2012

FMSCI 2W Homologation Form

TVS APACHE RTR 180

212MC003

A25, Krishna Towers, 50 Sardar Patel Road, Chennai 600113

Ph : (91) (44) 22352673, 6450665, Fax : (91) (44) 22351684
email : fmsci @vsnl.com, web : www.fmsci.in
 FMSCI Homologation:212MC003
Valid From :04-10-2012

Article Description

1. General
101 Manufacturer's Name TVS MOTOR COMPANY LIMITED

102 Manufacturer's address P.B. No. 4 , HARITA , HOSUR 635109

103 Brand name TVS

Model

(a) Model Year 2008

104 (b) Model Identification Name APACHE RTR 180

(c) Beginning Serial No. ENGINE No. : 0E6H82000003

(d) End Serial No.

105 Type Motorcycle Scooter Moped

106 ** Minimum weight 122 kgs

Right Side view of the vehicle Left Side view of the vehicle

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

2. Engine
201 Type of Engine Four Stroke Two Stroke

202 Number of Cylinders One

a) Bore ** 62.5 mm

b) Stroke ** 57.8 mm

203 ** c) Conrod length ** 106.45 mm

d) Supercharging Yes No

e) Type and number of compressors NA

204 Cubic capacity (Refer Manual) 177.3 cc

(a) Minimum Volume of Cylinder Head
16.80mm
205 ** (Refer Manual)
(b) No. of spark plugs per Cylinder 1

206 Compression Ratio (Refer Manual) 9.5 : 1

Piston

a) Material Aluminium Alloy

b) Minimum Weight (Refer Manual) ** 147.50 gm

2 ( in two grooves) + 3 (Oil rings in one groove)
207 ** c) No. of Rings per Piston
(Top : Stainless Steel, Bottom : Cast Iron)
d) Piston pin offset (Refer Manual) ** 0.5 mm

e) Piston pin material Steel

f) Piston pin weight 30 gms

Material

a) Crankcase Aluminium Alloy

b) Cylinder barrel Aluminium Alloy + CI Sleeve

c) Cylinder head Aluminium Alloy

d) Generator cover Aluminium Alloy

208 e) Primary case cover Aluminium Alloy

f) Clutch cover Aluminium Alloy

g) Crankshaft cover Aluminium Alloy

h) Gear Box cover Aluminium Alloy

i) Ignition cover Aluminium Alloy

k) Cylinder head cover (valve) Aluminium Alloy

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

Material Weight

l) Crank shaft ** (Refer Manual) Forged Steel 3310 gms **

208 m) Conrod ** (with cap, bolts and shell
Forged Steel 176 gms
bearings) (Refer Manual)
209 Thickness of tightened cylinder head gasket 0.22 mm
Position of Cylinder & head relative
210 25° degree
to the Crank Case
a) Method of cooling Air Liquid Air & Liquid
211
b) Type of liquid NA
Does the cylinder have a sleeve or liner Yes Material : Aluminium Alloy + CI
212
If yes, material Sleeve, No
Chrome Nickel Electrofusion
213 Cylinder barrel – coating
Others : No Coating

214 Reed Valve Rotary Valve

Method of Induction
Piston Port Poppet Valve

View of Engine / Crankcase Assembly – Left Side View of Engine / Crankcase Assembly– Right Side

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

View of Engine/Crankcase Assembly– Front Side View of Engine / Crankcase Assembly– Rear View

View of Engine/ Crankcase Assembly – Top View View of Engine / Crankcase Assembly– Bottom Side

A) Fuel feed by Carburettor

a) Make UCAL

b) Type / Model BS29

215
c) Venturi diameter 29 mm +/- 0.25 mm

d)Maximum diameter of Carburettor exit port 29 mm

e) Length of adaptor 26 ± 0.2 mm

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

Carburettor showing exit port

B) Fuel feed by Injection

a) Make NA

b) Model NA

c) Kind of fuel measurement Mechanical Electronic Hydraulic

215 d) Dimensions of intake pipe at the

NA
throttle or slide location

e) Number of effective fuel outlets NA

f) Position of injectors NA

f1) Manifold / Cylinderhead Manifold Cylinderhead

g) Sensors of injection system NA

h) Actuators of injection system NA

Injection System

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

Location of Sensors & Actuators

For Two Strokes Only

a) Number of Ports NA

Total NA

Intake NA
216
Transfer NA

Boost NA

Exhaust NA

b) Height of Ports

Intake mm

Transfer mm

Boost mm

Exhaust mm
216
c) Width of Ports

Intake mm

Transfer mm

Boost mm

Exhaust mm

For Four Strokes only

Inlet valves

a) Number One
217 **
b) Diameter ** 27.50 mm

c) Stem dia ** 5 mm

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

d) Overall length ** 79.00 mm

e) Weight ** 25 gms

f) Number of springs per valve 2

g) Type of valve springs Compression Coil

If more than one spring Inner Outer

22.5 under a load of 26.67 under a load of
h) Maximum length of the spring
68.7 ± 6.9 N 7 ± 0.5 N
i) External diameter of springs 16.4 +/- 0.2 mm 23 +/- 0.2 mm

j) Diameter of spring wire 2 2.8

k) Number of spring coils 7.74 5.88

l) Maximum free length of springs 30 mm 30.8 mm

Exhaust valves

a) Number One

b) Diameter ** 24.50 mm

c) Stem dia ** 5 mm

d) Overall length ** 78.40 mm

e) Weight ** 20 gms

f) Number of springs per valve 2

218 **
g) Type of valve springs Compression Coil
22.5 under a load of 26.67 under a load of
h) Maximum length of the spring
68.7 ± 6.9 N 7 ± 0.5 N
i) External diameter of springs 16.4 +/- 0.2 mm 23 +/- 0.2 mm

j) Diameter of spring wire 2 2.8

k) Number of spring coils 7.74 5.88

l) Maximum free length of springs 30 mm 30.8 mm

m) Diameter of pipe between manifold and
45.9 mm +/- 5% 55.56 mm +/- 5%
first silencer
Maximum valve lift

219 a) Intake 7.2 ± 0.1 mm

b) Exhaust 7 ± 0.1 mm

Tappet Rockerarm Oscillating Lever

220 Type of valve operation
Direct Hydraulic

Ratio

221 a) Rocker Arm 27.1 / 21.8

b) Oscillating lever NA47

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 FMSCI Homologation:212MC003
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c) Rocker Arm weight 60 gms with bearing/roller

222 Overhead valve Yes No

223 Overhead CAM Yes No

224 Pushrod Yes No

225 Method of Cam shaft drive Chain

CAM Timing

a) Inlet opens 6° ± 2° Degree BTDC

226 b) Inlet closes 41° ± 2° Degree ABDC

c) Exhaust opens 43° ± 2° Degree BBDC

d) Exhaust closes 4° ± 2° Degree ATDC

CAM dimensions
a) Inlet ** A=28 +/-0.1 mm

B=33.80+/-0.1 mm

b) Exhaust ** A=28+/-0.1 mm

B=33.69+/-0.1 mm
227 **
c) Weight of the Cam ** 484 gms

d) Number 1

e) Location Cylinder Head

f) Number of bearings per shaft 2

g) Inside diameter of bearings 10 +/- 0.1 mm

CAM Sprocket No. of teeth 32

O/D CAM Sprocket 62.17

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

Cam lift in mm (dismounted camshaft)

Intake Exhaust
Rotation Rotation Rotation Rotation
Lift in Lift in Lift in Lift in
Angle in Angle in angle in angle in
Mm mm Mm mm
Degrees Degrees Degrees Degrees
0 5.81 0 5.69
-5 5.74 +5 5.75 -5 5.63 +5 5.64
-10 5.56 +10 5.58 -10 5.49 +10 5.48
-15 5.27 +15 5.29 -15 5.20 +15 5.21
-30 3.74 +30 3.69 -30 3.79 +30 3.74
-45 1.83 +45 1.58 -45 1.96 +45 1.71
-60 0.54 +60 0.40 -60 0.61 +60 0.25
-75 0.16 +75 0.14 -75 0.17 +75 0.11
-90 0.07 +90 0.04 -90 0.07 +90 0.03
-105 0 +105 0 -105 0 +105 0
-120 0 +120 0 -120 0 +120 0
-135 0 +135 0 -135 0 +135 0
-150 0 +150 0 -150 0 +150 0
A shift of +/- 2 degrees of the whole measurement is accepted

Applicable to both 2 & 4 Stroke Engines

228 Type of Ignition IDI Inductive Type

229 Starting Devices Kick Self Both

a) Clutch wet dry

230 b) Method of operation Cable Hydraulic

c) Weight of Clutch Basket (Refer Manual) ** 1.82 kg

Transmission

Primary Drive

a) Method of primary drive Gear Belt Chain

b) If gear drive Helical Straight Cut

231 ** Primary Drive Ratio 3.095

If gears / Chain Drive Driven

a) No. of teeth ** 21 65

b) Thickness ** 18.5 mm 16 mm

if belt

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 FMSCI Homologation:212MC003
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a) Diameter of pulleys NA mm

Gear Box

a) Shell Material Aluminium Alloy

232 **
b) No. of speeds Five

c) Material of gears Steel and Cast Iron

Gear Ratio No. of teeth Thickness **

Drive Driven Drive Driven

First 2.917 12 35 12.4 11

Second 1.857 14 26 12 10

Third 1.333 18 24 8.9 9.6

Fourth 1.05 20 21 9.3 9.4

Fifth 0.88 25 22 10.1 9.9

Sixth NA NA NA NA NA

Secondary Drive
a) Method of Secondary Drive Chain Shaft Belt
233 ** b) Secondary Drive Ratio 3.385
c) If chain, No. of teeth ** Drive 14 Driven 46
d) If belt, diameter of pulleys NA

3 Chassis and Suspension

a) Main frame type Double Tubular Cradle Frame
301
b) Material (Gussets / Tubes) Steel Tubes

Frame

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 FMSCI Homologation:212MC003
Valid From :04-10-2012

Front Suspension
a) Method of suspension Hydraulic Telescopic
302
b) Front tube O.D. 30 mm
c) Lower Slider O.D. 38 mm
Rear Suspension
a) Method of suspension Mono Shock Twin Shock
303
b) Swinging Arm Type Tubular Rectangular Box Section
c) Material of Swinging Arm Steel
Wheels
304 a) Front wheel rim diameter (OD) 17 Inches
b) Width 1.85 Inches
a) Rear wheel rim diameter (OD) 17 Inches
305
b) Width 2.15 Inches
306 Oil Tank Capacity NA liters
Fuel Tank
307 a) Capacity 16 Litres
b) Material Steel

308 Has the fuel system an electrical pump No

4 Exhaust System
401 Detachable baffles Yes (external heat protection plate)
Weight of the silencer system with bolts for
402 ** 7.12 kgs
fixing the same **
403 Inner diameter of the bend of the silencer Dia. 29.4 mm

404 Anti Pollution System : Description Catalytic Converter

5. Brakes Front Rear

a) Number of pistons per caliper 2 1
b) OD of piston in caliper 27 mm 32.00 mm
501 c) Drum Brakes Yes No Yes No

c1) Internal diameter +/-1.5 mm +/-1.5 mm

c2) Number of linings per wheel
c3) Developed length of lining +/-1.5 mm +/-1.5 mm

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 FMSCI Homologation:212MC003
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c4) Width of lining +/- 1mm +/- 1mm

d) Disc Brakes Yes No Yes No

d1) Number of pads per wheel 2 2

d2) Number of calipers per wheel 1 1
d3) Caliper Material Aluminium Aluminium
d4) Thickness of new disc 4+/- 1 mm 4+/- 1 mm
d5) External diameter of disc 270 +/-1.5 mm 200 +/-1.5 mm
d6) External diameter of pads rubbing
270 +/-1.5 mm 200 +/-1.5 mm
surface
d7) Internal diameter of pads rubbing
227.5 +/-1.5 mm 185.5 +/-1.5 mm
surface
d8) Overall friction length of pads 74.5 +/-1.5 mm +/-1.5 mm
d9) Ventilated discs Yes No Yes No

6 Radiator
Radiator Core Dimensions

a) Height
601
b) Width

c) Depth

7 Airbox
a) Air Box Yes No

b) Material Plastic
701
c) RAM Air intake opening in fairing Yes No

d) Dimension

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