Apache RTR 160 Manual
Apache RTR 160 Manual
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Exclusive features of Apache RTR 160
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All New Racing Graphics
s
Racing Throttle Response Engine (RTR)
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Digital Speedo…with Service indicator system
i
B
Split Type sporty Handle bar
n
Bull horn pillion Handle
e
Adjustable Link type gear shift mechanism
G
270mm Front Disc brake
e x
16 LED Tail Lamp
ik
•RTR : Racing Throttle Response
B
•15.2 bhp engine
n
Benefit:
e
• Quick Response to the throttle.
G
• Feel of a race bike.
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IDI System
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Feature:
ik
TCI : Transistor controlled ignition
nB Benefit:
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Long and high intensity Spark for
better combustion of Fuel mixture.
x G
Help in cold start & Cold Recovery
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CAPACI TOR
ike
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Gas Filled Shock Absorber
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Feature
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Gas filled 5 step adjustable
shock absorber with Bottle
B
designed Canister
en Benefit
G
Comfortable ride even on bad
x
roads
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Feature
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• Stainless steel, sporty silencer
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with catalytic converter and
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exhaust resonator.
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• Narrow snout designed muffler.
B
Benefit
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• Sporty looks
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• Resonator helps to achieve good
G
power & Torque
x
• Rust Free
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• Catalytic converter reduces
pollution
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Feature
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• Sporty and Stylish
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• 16 liters (including Reserve –
B
2.5 ltr) capacity with flushed petrol
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tank cap
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Benefit
G
• Higher capacity Petrol Tank for
x
long distance ride.
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Twin City Lamps
e s Feature
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• Halogen HL bulb with Twin
B
city lamps
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Benefit
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• Brighter light
G
• Safer to ride in city traffic
condition
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RCF Technology
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[Link]
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• Roller Cam Follower
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• Auto De-Compression Valve
B
Benefit
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Friction free engine –
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Low maintenance
G
Longer engine life
x
Smoother engine
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No back kick during kick starting
s.c Feature
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• Powerful Engine -
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Power 15.2 BHP@8500 rpm
B
Torque13.1 Nm@6000 rpm
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• Engine with Charcoal Grey
e
colour is added look.
G
Benefit
x
• Excellent Initial pickup
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• Better top speed
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• Disc brakes with Sprocket
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design disc
B
Benefit
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• Sporty looks
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• Effective braking
G
• Better stability
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Any Gear Electric Start…
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Feature
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• Any Gear Self Starting
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• Constant mesh self starter
B
• SM-6 Motor
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Benefit
• Positive engagement
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• Effortless Starting
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• Soft button start
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Feature
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• Vehicle speed, clock,
i
odometer, Trip meter on LCD
B
screen.
en Benefit
G
• Guides the customer in time
x
• More accurate
s
• IE SURGE - Intake Exhaust
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Resonator Surge
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•Induction resonator on air filter
• Exhaust Resonator on Silencer
B
Benefit
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• Intake Resonator accelerates the air
e
fuel mixture flow during sudden
throttling and helps in quicker power
G
response to zoom the bike.
x
• Exhaust Resonator helps in clearing
e
exhaust gas quickly out of the silencer
during sudden throttling which results
N
in high torque.
[Link]
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• 5 Speed gear box
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• Link type Adjustable shifting
system
B
• Carbo-nitrating Gears
en
Benefit
• High speed
x G
• Racing bike gear shifting system.
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• Improved life of gears
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SPECIFICATIONS
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TVS Apache RTR 160 TVS Apache
Overall Length
Overall Width
ike
2020 mm
730 mm
1976 mm
743 mm
B
Overall Height 1050 mm 1100 mm
n
Ground Clearance 180 mm 165 mm
e
Wheel Base 1300 mm 1260 mm
G
Kerb Weight 136 kg 136 kg
x
Pay Load 130 kg 130 kg
e
Gross Vehicle W eight 266 kg 266 kg
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TVS Apache RTR 160
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TVS Apache
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Type 4 stroke ,air cooled, single cylinder OHC
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Bore 62 mm 57 mm
i
Stroke 52.9 mm 57.8 mm
Piston Displacement 159.7cc 147.5 cc
B
Carburettor Type Ucal mikuni BS - 26 Ucal mikuni BS - 26
n
Air Filter Double polyurethene foam filter element
e
Lubrication System Forced wet pump
G
2
Compression Pressure 10 - 13 kg/cm
x
Maximum Horse Power 11.19 KW (15.2 bhp) @ 8500 rpm 9.95 Kw(13.5 BHP)@8500 rpm
e
Maximum Torque 13.1 Nm @ 6000 rpm 12.3 Nm@6000 rpm
Valve Clearance (Cold) Inlet 0.08 / Exhaust 0.11 mm Inlet 0.07 / Exhaust 0.12 mm
N
Maximum Speed 118 kmph 108 kmph
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TVS Apache RTR 160 TVS Apache
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Clutch Wet Multiplate type
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Transmission Constant mesh 5 speed gearbox
Gear Shift Pattern All down heel - toe shift
B
Primary Reduction 65/21
n
Final Reduction 44/13
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First Gear 35/12
G
Third Gear 24/18
x
Fourth Gear 21/20
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Fifth Gear 22/25
SPECIFICATIONS
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TVS Apache RTR 160 TVS Apache
Frame
e s
Double Cradle SynchroSTIFF Double cradle tubular type
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Front Suspension and
lescopic Forks, 105mm Stroke Telescope oil damped 105mm
B
Travel
Monotube Inverted Gas filled shox Gas filled 5 step adjustable with
n
Rear Suspension
(MIG) with spring aid canester
e
Steering Angle 41'
°
Caster Angle 25.5 25.5'
G
Trail Length 81.3 mm 90mm
x
Brakes: Front 270 mm Petal Disc 130/240 mm dia Drum/Disc
e
Brakes: Rear 130 mm Drum 130 mm foot operated
Tyre Size Front 90/90 x 17” 90/90 x 17 - 6 ply
N
Tyre Size Rear 100/80 x 18” 100/80x 18
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SPECIFICATIONS TVS Apache RTR 160 TVS Apache
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Ignition System IDI -dual mode digital ignition - DC
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Sparkplug Bosch Super UR 5 DDC
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Sparkplug Gap 0.6 mm
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Battery Type 12V 9 Ah
B
Body Earthing Negative terminal
Generator 12V, 100W
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Head Light 35/35W Halogen HS1, Clear lens 12V, 35/35 W HS 1 halogen
with MFR
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Tail Light/Brake Light 0.5 W. LED-Twin triangle with prism 12 V, 5W / 21W
G
on lens
Turn Signal Light 12V,10W
x
High Beam Indicator Light 12V,2W
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Neutral Indicator Light 12V,3.4W
Speedometer Light 12V,3.4W
N
Economy & power mode lamp 12V,2W
Turn Signal Indicator Light 12V,2W
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TVS Apache RTR 160 TVS Apache
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Fuel Tank Including
16 Lts
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Reserve
i
Reserve 2.5 lts
B
Front Fork Oil 125 ± 2.5 ml each
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4T Oil
Oil (Grade)
Transmission cum Engine
1000ml(Overhauling)
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Oil (Qty)
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Carburettor Specifications
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Discription TVS APACHE RTR 160 TVS APACHE
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Carburettor Type BS26 CV Ucal Mikuni BS26 - X21 CV Ucal Mikuni
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Main Jet 105 102.5
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Needle Jet P2
Jet Needle QK
B
E - ring position 2 nd from top
n
Pilot Jet 15 12.5
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Pilot air jet (1) 1.45 1.45
Pilot air jet (2) NA
G
CA - 3.9(2 vacuum sensing CA - 3.9(1 vacuum sensing
Piston valve
holes) hole)
x
Throttle Valve 120
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MCS screw - No of turns 2±1(1 ~ 3 turns out)
Idling RPM 1400±50
N
Idling CO%(with SAI) 0.8 ~ 1.2% 0.6 ± 0.4%
Idling CO%(without SAI) 3.5 ~ 4.5%
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increased.
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bigger Inlet & Exhaust valve
B
seats provided.
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Painted with Charcoal grey
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colour.
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Cylinder Block
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ike Bore Dia. increased to 62 mm
Auto Chain Tensioner mounting
B
design is changed.
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159.7 cm3 embossed for
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identification.
G
Painted with Charcoal grey colour.
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Piston Assy.
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B
Piston Rings dia increased to
match the new piston.
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Piston Pin and locks also modified
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Crankshaft Assy.
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160cc
nB
Connecting rod modified.
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Chamfer on Crank web are bigger.
x G
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150cc
B
Rod comp. Clutch release is
modified.
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Charcoal grey painting is
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provided
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Auto Chain Tensioner
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B
New Part
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Strip coil type tensioner
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Crankcase RH
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B
Guide bush provided for Cam
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Guide bush gear shift shaft.
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Painted with charcoal grey
colour.
x G
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Crankcase LH
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B
Painted with Charcoal grey
n
colour.
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Clutch Assy.
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Clutch plate Drive and plate
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driven are modified.
Clutch spring are changed.
nB
Clutch plate serrations
reduced to 45( Apache 150 – 48
e
serrations).
G
Plain surface provided for
x
pressure plates (Apache 150 –
dotted surface)
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Charcoal grey colour.
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Stator coil assy.
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New Part
ik
Charging and lighting coils
increased to 8(Apache 150 – 7
B
coils)
n
Since Source coil is not
e
available here, that location is
used for one additional lighting
G
/charging coil.
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CV Carburetor
m
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New Part
s
Fuel Jets and Tuning
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specifications changed
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Main Jet – 105
i
Pilot Jet – 15
B
Piston Valve CA-3.9(1 vacuum
n
hole)
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CO (with SAI) – 0.8 ~ 1.2%
G
Since change in By pass pitch ,
x
RTR 160 have new carburetor
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body
Can not interchange with
N
Apache 150cc
s.c 150cc
B
Valve face diameter increased
n
Inlet tappet clearance – 0.07 mm
e
Exhaust tappet clearance – 0.11
mm
x G
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Exhaust
Inlet
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New Part.
ik
Narrow snout Muffler Assy.
B
design is to suit the new styling.
n
Mounting bracket point is
changed.
e
Exhaust resonator position
G
shifted to bottom side vehicle.
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Lever Kick Starter
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B
Design is changed to suit the
n
new styling.
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Suppresser Cap
m
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B
Suppressor cap design is
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changed to avoid the water
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entry.
x G
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Lever Gear Shifting
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New Part.
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Link type design provided to
give racing bike feel during gear
B
shift.
n
Cam gear shift design changed
e
to match the changes in
Crankcase RH for smoother gear
G
shifting.
x
Transmission gears are same
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as Apache 150cc.
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B
New part.
n
To suit the new styling.
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Wiring Harness
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New Part.
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New couplers to connect the
i
LED tail lamp.
B
Water proof coupler provided
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for avoiding the water entry.
e
Special coupler provided to
connect the digital speedometer.
x G
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Relay pass by
m
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New part
ik
Relay unit provided for Pass
by operation.
B
Pass by will work in both DC
n
and AC.
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TCI Unit
om
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160cc
B
changed in TCI of RTR.
n
For identification IDI in grey
e
colour.
x G
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150cc
om
s.c New part.
e
Split type handle bar to suit the
k
new styling.
i
Handle bars can be adjusted to
B
two positions as per the
requirement.
en
Upper bracket cover added for
styling.
x G
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Bracket Pillion Foot Rest
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New part.
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diecasted pillion foot rest
B
holder.
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Charcoal Grey colour to
match the look of the bike.
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Bracket Side Stand
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B
To improve the Part lift.
en
x G
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Chain Case
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New part
i
both Chain case upper and
B
Lower are modified to match the
n
new swing arm fitments.
e
Dimple profile provided at inner
side of case to avoid wheel
G
fouling during the ride.
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Rear Fender
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ike New part.
B
Rear fender design is
changed to suit the new
n
styling.
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Number Plate Lamp
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B
Rear Reflector is fitted to lamp
n
body.
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Digital Speedo Hub Drive
s.c
ike New Part.
B
Connected to digital Speedo
meter through the wires.
en
Speedo cable is not
provided.
x G
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Front Fork RH
m
s.c
ike New Part.
B
Outer Tube design is changed
n
Disk Mounting point is changed.
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Vibration Dampers & Handle Grip
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ike New Part.
B
Handle grip is modified
n
Vibration damper is modified.
e
Chrome plating is provided for
Clutch lever and Front Brake lever.
x G
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Engine Guard
om
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ike New Part.
B
To provide a sporty look to the
n
bike.
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Gas filled Rear shock Absorbers
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New Part.
ik
Canister Design modified.
B
Filled with Nitrogen Gas.
n
Lower mounting bracket length
e
increased.
x G
Ne
150cc 160cc
s.c
ike New Part.
B
Disc mounting positions changed
n
to mount the 270 mm disc.
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APACHE - I GNI TI ON CI RCUI T
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Charging Coil
s
WR B
e
RW BW
k
RR Unit
i
10A Fuse
BW R ENGINE KILL SWITCH
R
SELF STARTER
B
Battery BW Ignition B SWITCH
Switch
n
BW
Or
DC CIRCUIT Or
e
W B B
Br BlR
DC TCI Digital
G
SPEEDOMETER
BW Or Bl
PULSER COIL
x
GW
HT COIL BlW
TCS
e
HT Cord THROTTLE CONTROL SWITCH
N
Spark Plug
s.c
e
10A Fuse
k
BW R ENGINE KILL SWITCH
i
R
SELF STARTER
BW
Battery Ignition B
RELAY UNIT
B
Switch
BW
Or
n
DC CIRCUIT Or
W B B
e
Br BlR
DC IDI Digital
BW SPEEDOMETER
Or Bl
G
PULSER COIL
GW
HT COIL BlW
TCS
x
HT Cord THROTTLE CONTROL SWITCH
e
Spark Plug
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Charging Coil BW
s
WR B DC TCI
e
RW BW ENGINE KILL
SWITCH
k
RR Unit B SELF STARTER
i
10A Fuse B SWITCH
BW R
R
B
Battery BW Ignition
Switch
n
Or
e
Or Or Or Or Horn(2) DC TCI
Or
lbl
G
Flasher TSL Switch
[Link] Switch [Link]. Switch RELAY PASS BY L R
Unit
x
GB Fr. TSL Fr. TSL
Y Or G
W Y
W Horn V
lG
e
High/Low Beam switch Switch Rr. TSL Rr. TSL
BW
N
[Link] PASS BY SWITCH
BW
Lighting Switch
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ENGINE KILL
DC TCI SWITCH
s
B
10A Fuse B
R
e
R
BW BW Ignition
k
Battery Switch
B i
Gr TO DC Circuit
B BlW
n
Clutch S witch S tarter Button
e
Or
BlW
G
Neutral Lamp
x
Bl
Bl
e
Starter Relay Neutral Switch
S TARTER MOTOR
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Lighting Coil
s
Y B
W PASS BY SWITCH
e
BW
YR GB
k
RR Unit OR
i
YW RELAY PASS BY
B
Lighting Switch
n
Yor
Y
e
Gr
G
YB
Gr Gr
x
Gr Gr Gr Headlamp
SPEEDOMETER Number Tail
City City
e
plate Lamp
lamp lamp lamp
H
BW BW BW BW
N
BW WR
L BW
Headlamp Switch
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Lighting Coil
Resistance :0.25 - 1.0 ohm
s
Lighting coil
e
200 R BW
Ohm s
+ B
-
ik
Pulser Coil Charging Coil
Re sista nce: 125 - 150 Ohms Re sista nce: 0.4 - 1.0 Ohm s
B
Charging
Puls e r coil coil
n
Br WR
W BW
2000
Ohm s R 200
Ohm s R
+ +
- B - B
e
IGNITION COIL TESTING
G
Secondary Coil
Primary Coil
x
Re sista nce: 11.0 - 13.0 KOhms
Resistance : 2.0 - 4.0 Ohm
e
Ignition coil Ignition coil
HT CORD
Or
200 Bl HT CORD 20K
Oh ms Oh ms
+ +
-
N
-
To Spar k Plug From CDI Unit
e
[Link] ITEMS
k
[Link]/GAP
i
[Link] CHECKS
B
[Link] TIGHTNESS CHECKS
n
[Link] CHECKS (AFTER STARTING THE ENGINE)
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[Link] FUNCTION CHECKS
[Link] TRIAL
G
[Link] TRIAL (ON STAND)
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Customer I nstallation
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Basic Check points before starting the Vehicle
.
•All controls operations(clutch,brake,throttle,gear shifting)
s
•Explain all settings on Digital Speedometer
• Tank capacity : 16lit Res: 2.5lit
e
•Tyre pressure
•Battery condition – Proper functioning of horn,brake lights,turn signal
k
indicators,electrolyte level
i
•Tool kit
•First aid kit
B
•Engine oil level
•Lighting
n
Service schedule
e
•Explain Service schedule of Apache RTR 160 as per owners manual
Warranty
G
•Warranty period, Parts not covered under warranty, Limitations of warranty.
•Tips for achieving best performance from vehicle
x
•Proper tyre pressure
e
•Battery condition checking
•Usage of IFTEX for petrol(2ml/ltr)
N
•Running in period
•Riding tips
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Se rvice Kms Month Fre e/Pay
s.
I 500 - 750 1 month
Free
III 5500 - 6000 6 Months
ik
IV 8500 - 9000 9 Months
B
V 11500 - 12000 12 Months
n
VII 17500 - 18000 18 Months
e
VIII 20500 - 21000 21 Months
Pay
G
IX 23500 - 24000 24 Months
x
X 26500 - 27000 27 Months
e
XI 29500 - 30000 30 Months
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Periodic Maintenance
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Periodic Maintenance
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Periodic Maintenance
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