL 10
TROUBLE SHOOTING 11
STARTING TROUBLE 11

SERVICE INFORMATION
POOR PICK-UP 12
GEAR SHIFTING RELATED 13
SMOKY EXHAUST (WHITE SMOKE) 13
SMOKY EXHAUST (BLACK SMOKE) 14
ENGINE OVER HEATING 14
HIGH FUEL CONSUMPTION 14
EXCESSIVE CO 15
JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM 15
HEAD LAMP NOT WORKING 15
HORN NOT WORKING 15
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

SERVICE DATA

VALVE AND VALVE GUIDE Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Valve diameter Inlet 24.900

–
Exhaust 19.300

2 Valve clearance Inlet 0.06

–
Exhaust 0.08

3 Valve stem (OD) Inlet 4.470 ~ 4.455

–
Exhaust 4.485 ~ 4.470

4 Guide valve (ID) Inlet

4.500 ~ 4.512 –
Exhaust

5 Guide valve to valve stem clearance Inlet 0.045 ~ 0.057 0.050

Exhaust 0.027 ~ 0.042 0.080

6 Valve stem runout Inlet

– 0.050
Exhaust

7 Valve head thickness Inlet

– 0.500 (min)
Exhaust

8 Valve head radial runout Inlet

0.030 0.075
Exhaust

9 Spring valve free length Inner

39.75 < 38.75
Outer

CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER (CYLINDER HEAD) Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Cam lobe height Inlet 33.402 ~ 33.422 33.35

Exhaust 33.251 ~ 33.271 33.20

2 Cam shaft complete runout – – 0.080

3 Shaft valve rocker arm (OD) Inlet

8.000 ~ 7.991 –
Exhaust

4 Cam chain elongation (20 pitch) – – 128.20

5 Head complete cylinder distortion – – 0.050

7-1
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

CYLINDER, PISTON AND RINGS PISTON Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Compression pressure – 90 ~ 120 psi @ 640 RPM

–
(6.3 ~ 8.4 kg/cm²)

2 Cylinder to piston clearance – 0.040 ~ 0.045 0.120

–
3 Cylinder bore diameter – 66.000 ~ 66.015

4 Piston dia. (measure 10 mm from skirt end) – 65.960 ~ 65.970 –

5 Cylinder complete distortion – – 0.050

6 Ring piston free end gap Top 7.200 5.700

2nd 5.800 4.400

7 Ring piston closed end gap Top 0.150 ~ 0.300 0.700

2nd 0.350 ~ 0.500 0.700

8 Ring to groove clearance Top 0.025 ~ 0.065 0.120

2nd 0.015 ~ 0.055 0.100

9 Ring piston groove width Top 0.8005 ~ 0.8025

2nd 0.8005 ~ 0.8025 –
Oil Ring 1.5050 ~ 1.5200

10 Ring piston thickness Top &

0.775 ~ 0.790 –
2nd

11 Piston pin hole (ID) – 15.002 ~ 15.008 15.030

12 Pin piston (OD) – 14.996 ~ 15.000 14.992

CRANKSHAFT COMPLETE AND BALANCER SHAFT Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Connecting rod small end (ID) 15.003 ~ 15.009 15.040

2 Connecting rod deflection – 3.0

3 Connecting rod big end side clearance 0.150 ~ 0.400 0.650

4 Connecting rod big end width 16.950 ~ 17.000 –

5 Crank web to web width 53 ± 0.2 –

6 Crankshaft complete runout 0.040 0.100

7 Balancer shaft runout – 0.100

7-2
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

CLUTCH Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Cable clutch free play at lever end (in engin cold condition) 8 ~ 15 –

2 Plate clutch drive thickness 2.920 ~ 3.080 2.600

3 Plate clutch drive claw thickness 15.750 ~ 15.850 15.300

4 Plate clutch driven distortion 0.05 0.100

5 Spring clutch free length 25.9 28.8

TRANSMISSION SPECIFICATION

[Link]. DESCRIPTION SPECIFICATION

1 Primary reduction ratio 2.818 (62/22)

2 Final reduction ratio 3.461 (45/13)

3 Gear ratio
First gear 2.917 (35/12)
Second gear 1.857 (26/14)
Third gear 1.333 (24/18)
Fourth gear 1.050 (21/20)
Fifth gear 0.880 (22/25)

TRANSMISSION Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Shift fork to groove clearance Fork low speed

– 0.300
Fork high speed

2 Drive chain - 20 pitch length 259.4 256

3 Drive chain slack 20 ~ 25 –

SUSPENSION Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Front fork stroke length 130 –

2 Front fork spring length 438 428

3 Front fork oil grade KYB G10 oil

4 Front fork oil capacity (each leg) 325 ± 2 cc

7-3
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

BEARING SPECIFICATION

6302Z/C3 (15x42x13) 6302Z/C3 (15x42x13) (ON

(ON WHEEL HUB LH) WHEEL HUB RH)

AXLE FRONT

6001/C3/RS (12x28x8) ( 6004/C3 (20x42x12) (RH

LH SIDE - CAM SPROCKET END ) SIDE)

CAM SHAFT

6207 (35x72x17) (ON 6207 (35x72x17) (ON

CRANKSHAFT LH) CRANKSHAFT RH)

CRANKSHAFT

6302/C3 (15x42x13) (ON 6302/C3 (15x42x13) (ON

BALANCER SHAFT LH) BALANCER SHAFT RH)

BALANCER SHAFT
6006/C3 (30x55x13) (ON
CRANKCASE RH)
6201/RS1/C3 (12x32x10) (ON
CRANKCASE LH)

SHAFT COMPLETE COUNTER

(Shaft clutch)
6002/C3 (15x32x9) (ON CLUTCH
RELEASE PLATE)
6204/C3/RS (20x47x14)
ON CRANKCASE LH)

SHAFT COMPLETE DRIVE NEEDLE BEARING NB (15x23x12) (ON

(Shaft drive) CRANKCASE RH)

6202Z/C3 (15x35x11) (ON 6302Z/C3 (15x42x13) (ON

WHEEL HUB LH) WHEEL HUB RH)

AXLE REAR

6205/RS1/C3 (25x52x15) (ON DRUM

REAR SPROCKET)

7-4
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

CARBURETTOR ASSEMBLY

[Link]. DESCRIPTION SPECIFICATION

1 Carburettor type KEIHIN CV 30VE

2 Carburettor identification number

3 Main Jet 112

4 Needle jet NA

5 Jet needle NUQA

6 E - Ring position NA

7 Pilot Jet 38

8 Piston valve NA

9 Air screw turns 1~ 4 turns

10 Idling rpm 1500 ± 100

11 Idling CO % (with SAI and CAT) 1.0 ~ 3.0 % by volume

12 Cable assembly throttle free play 1 ~ 2 mm

7-5
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

ELECTRICAL

[Link]. DESCRIPTION SPECIFICATION

1 Ignition timing 5° ± 2° BTDC @ 1400 rpm & 37° ± 5°

BTDC @ 5500 ± 200 rpm

2 Spark plug type BOSCH UR4KE

3 Spark plug gap 0.7 mm

4 Pulsar coil resistance 360 ~ 440 ohms

5 Ignition coil resistance Primary winding 4.05 ~ 4.95 ohms

Secondary winding 10.8 ~ 12.32 k ohms

6 Stator coil resistance 0.2 ~1.2 ohms

7 Thermal sensor 3 ~ 14 k ohms

8 Gear Position sensor Neutral 0.75 kilo ohms

First gear 0.3 kilo ohms
Second gear 1.5 kilo ohms
Third gear 2.7 kilo ohms
Fourth gear 5.6 kilo ohms
Fifth gear 15 kilo ohms

9 Charging performance 14.5 ± 0.3V @ 2500 rpm and above

10 Battery (Type / Amp.) 12V, 9 Ah

11 Battery open circuit voltage Full charge 12.9 Volts

Needs charging 12 Volts

12 Battery electrolyte specific gravity Full charge 1.28

Needs charging 1.25

13 Fuel sender unit resistance Full 4 ~ 6 ohms

Empty 108 ~ 112 ohms

14 Generator 12V, 200 W

15 Head lamp - high / low beam 12V, H4 60/55W H4

16 Position lamps LED lamp (2W), 2 nos.

17 Tail lamp / brake lamp LED indicator (1W max. / 2.5W max.)

18 Turn signal lamp 12V, 10W x 4 nos

19 Instrument panel LCD / LED indicators

20 Horn 12V, DC x 2

21 Fuse 12V 15A and 10A each one (blade type)

7-6
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

BRAKE AND WHEEL ASSEMBLY Unit : mm

[Link]. DESCRIPTION STANDARD SERVICE LIMIT

1 Disc plate face out 0.05 0.10

2 Disc plate thickness 4.5 4.0

3 Disc pad thickness 6.2 –

4 Alloy wheel runout (front and rear) Axial 0.6 –

Radial 0.6 –

5 Axle runout Front

0.25 / 100 mm –
Rear

6 Tyre size Front 90/90 x 17” –

Rear 130/70 x 17” –

7 Tyre tread depth Front – 1.5

Rear – 1.5

8 Tyre pressure - Front Solo

1.75 kg/cm² (25 psi) –
Dual

9 Tyre pressure - Rear Solo 2.00 kg/cm² (25 psi) –

Dual 2.25 kg/cm² (32 psi) –

10 Swing arm axle runout 0.6 –

11 Front fork oil level (height) 114 mm –

Note:
Any part in use is subject to wear and tear. The maximum amount of acceptable wear is called ”Service Limit”. Any part which is
within the service limit is expected to provide a satisfactory period of service life.

7-7
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TIGHTENING TORQUE

ENGINE

[Link]. DESCRIPTION QUANTITY TORQUE IN Nm

1 Bolt, cover cylinder head mounting 4 10 ± 2

2 Bolt, cylinder head mounting 2 24.5 ± 2.5

3 Bolt, cam chain tensioner 4 12 ± 2

4 Nut, cylinder head mounting (at side) 2 7±1

5 Bolt, camshaft sprocket mounting 1 18 ± 2

6 CRR csk head screw, camshaft holder 1 4±1

7 CRR csk head screw, pipe intake 2 10 2±

8 Bolt, cylinder head 4 7 1±

9 Nut, cylinder mounting (at side) 2 7 1±

10 Hexagonal flange bolt, cover clutch mounting 11 10 ± 2

11 Hexagonal socket head cap screw, Cover clutch 1 10 ± 2

12 Hexagonal bolt, plate clutch release 4 10 ± 2

13 Nut, clutch shaft mounting 1 60 ± 10

14 Bolt, oil pump mounting 3 8±2

15 Hexagonal bolt, gear shit cam stopper 1 6±1

16 CRR csk head screw, index star 1 8±2

17 Nut, gear primary drive mounting 1 60 ± 5

18 Nut, balancer shaft 1 30 ± 5

19 Hexagonal flange nut, magneto rotor mounting 1 80 ± 5

20 Hexagonal flange bolt, crankcase mounting 15 10 ± 2

21 Hexagonal flange bolt, stator coil mounting 3 10 ± 2

22 Hexagonal screw, sprocket engine mounting 2 8±1

23 Hexagonal flange bolt, cover magneto mounting 9 10 ± 2

24 Plug comp oil drain 1 22.5 ± 2.5

25 Bolt, lever assembly gear shift 1 10 ± 2

26 Hexagonal socket head cap screw, muffler complete front mounting 2 18.1 ± 1.3

27 U nut, engine mounting 4 27 ± 3

28 Spark plug 1 12.5 ± 2.5

7-8
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TIGHTENING TORQUE

CHASSIS

[Link]. DESCRIPTION QUANTITY TORQUE IN Nm

1 U nut, axle front 1 76 ± 18

2 Special screw, Disc plate (Front wheel ) 6 31 ± 3

3 Hexagonal socket head cap screw, front fork upper mounting (upper bracket) 2 19 ± 2

3
4 Bolt, front fork lower mounting (under bracket complete) 2 36 ± 4

5 Lock nut, steering 1 80 ± 20

6 Hexagonal socket head cap screw, handle bar assembly 2 16 ± 2

7 Hexagonal socket head cap screw, handle bar adjuster 2 10 ± 2

8 Hexagonal socket head cap screw, pillion handle mounting 4 18 ± 2

9 Nut, swing arm assembly mounting 1 40 ± 4

10 Bolt, shockabsorber mounting 2 40 ± 4

11 Nut, axle complete rear 1 78 ± 18

12 Bolt, saree guard mounting (at frame) 4 27 ± 3

13 Bolt, chain case complete mounting 4 8±2

14 Nut, side stand mounting 1 37 ± 3

15 Bolt, Center stand mounting 2 37 ± 3

16 Bolt, front fender mounting 4 18 ± 3

17 CRR screw, front fender mounting 2 3±1

18 Bolt, Master cylinder mounting (front) 2 10 ± 2

19 CRR screw, Reservoir rear 1 3±1

20 Bolt, Master cylinder mounting (rear) 2 30 ± 2

21 Banjo bolt, Master cylinder and caliper mounting (front & rear) 4 30 ± 2

22 Nut, muffler assembly mounting (at rear) 1 19.6 ± 2

23 Hexagonal socket head cap screw, Muffler mounting (at front) 2 18.1 ± 1.3

24 Hexagonal socket head cap screw, Muffler mounting (at frame) 1 18.1 ± 1.3

25 Bolt, bracket crash guard 4 27 ± 3

7-9
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

SPECIAL MATERIAL REQUIRED FOR MAINTENANCE

The following recommended materials are required for maintenance work on the TVS Apache RTR 200 4V and should be kept in hand for
ready use.

[Link]. APPLICATION MATERIAL

LUBRICANTS

1 Front fork oil seal lip Kluber Centoplex 2 or equivalent

2 Swingarm assembly pivot, throttle grip, speedo BP MP Grease No.3, Servo Gem (IOC) No.3 and
cable, brake cams and control levers Bechem premium grade 3

3 Steering races, steering cup and steering cone Bechem premium grade 3

4 Centre stand / side stand pivot and kick starter TVS TRU4 FULLY SYNTHETIC oil
pedal pivot 5

Engine cum transmission oil TVS TRU4 FULLY SYNTHETIC oil

(SAE10W30 SL-JASO MA2)

6 Front fork oil KYB G10 oil

7 Drive chain lubricant TVS TRU SPRAY

ADHESIVES

1 Liquid gasket Threebond TB1104

2 Packing seal cover cylinder head Locktite 5205

3 Fastening nuts adhesion Anabond thread locker

4 Fastening rubber, plastics and ceramic Anabond (Eng) Cyanoacrylate adhesive 202 and 201
Dendrite adhesive

5 Bearing fitment adhesive Specfit

CLEANING SOLVENTS

1 Crankcase, shafts, gears and filter air cleaner Inflammable solvent like kerosene

2 Piston and rings Carbon tetra chloride and Acetone carbon chloride

3 Carburettor Carbon tetra chloride

BRAKE FLUID

1 TVS Girling DOT 3 / DOT 4

USE OF GENUINE TVS MOTOR COMPANY PARTS

When replacing any part of the machine, always use TVS-M genuine parts only. Non genuine parts will reduce the performance of TVS Apache
RTR 200 4V and cause failures.

FUEL

ITEM SPECIFICATION

Fuel type Unleaded Petrol

Fuel tank capacity including reserve 12 litres

Reserve 2.5 litres

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 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TROUBLE SHOOTING

A. STARTING TROUBLE

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

A1 Self starter not working Battery voltage is less Charge the battery / replace

Loose connection Tighten

Defective starter motor Replace

Defective starter relay Replace

Defective starter switch Replace

Defective gear position sensor Replace

Defective TCI Replace

Defective speedometer Replace

No continuity of wiring in harness Replace

A2 No fuel flow to carburettor No fuel in fuel tank Fill petrol

Clogged fuel cock filter / sediment filter Clean

Blockage of vent hole in cap fuel tank Clear vent hole

A3 No spark / weak spark /

intermittent spark Battery dead Replace

Incorrect spark plug gap Replace

Dirty spark plug Clean

Bridging of electrodes Replace

Loose suppressor cap Correct / fix properly

Water entry between suppressor cap Clean

and spark plug Oily

sparkplug Check oil leakages through rings,

valves into combustion chamber and
correct

Defective engine kill switch Correct / Replace

Defective ignition coil Replace

Defective ignition switch Replace

Defective TCI Replace

Defective pulsar coil Replace

A4 Incorrect valve timing Valve timing marks not matching Correct valve timing

Improper valve tappet clearance Adjust tappets

A5 Induction leakage Loose carburettor mounting Tighten

Damaged intake pipe and gasket Replace

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 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TROUBLE SHOOTING

A. STARTING TROUBLE (Contd.)

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

A6 Improper carburation Sticky / worn out float needle Clean / replace

Loose main jet / pilot jet Tighten

Blocked passages Clean the passages

Incorrect MCS adjustment Tune up correctly

Excessive CO Tune up correctly

Incorrect jet size Replace with specified size

Incorrect float height Correct

Blockage of air filter inlet Correct

A7 Poor compression Leakage through head gasket Tighten nuts / replace gasket

Incorrect valve clearances Adjust to specification

Worn out piston rings Replace

Worn out cylinder and piston Replace

Leakage through valve Do lapping and correct

B. POOR PICK-UP

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

B1 No free movement of vehicle Brake binding Adjust both brakes

Low tyre pressure Inflate to specification

Jammed wheel bearings Replace / lubricate

Tight chain Adjust free play

Tight drive shaft Check and correct circlip seating

B2 Improper ignition Refer complaint No. A3 Refer

complaint No. A4

B3 Improper carburation Refer complaint No. A6

B4 Clutch slippage Incorrect free play Adjust as per specification

Burnt drive, driven plates Check and replace

B5 Poor compression Refer complaint No. A7

B6 Poor engine response on Block at air cleaner inlet Remove blockage

acceleration below the cover frame

B7 Jerking at particular RPM Blockage of carburettor Clean / correct

breather hose and improper routing

7-12
 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TROUBLE SHOOTING

C. GEAR SHIFTING RELATED

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

C1 Gear shifting hard Improper free play in clutch lever Adjust free play to specification

Gear shift lever fouling with foot rest Inspect and correct

Poor engine oil quality Replace

Improper drive chain slackness Inspect and adjust

C2 Neutral lamp not working Contact gear shift switch defective Correct / Replace

Gear position sensor defective Replace

Loose connection Correct

No continuity in wiring harness Replace

Neutral lamp LED not working Replace speedometer

D. SMOKY EXHAUST (WHITE SMOKE)

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

D1 Burning of oil in Oil mixed in fuel Replace fuel in tank and clean
combustion chamber

Adulterated fuel Replace fuel in tank and clean

Improper routing / clogged breather pipe Correct routing / clean Damaged seal

valve stem oil / valve stem Replace Incorrect fitment of 2nd and Oil rings

Fit properly

Worn out piston rings Replace Rings

Worn out cylinder and piston Replace cylinder and piston

Engine oil level exceeded maximum limit Fill to the specified level

E. SMOKY EXHAUST (BLACK SMOKE)

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

E1 Very rich mixture Sticky / worn out float needle Correct / replace

Worn out jets Replace

Clogged air filter Clean / replace

Punctured float Replace

Choke plunger stuck Correct

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 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TROUBLE SHOOTING

F. ENGINE OVER HEATING

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

F1 Poor cooling Cooling fins covered with mud Clean

F2 No free movement of vehicle Refer complaint No. B1 F3

Incorrect ignition Refer complaint No. A3

F4 Poor lubrication Incorrect type of oil Use recommended oil

Low quantity / poor quality Top up / replace as specified

Oil filter clogged Clean / replace

Defective oil pump Replace

Blocked oil passages Clean / Correct

F5 Clutch slippage Refer complaint No. B4

F6 High compression pressure Excessive carbon deposition Decarbonise engine & muffler

F7 Incorrect valve timing Improper valve clearance Check and adjust

F8 Incorrect sparkplug Wrong heat range of sparkplug Replace

G. HIGH FUEL CONSUMPTION

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

G1 Refer complaint Nos. B1, 2, 3, 4, 5, 6 & 7

G2 Fuel leakages Leakage through fuel tank, fuel hose, Correct leakages fuel cock and
carburettor

H. EXCESSIVE CO

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

H1 Improper carburation Refer complaint No. A6

H2 Malfunctioning of Wrongly selected settings Correct

exhaust gas analyser / accessories

H3 Rich mixture Refer complaint No. E1

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 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL

TROUBLE SHOOTING

I. JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

I1 Excessive CO Improper idling rpm Adjust idling

J. HEAD LAMP NOT WORKING

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

J1 Bulb fused Defective bulb Replace

J2 No power supply to bulb Loose contact in bulb holder/switch Correct contacts

Loose contact in wiring couplers Correct contacts

Defective TCI Replace TCI

Wiring cut Replace wiring harness

No power supply from stator coil Check stator coil resistence

Defective RR unit Replace

K. HORN NOT WORKING

STEP REASON POSSIBLE CAUSE COUNTER MEASURE

K1 No sound Blown fuse Replace

No / discharged battery Fix / recharge

Defective horn Replace

Defective horn button Correct / replace

Wiring cut / disconnected terminal Replace / connect

K2 Weak / irregular sound Loose connection Correct

Discharged battery Recharge

Incorrect tuning of horn Tune properly (lock the nut after

tuning)

K3 Rippling noise Defective connections Check each terminal

Defective horn Replace

Loose clamp Correct

7-15