Apache RTR 160 Manual PDF

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N PRODUCT TRAI NI NG CENTRE
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Exclusive features of Apache RTR 160
o m
c
All New Racing Graphics
Racing Throttle Response Engine (RTR)
s .
Split Type sporty Handle bar
ik e
Digital Speedo…with Service indicator system
n B
Bull horn pillion Handle
Adjustable Link type gear shift mechanism
e
270mm Front Disc brake
G
x
16 LED Tail Lamp
Ne PRODUCT TRAI NI NG CENTRE

RTR…
o m
Feature:
s . c
ik e
•RTR : Racing Throttle Response
•15.2 bhp engine
n B Benefit:
• Quick Response to the throttle.
G e • Feel of a race bike.
e x
IDI System
o m
Feature:
s . c
e
TCI : Transistor controlled ignition
ik
n B Benefit:
Long and high intensity Spark for
G e better combustion of Fuel mixture.

Help in cold start & Cold Recovery
e x
CDI Vs IDI
o m
s . c
CAPACI TOR
ik e
n B
G e
e x
Gas Filled Shock Absorber
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Feature
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ik e
Gas filled 5 step adjustable
shock absorber with Bottle
designed Canister
n B Benefit
G e Comfortable ride even on bad

roads
e x
Sporty Silencer
Feature
o m
. c
• Stainless steel, sporty silencer
s
with catalytic converter and
e
exhaust resonator.
ik
• Narrow snout designed muffler.
Benefit
n B • Sporty looks
• Resonator helps to achieve good
G e power & Torque

• Rust Free
e x • Catalytic converter reduces

pollution

Stylish Contoured Fuel Tank
o m
Feature
s . c
ik e
• Sporty and Stylish
• 16 liters (including Reserve –
2.5 ltr) capacity with flushed petrol
n B tank cap
Benefit
G e • Higher capacity Petrol Tank for

long distance ride.
e x
Halogen HL Bulb with
Twin City Lamps
o m
Feature
s . c
ik e
• Halogen HL bulb with Twin
city lamps
B
Benefit
n
• Brighter light
G e • Safer to ride in city traffic

condition
e x
RCF Technology
o m
Feature
s . c
e
• Roller Cam Follower
ik
• Auto De-Compression Valve
Benefit
n B Friction free engine –

Low maintenance
G e Longer engine life

Smoother engine
e x No back kick during kick starting

Racing Response Engine…
o m
Feature
s .
• Powerful Engine -
c
ik e
Power 15.2 BHP@8500 rpm
Torque13.1 Nm@6000 rpm
n B • Engine with Charcoal Grey

colour is added look.
G e Benefit
• Excellent Initial pickup
e x • Better top speed

270mm Disc Brakes…
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Feature
s . c
ik e• Disc brakes with Sprocket
design disc
Benefit
n B • Sporty looks
• Effective braking
G e • Better stability
e x
Any Gear Electric Start…
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Feature
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• Any Gear Self Starting
• Constant mesh self starter
B
• SM-6 Motor
n
Benefit
e
• Positive engagement
G
• Effortless Starting
x
• Soft button start

Digital Speedo…
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Feature
s . c
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• Vehicle speed, clock,
odometer, Trip meter on LCD
screen.
n B Benefit
G e • Guides the customer in time

• More accurate
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IE SURGE…
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Feature
Resonator Surge
s .
• IE SURGE - Intake Exhaust
ik e
•Induction resonator on air filter
• Exhaust Resonator on Silencer
B
Benefit
n
• Intake Resonator accelerates the air
fuel mixture flow during sudden
e
throttling and helps in quicker power
response to zoom the bike.
xG • Exhaust Resonator helps in clearing

exhaust gas quickly out of the silencer
e
during sudden throttling which results
in high torque.

5 – Speed Transmission…
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Feature
s
• 5 Speed gear box
. c
ik
system
e
• Link type Adjustable shifting
B
• Carbo-nitrating Gears
n
Benefit
e
• High speed
G
• Racing bike gear shifting system.
x
• Improved life of gears

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Dimensions
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SPECIFICATIONS TVS Apache RTR 160
s . c
TVS Apache
Overall Length
Overall Width
Overall Height
2020 mm
730 mm
1050 mm
ik e 1976 mm
743 mm
1100 mm
Ground Clearance
Wheel Base
n B
180 mm
1300 mm
165 mm
1260 mm
G e
Kerb Weight
Pay Load
136 kg
130 kg
136 kg
130 kg
x
Gross Vehicle W eight 266 kg 266 kg

Engine
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SPECIFICATIONS
Type
TVS Apache RTR 160
s . c
TVS Apache
4 stroke ,air cooled, single cylinder OHC
e
Bore 62 mm 57 mm
Stroke 52.9 mm 57.8 mm
ik
Piston Displacement 159.7cc 147.5 cc
Carburettor Type Ucal mikuni BS - 26 Ucal mikuni BS - 26
B
Air Filter Double polyurethene foam filter element
n
Starting System Kick start / Electric start
Lubrication System Forced wet pump
e
Compression Ratio 9.5:1
2
Compression Pressure 10 - 13 kg/cm
G
Maximum Horse Power 11.19 KW (15.2 bhp) @ 8500 rpm 9.95 Kw(13.5 BHP)@8500 rpm
x
Maximum Torque 13.1 Nm @ 6000 rpm 12.3 Nm@6000 rpm
Inlet 0.08 / Exhaust 0.11 mm Inlet 0.07 / Exhaust 0.12 mm
e
Valve Clearance (Cold)
Maximum Speed 118 kmph 108 kmph
N
Engine Idling Speed 1400±100
PRODUCT TRAI NI NG CENTRE

Transmission
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s . c
TVS Apache
e
Clutch Wet Multiplate type
Transmission Constant mesh 5 speed gearbox
ik
Gear Shift Pattern All down heel - toe shift
Primary Reduction 65/21
Final Reduction
First Gear
n B 44/13
35/12
e
Second Gear 26/14
Third Gear 24/18
G
Fourth Gear 21/20
x
Fifth Gear 22/25

m
Chassis
. c
TVS Apache
o
Frame Double Cradle SynchroSTIFF
e s
Double cradle tubular type
ik
Front Suspension and
lescopic Forks, 105mm Stroke Telescope oil damped 105mm
Travel
B
Monotube Inverted Gas filled shox Gas filled 5 step adjustable with
Rear Suspension
(MIG) with spring aid canester
n
Steering Angle 41'
e
°
Caster Angle 25.5 25.5'
Trail Length 81.3 mm 90mm
xG
Brakes: Front
Brakes: Rear
270 mm Petal Disc
130 mm Drum
130/240 mm dia Drum/Disc
130 mm foot operated
e
Tyre Size Front 90/90 x 17” 90/90 x 17 - 6 ply
Tyre Size Rear 100/80 x 18” 100/80x 18

Electrical
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SPECIFICATIONS TVS Apache RTR 160 TVS Apache
Ignition System
Sparkplug
s
Bosch Super UR 5 DDC
.
IDI -dual mode digital ignition - DC
e
Sparkplug Gap 0.6 mm
ik
Battery Type 12V 9 Ah
Body Earthing Negative terminal
Generator 12V, 100W
Head Light
with MFR
n B
35/35W Halogen HS1, Clear lens
0.5 W. LED-Twin triangle with prism

12V, 35/35 W HS 1 halogen
e
Tail Light/Brake Light 12 V, 5W / 21W
on lens
Turn Signal Light 12V,10W
xG
High Beam Indicator Light
Neutral Indicator Light
Speedometer Light
12V,2W
12V,3.4W
12V,3.4W
Ne
Economy & power mode lamp
Turn Signal Indicator Light
12V,2W
12V,2W

Capacity
o m
SPECIFICATIONS
Fuel Tank Including
TVS Apache RTR 160
s . c TVS Apache
e
16 Lts
Reserve
Reserve 2.5 lts
ik
Front Fork Oil 125 ± 2.5 ml each
B
Transmission cum Engine
4T Oil
Oil (Grade)
Transmission cum Engine
n
1000ml(Overhauling)
Oil (Qty)
G e
e x
Carburettor Specifications
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Discription
Carburettor Type
TVS APACHE RTR 160
BS26 CV Ucal Mikuni
s . c
TVS APACHE
BS26 - X21 CV Ucal Mikuni
e
Main Jet 105 102.5
Needle Jet P2
ik
Jet Needle QK
E - ring position 2 nd from top
Pilot Jet
Pilot air jet (1)
n B 15
1.45
12.5
1.45
e
Pilot air jet (2) NA
CA - 3.9(2 vacuum sensing CA - 3.9(1 vacuum sensing
Piston valve
holes) hole)
G
Throttle Valve 120
x
MCS screw - No of turns 2±1(1 ~ 3 turns out)
Idling RPM 1400±50
Ne
Idling CO%(with SAI)
Idling CO%(without SAI)
0.8 ~ 1.2%
3.5 ~ 4.5%

0.6 ± 0.4%
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n B
G e
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Cylinder Head
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Combustion Chamber diameter
ik e
increased.
bigger Inlet & Exhaust valve
seats provided.
n B Painted with Charcoal grey

colour.
G e
e x
Cylinder Block
o m
s . c
ik e
Bore Dia. increased to 62 mm
Auto Chain Tensioner mounting
design is changed.
n B 159.7 cm3 embossed for

identification.
G e Painted with Charcoal grey colour.
e x
Piston Assy.
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s . c
ik e
Piston Dia. increased to 62 mm
Piston Rings dia increased to
B
match the new piston.
n
Piston Pin and locks also modified
G e
e x
Crankshaft Assy.
o m
s . c
160cc
ik e
Crankshaft web weight increased.
B
Connecting rod modified.
n
Chamfer on Crank web are bigger.
G e
x
150cc
e
Clutch Cover
o m
s . c
ik e
New Part
Rod comp. Clutch release is
modified.
n B Charcoal grey painting is

provided
G e
e x
Auto Chain Tensioner
o m
s . c
ik e
New Part
n B Strip coil type tensioner
G e
e x
Crankcase RH
o m
s . c
ik e
New Part
Guide bush provided for Cam
B
Guide bush gear shift shaft.
n
Painted with charcoal grey
e
colour.
xG
Crankcase LH
o m
s . c
ik e
New Part
B
Painted with Charcoal grey
colour.
e n
xG
Clutch Assy.
o m
New Part
s . c
Clutch plate Drive and plate
ik e
driven are modified.
Clutch spring are changed.
B
Clutch plate serrations
reduced to 45( Apache 150 – 48
e n serrations).
Plain surface provided for
G
pressure plates (Apache 150 –
x
dotted surface)

Cover Magneto
o m
s
New Part
. c
ik e Charcoal grey colour.
n B
G e
e x
Stator coil assy.
o m
New Part
s . c
ik e
Charging and lighting coils
increased to 8(Apache 150 – 7
coils)
n B Since Source coil is not

available here, that location is
e
used for one additional lighting
/charging coil.
xG
CV Carburetor
New Part
o m
. c
Fuel Jets and Tuning
s
specifications changed
ik e
Main Jet – 105
Pilot Jet – 15
B
Piston Valve CA-3.9(1 vacuum
hole)
e n CO (with SAI) – 0.8 ~ 1.2%

Since change in By pass pitch ,
xG RTR 160 have new carburetor

body
Ne Can not interchange with

Apache 150cc

Inlet & Exhaust Valve
o m
RTR 150cc
s . c
ik e
New Parts
Valve face diameter increased
n B Inlet tappet clearance – 0.07 mm

Exhaust tappet clearance – 0.11
e
mm
xG
Ne
Exhaust
Inlet

Silencer Assy.
o m
s . c
e
New Part.
ik
Narrow snout Muffler Assy.
design is to suit the new styling.
n B Mounting bracket point is

changed.
e
Exhaust resonator position
shifted to bottom side vehicle.
xG
Lever Kick Starter
o m
s . c
ik e
New Part.
Design is changed to suit the
n B new styling.
G e
e x
Suppresser Cap
o m
s . c
ik e New part.
B
Suppressor cap design is
changed to avoid the water
e n entry.
xG
Lever Gear Shifting
o m
New Part.
s . c
ik e
Link type design provided to
give racing bike feel during gear
shift.
n B Cam gear shift design changed

to match the changes in
e
Crankcase RH for smoother gear
shifting.
xG Transmission gears are same

as Apache 150cc.

Rear Brake Pedal
o m
s . c
ik e
New part.
n B To suit the new styling.
G e
e x
Wiring Harness
o m
New Part.
s . c
e
New couplers to connect the
ik
LED tail lamp.
Water proof coupler provided
n B for avoiding the water entry.

Special coupler provided to
e
connect the digital speedometer.
xG
Relay pass by
o m
New part
s . c
ik e
Relay unit provided for Pass
by operation.
B
Pass by will work in both DC
and AC.
e n
xG
TCI Unit
o m
s . c
160cc
ik e
New part.
Ignition timing curves are
changed in TCI of RTR.
n B For identification IDI in grey

colour.
G e
e x 150cc

Handle Bar
o m
New part.
s . c
Split type handle bar to suit the
e
new styling.
ik
Handle bars can be adjusted to
two positions as per the
B
requirement.
n
Upper bracket cover added for
styling.
G e
e x
Bracket Pillion Foot Rest
o m
New part.
s . c
ik ediecasted pillion foot rest
holder.
n B Charcoal Grey colour to

match the look of the bike.
G e
e x
Bracket Side Stand
o m
s . c
ik eNew Part.
To improve the Part lift.
n B
G e
e x
Chain Case
o m
s . c
e
New part
ik
both Chain case upper and
Lower are modified to match the
B
new swing arm fitments.
n
Dimple profile provided at inner
e
side of case to avoid wheel
fouling during the ride.
xG
Rear Fender
o m
s . c
ik eNew part.
Rear fender design is
B
changed to suit the new
styling.
e n
xG
Number Plate Lamp
o m
s . c
ik e
Design is changed.
Rear Reflector is fitted to lamp
n B body.
G e
e x
Digital Speedo Hub Drive
o m
s . c
ik e
New Part.
Connected to digital Speedo
B
meter through the wires.
n
Speedo cable is not
provided.
G e
e x
Front Fork RH
o m
s . c
ik e
New Part.
Outer Tube design is changed
n B Disk Mounting point is changed.
G e
e x
Vibration Dampers & Handle Grip
o m
s . c
ik e
New Part.
Handle grip is modified
n B Vibration damper is modified.

Chrome plating is provided for
e
Clutch lever and Front Brake lever.
xG
Engine Guard
o m
s . c
ik e
New Part.
B
To provide a sporty look to the
bike.
e n
xG
Gas filled Rear shock Absorbers
o m
New Part.
s . c
ik e
Canister Design modified.
Filled with Nitrogen Gas.
n B Lower mounting bracket length

increased.
G e
e x
150cc 160cc

Front Wheel Assy.
o m
s . c
ik e
New Part.
B
Disc mounting positions changed
to mount the 270 mm disc.
e n
xG
APACHE - IGNITION CIRCUIT
Charging Coil
o m
RW
WR B
BW
s . c
e
RR Unit
10A Fuse
ik
BW R ENGINE KILL SWITCH
R
SELF STARTER
Battery BW Ignition B SWITCH
Switch
B
BW
Or Or
n
DC CIRCUIT
W B B
e
Br BlR
DC TCI Digital
SPEEDOMETER
BW Or Bl
G
PULSER COIL
GW
HT COIL BlW
TCS
e x Spark Plug
HT Cord THROTTLE CONTROL SWITCH

m
APACHE – IDI CIRCUIT
. c o
BW
10A Fuse
R
R
e s
ENGINE KILL SWITCH
ik
SELF STARTER
BW
Battery Ignition B
RELAY UNIT
Switch
BW
B
Or
DC CIRCUIT Or
W B B
n
Br BlR
DC IDI Digital
e
BW SPEEDOMETER
Or Bl
PULSER COIL
GW
HT COIL BlW
G
TCS
HT Cord THROTTLE CONTROL SWITCH
e x Spark Plug

APACHE - CHARGING CIRCUIT
Charging Coil
o m
c
BW
.
WR B DC TCI
s
RW BW ENGINE KILL
SWITCH
e
RR Unit B SELF STARTER
10A Fuse B SWITCH
ik
BW R
R
Battery BW Ignition
Switch
Or Or Or Or
n B Or
Horn(2) DC TCI
e
Or
Flasher lbl TSL Switch
Fr.Br Switch Rr.Br. Switch RELAY PASS BY L R
Unit
G
GB Fr. TSL Fr. TSL
Y Or G
W Y
W Horn V
x
High/Low Beam switch Switch Rr. TSL lG Rr. TSL
BW
e
Brake Light YBl TSL Indy TSL Indy
HEAD.LAMP PASS BY SWITCH
BW
N
Lighting Switch

APACHE – SELF START CIRCUIT
o m BW
c
ENGINE KILL
DC TCI SWITCH
.
B
10A Fuse B
R
s
R
BW BW Ignition
e
Battery Switch
ik
Gr TO DC Circuit
B BlW
Clutch S witch
n B S tarter Button
Or
e
BlW
Neutral Lamp
G
Bl
Bl
x
Starter Relay Neutral Switch
S TARTER MOTOR

APACHE - LIGHTING CIRCUIT
o m
c
Lighting Coil
.
Y B
W
s
PASS BY SWITCH
BW
GB
e
YR
RR Unit OR
ik
YW RELAY PASS BY
Lighting Switch
Gr
n B Yor
Y
e
YB
Gr
G
Gr
Gr Gr Gr Headlamp
SPEEDOMETER Number Tail
x
plate City City
Lamp
lamp lamp lamp
H
e
BW BW BW BW
BW WR
L BW
N
Headlamp Switch

A P A CH E - CO I L T E S T I N G
Lighting Coil
o m
c
Resistance :0.25 - 1.0 ohm
.
Lighting coil
s
Y
200 R BW
Ohm s
+ B
-
Pulser Coil
Re sista nce: 125 - 150 Ohms
Puls e r coil
ik e Charging Coil
Re sista nce: 0.4 - 1.0 Ohm s
Charging
coil
B
Br WR
W BW
2000
Ohm s R 200
Ohm s R
+ +
- B - B
e Primary Coil n
IGNITION COIL TESTING
Secondary Coil
G
Re sista nce: 11.0 - 13.0 KOhms
Resistance : 2.0 - 4.0 Ohm
x
Ignition coil Ignition coil
HT CORD
Or
Bl HT CORD
e
200 20K
Oh ms Oh ms
+ +
- -
To Spar k Plug From CDI Unit

PDI
o m
01.CHECK FOR PAINT SCRATCHES/DAMAGES
02.MISSING ITEMS
s . c
e
03.ALIGNMENTS/GAP
ik
04.STANDARD CHECKS
05.FASTENER TIGHTNESS CHECKS
n B
06.GENERAL CHECKS (AFTER STARTING THE ENGINE)
07.ELECTRICAL FUNCTION CHECKS
G e
08.ROAD TRIAL
09.POST TRIAL (ON STAND)
e x
Customer Installation
Basic Check points before starting the Vehicle
o m
c
•All controls operations(clutch,brake,throttle,gear shifting)
.
•Explain all settings on Digital Speedometer
• Tank capacity : 16lit Res: 2.5lit
s
•Tyre pressure
•Battery condition – Proper functioning of horn,brake lights,turn signal
e
indicators,electrolyte level
ik
•Tool kit
•First aid kit
•Engine oil level
B
•Lighting
Service schedule
n
•Explain Service schedule of Apache RTR 160 as per owners manual
Warranty
G e
•Warranty period, Parts not covered under warranty, Limitations of warranty.
•Tips for achieving best performance from vehicle
•Proper tyre pressure
x
•Battery condition checking
•Usage of IFTEX for petrol(2ml/ltr)
e
•Running in period
•Riding tips

Se rvice
Service Schedule
Kms Month
o m
Fre e/Pay
II
500 - 750
2500 - 3000
1 month
3 Months
s . c
Free
e
III 5500 - 6000 6 Months
IV 8500 - 9000 9 Months
ik
V 11500 - 12000 12 Months
B
VI 14500 - 15000 15 Months
n
VII 17500 - 18000 18 Months
VIII 20500 - 21000 21 Months
Pay
IX
G e 23500 - 24000
26500 - 27000
24 Months
27 Months
x
XI 29500 - 30000 30 Months
e
Warranty Period: 30000kms/24 months

Periodic Maintenance
o m
s . c
ik e
n B
G e
e x
o m
s . c
ik e
n B
G e
e x
o m
s . c
ik e
n B
G e
e x
o m
s . c
ik e
n B
G e
e x
o m
s . c
ik e
n B
G e
e x

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o m

Ne PRODUCT TRAI NI NG CENTRE

G e • Feel of a race bike.

G e better combustion of Fuel mixture.

G e Comfortable ride even on bad

G e power & Torque

e x • Catalytic converter reduces

N PRODUCT TRAI NI NG CENTRE

G e • Higher capacity Petrol Tank for

G e • Safer to ride in city traffic

n B Friction free engine –

G e Longer engine life

e x No back kick during kick starting

N PRODUCT TRAI NI NG CENTRE

n B • Engine with Charcoal Grey

e x • Better top speed

N PRODUCT TRAI NI NG CENTRE

Ne PRODUCT TRAI NI NG CENTRE

G e • Guides the customer in time

xG • Exhaust Resonator helps in clearing

N PRODUCT TRAI NI NG CENTRE

Ne PRODUCT TRAI NI NG CENTRE

Ne PRODUCT TRAI NI NG CENTRE

Lubrication System Forced wet pump

Inlet 0.08 / Exhaust 0.11 mm Inlet 0.07 / Exhaust 0.12 mm

PRODUCT TRAI NI NG CENTRE

Ne PRODUCT TRAI NI NG CENTRE

SPECIFICATIONS TVS Apache RTR 160

N PRODUCT TRAI NI NG CENTRE

0.5 W. LED-Twin triangle with prism

PRODUCT TRAI NI NG CENTRE

PRODUCT TRAI NI NG CENTRE

n B Painted with Charcoal grey

n B 159.7 cm3 embossed for

G e Painted with Charcoal grey colour.

n B Charcoal grey painting is

n B Strip coil type tensioner

Ne PRODUCT TRAI NI NG CENTRE

n B Since Source coil is not

e n CO (with SAI) – 0.8 ~ 1.2%

xG RTR 160 have new carburetor

Ne Can not interchange with

PRODUCT TRAI NI NG CENTRE

n B Inlet tappet clearance – 0.07 mm

PRODUCT TRAI NI NG CENTRE

n B Mounting bracket point is

n B Cam gear shift design changed

xG Transmission gears are same

Ne PRODUCT TRAI NI NG CENTRE

n B To suit the new styling.

n B for avoiding the water entry.

n B For identification IDI in grey

N PRODUCT TRAI NI NG CENTRE

n B Charcoal Grey colour to

n B Disk Mounting point is changed.

n B Vibration damper is modified.

n B Lower mounting bracket length

N PRODUCT TRAI NI NG CENTRE

N PRODUCT TRAI NI NG CENTRE

HT Cord THROTTLE CONTROL SWITCH

N PRODUCT TRAI NI NG CENTRE

PRODUCT TRAI NI NG CENTRE

Ne PRODUCT TRAI NI NG CENTRE