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PRODUCT TRAI NI NG CENTRE

PRODUCT TRAI NI NG CENTRE


PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
PRODUCT TRAI NI NG CENTRE
Exclusive features of Apache RTR 160
All New Racing Graphics
Racing Throttle Response Engine (RTR)
Digital Speedo…with Service indicator system
Split Type sporty Handle bar
Bull horn pillion Handle
Adjustable Link type gear shift mechanism
270mm Front Disc brake
16 LED Tail Lamp

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RTR…

Feature:
•RTR : Racing Throttle Response
•15.2 bhp engine
Benefit:
• Quick Response to the throttle.
• Feel of a race bike.

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IDI System

Feature:
TCI : Transistor controlled ignition

Benefit:
Long and high intensity Spark for
better combustion of Fuel mixture.
Help in cold start & Cold Recovery

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CDI Vs IDI

CAPACI TOR

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Gas Filled Shock Absorber

Feature
Gas filled 5 step adjustable
shock absorber with Bottle
designed Canister

Benefit
Comfortable ride even on bad
roads

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Sporty Silencer
Feature
• Stainless steel, sporty silencer
with catalytic converter and
exhaust resonator.
• Narrow snout designed muffler.
Benefit
• Sporty looks
• Resonator helps to achieve good
power & Torque
• Rust Free
• Catalytic converter reduces
pollution

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Stylish Contoured Fuel Tank

Feature
• Sporty and Stylish
• 16 liters (including Reserve –
2.5 ltr) capacity with flushed petrol
tank cap
Benefit
• Higher capacity Petrol Tank for
long distance ride.

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Halogen HL Bulb with
Twin City Lamps
Feature
• Halogen HL bulb with Twin
city lamps
Benefit
• Brighter light
• Safer to ride in city traffic
condition

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RCF Technology

Feature
• Roller Cam Follower
• Auto De-Compression Valve
Benefit
Friction free engine –
Low maintenance
Longer engine life
Smoother engine
No back kick during kick starting

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Racing Response Engine…

Feature
• Powerful Engine -
Power 15.2 BHP@8500 rpm
Torque13.1 Nm@6000 rpm
• Engine with Charcoal Grey
colour is added look.
Benefit
• Excellent Initial pickup
• Better top speed

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270mm Disc Brakes…

Feature
• Disc brakes with Sprocket
design disc
Benefit
• Sporty looks
• Effective braking
• Better stability

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Any Gear Electric Start…

Feature
• Any Gear Self Starting
• Constant mesh self starter
• SM-6 Motor
Benefit
• Positive engagement
• Effortless Starting
• Soft button start

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Digital Speedo…

Feature
• Vehicle speed, clock,
odometer, Trip meter on LCD
screen.

Benefit
• Guides the customer in time
• More accurate

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IE SURGE…
Feature
• IE SURGE - Intake Exhaust
Resonator Surge
•Induction resonator on air filter
• Exhaust Resonator on Silencer
Benefit
• Intake Resonator accelerates the air
fuel mixture flow during sudden
throttling and helps in quicker power
response to zoom the bike.
• Exhaust Resonator helps in clearing
exhaust gas quickly out of the silencer
during sudden throttling which results
in high torque.

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5 – Speed Transmission…
Feature
• 5 Speed gear box
• Link type Adjustable shifting
system
• Carbo-nitrating Gears
Benefit
• High speed
• Racing bike gear shifting system.
• Improved life of gears

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PRODUCT TRAI NI NG CENTRE
Dimensions

SPECIFICATIONS TVS Apache RTR 160 TVS Apache

Overall Length 2020 mm 1976 mm

Overall Width 730 mm 743 mm

Overall Height 1050 mm 1100 mm

Ground Clearance 180 mm 165 mm

Wheel Base 1300 mm 1260 mm

Kerb Weight 136 kg 136 kg

Pay Load 130 kg 130 kg

Gross Vehicle W eight 266 kg 266 kg

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Engine
SPECIFICATIONS TVS Apache RTR 160 TVS Apache
Type 4 stroke ,air cooled, single cylinder OHC

Bore 62 mm 57 mm
Stroke 52.9 mm 57.8 mm
Piston Displacement 159.7cc 147.5 cc
Carburettor Type Ucal mikuni BS - 26 Ucal mikuni BS - 26

Air Filter Double polyurethene foam filter element

Starting System Kick start / Electric start

Lubrication System Forced wet pump

Compression Ratio 9.5:1


2
Compression Pressure 10 - 13 kg/cm

Maximum Horse Power 11.19 KW (15.2 bhp) @ 8500 rpm 9.95 Kw(13.5 BHP)@8500 rpm

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

Maximum Speed 118 kmph 108 kmph

Engine Idling Speed 1400±100

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Transmission

SPECIFICATIONS TVS Apache RTR 160 TVS Apache


Clutch Wet Multiplate type
Transmission Constant mesh 5 speed gearbox
Gear Shift Pattern All down heel - toe shift
Primary Reduction 65/21
Final Reduction 44/13

First Gear 35/12

Second Gear 26/14


Third Gear 24/18

Fourth Gear 21/20


Fifth Gear 22/25

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Chassis

SPECIFICATIONS TVS Apache RTR 160 TVS Apache

Frame Double Cradle SynchroSTIFF Double cradle tubular type

Front Suspension and


lescopic Forks, 105mm Stroke Telescope oil damped 105mm
Travel
Monotube Inverted Gas filled shox Gas filled 5 step adjustable with
Rear Suspension
(MIG) with spring aid canester

Steering Angle 41'


°
Caster Angle 25.5 25.5'
Trail Length 81.3 mm 90mm
Brakes: Front 270 mm Petal Disc 130/240 mm dia Drum/Disc
Brakes: Rear 130 mm Drum 130 mm foot operated
Tyre Size Front 90/90 x 17” 90/90 x 17 - 6 ply
Tyre Size Rear 100/80 x 18” 100/80x 18

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Electrical
SPECIFICATIONS TVS Apache RTR 160 TVS Apache
Ignition System IDI -dual mode digital ignition - DC
Sparkplug Bosch Super UR 5 DDC
Sparkplug Gap 0.6 mm
Battery Type 12V 9 Ah
Body Earthing Negative terminal
Generator 12V, 100W

Head Light 35/35W Halogen HS1, Clear lens 12V, 35/35 W HS 1 halogen
with MFR

Tail Light/Brake Light 0.5 W. LED-Twin triangle with prism 12 V, 5W / 21W


on lens
Turn Signal Light 12V,10W
High Beam Indicator Light 12V,2W
Neutral Indicator Light 12V,3.4W
Speedometer Light 12V,3.4W
Economy & power mode lamp 12V,2W
Turn Signal Indicator Light 12V,2W

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Capacity
SPECIFICATIONS TVS Apache RTR 160 TVS Apache
Fuel Tank Including
16 Lts
Reserve
Reserve 2.5 lts

Front Fork Oil 125 ± 2.5 ml each

Transmission cum Engine


4T Oil
Oil (Grade)
Transmission cum Engine
1000ml(Overhauling)
Oil (Qty)

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Carburettor Specifications
Discription TVS APACHE RTR 160 TVS APACHE
Carburettor Type BS26 CV Ucal Mikuni BS26 - X21 CV Ucal Mikuni
Main Jet 105 102.5
Needle Jet P2
Jet Needle QK
E - ring position 2 nd from top
Pilot Jet 15 12.5
Pilot air jet (1) 1.45 1.45
Pilot air jet (2) NA
CA - 3.9(2 vacuum sensing CA - 3.9(1 vacuum sensing
Piston valve
holes) hole)
Throttle Valve 120
MCS screw - No of turns 2±1(1 ~ 3 turns out)
Idling RPM 1400±50
Idling CO%(with SAI) 0.8 ~ 1.2% 0.6 ± 0.4%
Idling CO%(without SAI) 3.5 ~ 4.5%

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PRODUCT TRAI NI NG CENTRE
Cylinder Head

Combustion Chamber diameter


increased.
bigger Inlet & Exhaust valve
seats provided.
Painted with Charcoal grey
colour.

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Cylinder Block

Bore Dia. increased to 62 mm


Auto Chain Tensioner mounting
design is changed.
159.7 cm3 embossed for
identification.
Painted with Charcoal grey colour.

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Piston Assy.

Piston Dia. increased to 62 mm


Piston Rings dia increased to
match the new piston.
Piston Pin and locks also modified

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Crankshaft Assy.

160cc Crankshaft web weight increased.


Connecting rod modified.
Chamfer on Crank web are bigger.

150cc

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Clutch Cover

New Part
Rod comp. Clutch release is
modified.
Charcoal grey painting is
provided

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Auto Chain Tensioner

New Part
Strip coil type tensioner

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Crankcase RH

New Part
Guide bush provided for Cam
Guide bush gear shift shaft.
Painted with charcoal grey
colour.

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Crankcase LH

New Part
Painted with Charcoal grey
colour.

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Clutch Assy.

New Part
Clutch plate Drive and plate
driven are modified.
Clutch spring are changed.
Clutch plate serrations
reduced to 45( Apache 150 – 48
serrations).
Plain surface provided for
pressure plates (Apache 150 –
dotted surface)

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Cover Magneto

New Part
Charcoal grey colour.

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Stator coil assy.

New Part
Charging and lighting coils
increased to 8(Apache 150 – 7
coils)
Since Source coil is not
available here, that location is
used for one additional lighting
/charging coil.

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CV Carburetor
New Part
Fuel Jets and Tuning
specifications changed
Main Jet – 105
Pilot Jet – 15
Piston Valve CA-3.9(1 vacuum
hole)
CO (with SAI) – 0.8 ~ 1.2%
Since change in By pass pitch ,
RTR 160 have new carburetor
body
Can not interchange with
Apache 150cc

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Inlet & Exhaust Valve
RTR 150cc

New Parts
Valve face diameter increased
Inlet tappet clearance – 0.07 mm
Exhaust tappet clearance – 0.11
mm

Exhaust
Inlet

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Silencer Assy.

New Part.
Narrow snout Muffler Assy.
design is to suit the new styling.
Mounting bracket point is
changed.
Exhaust resonator position
shifted to bottom side vehicle.

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Lever Kick Starter

New Part.
Design is changed to suit the
new styling.

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Suppresser Cap

New part.
Suppressor cap design is
changed to avoid the water
entry.

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Lever Gear Shifting

New Part.
Link type design provided to
give racing bike feel during gear
shift.
Cam gear shift design changed
to match the changes in
Crankcase RH for smoother gear
shifting.
Transmission gears are same
as Apache 150cc.

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Rear Brake Pedal

New part.
To suit the new styling.

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Wiring Harness

New Part.
New couplers to connect the
LED tail lamp.
Water proof coupler provided
for avoiding the water entry.
Special coupler provided to
connect the digital speedometer.

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Relay pass by

New part
Relay unit provided for Pass
by operation.
Pass by will work in both DC
and AC.

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TCI Unit

New part.
160cc Ignition timing curves are
changed in TCI of RTR.
For identification IDI in grey
colour.

150cc

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Handle Bar
New part.
Split type handle bar to suit the
new styling.
Handle bars can be adjusted to
two positions as per the
requirement.
Upper bracket cover added for
styling.

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Bracket Pillion Foot Rest

New part.
diecasted pillion foot rest
holder.
Charcoal Grey colour to
match the look of the bike.

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Bracket Side Stand

New Part.
To improve the Part lift.

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Chain Case

New part
both Chain case upper and
Lower are modified to match the
new swing arm fitments.
Dimple profile provided at inner
side of case to avoid wheel
fouling during the ride.

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Rear Fender

New part.
Rear fender design is
changed to suit the new
styling.

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Number Plate Lamp

Design is changed.
Rear Reflector is fitted to lamp
body.

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Digital Speedo Hub Drive

New Part.
Connected to digital Speedo
meter through the wires.
Speedo cable is not
provided.

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Front Fork RH

New Part.
Outer Tube design is changed
Disk Mounting point is changed.

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Vibration Dampers & Handle Grip

New Part.
Handle grip is modified
Vibration damper is modified.
Chrome plating is provided for
Clutch lever and Front Brake lever.

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Engine Guard

New Part.
To provide a sporty look to the
bike.

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Gas filled Rear shock Absorbers

New Part.
Canister Design modified.
Filled with Nitrogen Gas.
Lower mounting bracket length
increased.

150cc 160cc

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Front Wheel Assy.

New Part.
Disc mounting positions changed
to mount the 270 mm disc.

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APACHE - IGNITION CIRCUIT
Charging Coil
WR B

RW BW

RR Unit
10A Fuse
BW R ENGINE KILL SWITCH
R
SELF STARTER
Battery BW Ignition B SWITCH
Switch
BW
Or
DC CIRCUIT Or

W B B
Br BlR
DC TCI Digital
SPEEDOMETER
BW Or Bl
PULSER COIL
GW
HT COIL BlW
TCS

HT Cord THROTTLE CONTROL SWITCH

Spark Plug

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APACHE – IDI CIRCUIT

10A Fuse
BW R ENGINE KILL SWITCH
R
SELF STARTER
BW
Battery Ignition B
RELAY UNIT
Switch
BW
Or
DC CIRCUIT Or

W B B
Br BlR
DC IDI Digital
BW SPEEDOMETER
Or Bl
PULSER COIL
GW
HT COIL BlW
TCS

HT Cord THROTTLE CONTROL SWITCH

Spark Plug

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APACHE - CHARGING CIRCUIT
Charging Coil BW

WR B DC TCI

RW BW ENGINE KILL
SWITCH
RR Unit B SELF STARTER
10A Fuse B SWITCH
BW R
R

Battery BW Ignition
Switch

Or

Or Or Or Or Horn(2) DC TCI
Or
Flasher lbl TSL Switch
Fr.Br Switch Rr.Br. Switch RELAY PASS BY L R
Unit
GB Fr. TSL Fr. TSL
Y Or G
W Y
W Horn V
High/Low Beam switch Switch Rr. TSL lG Rr. TSL
BW

Brake Light YBl TSL Indy TSL Indy


HEAD.LAMP PASS BY SWITCH
BW
Lighting Switch

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APACHE – SELF START CIRCUIT BW

ENGINE KILL
DC TCI SWITCH
B
10A Fuse B
R
R

BW BW Ignition
Battery Switch

Gr TO DC Circuit
B BlW

Clutch S witch S tarter Button

Or
BlW

Neutral Lamp

Bl
Bl

Starter Relay Neutral Switch


S TARTER MOTOR

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APACHE - LIGHTING CIRCUIT

Lighting Coil
Y B
W PASS BY SWITCH
BW
YR GB
RR Unit OR
YW RELAY PASS BY

Lighting Switch
Yor
Y
Gr

YB
Gr Gr
Gr Gr Gr Headlamp
SPEEDOMETER Number Tail
plate City City
Lamp
lamp lamp lamp
H
BW BW BW BW
BW WR
L BW
Headlamp Switch

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A P A CH E - CO I L T E S T I N G
Lighting Coil
Resistance :0.25 - 1.0 ohm

Lighting coil

Y
200 R BW
Ohm s
+ B
-

Pulser Coil Charging Coil


Re sista nce: 125 - 150 Ohms Re sista nce: 0.4 - 1.0 Ohm s
Charging
Puls e r coil coil

Br WR
W BW
2000
Ohm s R 200
Ohm s R
+ +
- B - B

IGNITION COIL TESTING

Secondary Coil
Primary Coil
Re sista nce: 11.0 - 13.0 KOhms
Resistance : 2.0 - 4.0 Ohm

Ignition coil Ignition coil


HT CORD
Or
200 Bl HT CORD 20K
Oh ms Oh ms
+ +
- -
To Spar k Plug From CDI Unit

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PDI
01.CHECK FOR PAINT SCRATCHES/DAMAGES
02.MISSING ITEMS
03.ALIGNMENTS/GAP
04.STANDARD CHECKS
05.FASTENER TIGHTNESS CHECKS
06.GENERAL CHECKS (AFTER STARTING THE ENGINE)
07.ELECTRICAL FUNCTION CHECKS
08.ROAD TRIAL
09.POST TRIAL (ON STAND)

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Customer Installation
Basic Check points before starting the Vehicle
•All controls operations(clutch,brake,throttle,gear shifting)
•Explain all settings on Digital Speedometer
• Tank capacity : 16lit Res: 2.5lit
•Tyre pressure
•Battery condition – Proper functioning of horn,brake lights,turn signal
indicators,electrolyte level
•Tool kit
•First aid kit
•Engine oil level
•Lighting
Service schedule
•Explain Service schedule of Apache RTR 160 as per owners manual
Warranty
•Warranty period, Parts not covered under warranty, Limitations of warranty.
•Tips for achieving best performance from vehicle
•Proper tyre pressure
•Battery condition checking
•Usage of IFTEX for petrol(2ml/ltr)
•Running in period
•Riding tips

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Service Schedule
Se rvice Kms Month Fre e/Pay

I 500 - 750 1 month

II 2500 - 3000 3 Months

Free
III 5500 - 6000 6 Months

IV 8500 - 9000 9 Months

V 11500 - 12000 12 Months

VI 14500 - 15000 15 Months

VII 17500 - 18000 18 Months

VIII 20500 - 21000 21 Months

Pay
IX 23500 - 24000 24 Months

X 26500 - 27000 27 Months

XI 29500 - 30000 30 Months

Warranty Period: 30000kms/24 months

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Periodic Maintenance

PRODUCT TRAI NI NG CENTRE


Periodic Maintenance

PRODUCT TRAI NI NG CENTRE


Periodic Maintenance

PRODUCT TRAI NI NG CENTRE


Periodic Maintenance

PRODUCT TRAI NI NG CENTRE


PRODUCT TRAI NI NG CENTRE

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