TVS Apache RTR 160 4V User manual

FOREWORD
I
Thank you for choosing the TVS Apache RTR 160 4V (with ABS / Non ABS).
It features new decals, an LED headlamp, a secure wave bite key with over 9,000 combination, high performance radial
tyres, a refreshed colour look and convenient feather touch start technology.
Dear Racer,
Here’s to your new lap on the Apache RTR 160 4V.
TVS MOTOR COMPANY LIMITED
The performance machine also comes with a Single-Channel ABS. Every corner on the track while the ABS and recovery
of the wheel lock achieving superior braking performance.
As a proud owner of the TVS Apache RTR 160 4V, you are now part of the 3.5 million strong TVS Racing families.
This manual explains the features and operations of your TVS Apache RTR 160 4V. Please read it carefully and follow the
instructions to enjoy the ultimate racing experience. To prolong your journey on the TVS Apache RTR 160 4V, we urge
you to get your services only at TVS Motor Company Authorised Distributors or Dealers / Authorised Service Centers.
There’s always a deep connection between man and race machine. The TVS Apache RTR 160 4V takes that connection
to another level, with TVS SmartXonnect - a Bluetooth based connection between your smartphone and race machine
that provides call and SMS notifications, turn-by-turn navigation and comprehensive racing statistics to give you a
winning edge.

Accessories shown in the picture may not be a part of standard equipment.
Pictures shown in this manual are of Apache RTR 160 4V rear disc brake version until it is specified.
Your motorcycle is provided with always glowing head lamp. The head lamp glows automatically
once the engine is started.
Note
Prior permission of TVS Motor Company Limited is required for quoting, copying or reproducing any part of this owner’s
manual.
Always keep your owner‘s manual in the motorcycle and give it to the new owner if you ever sell your TVS Apache RTR
160 4V.
Take time to familiarize yourself with your TVS Apache RTR 160 4V and its performance characteristics.
This owner‘s manual contains a host of useful information. Please take the time to read this manual before you ride your
new TVS Apache RTR 160 4V. Get familiarised with the operation of your motorcycle for maximum safety and pleasure.
The better you know your vehicle, the more pleasure you will experience riding your new vehicle. Ensure that anyone
else riding your TVS Apache RTR 160 4V does the same.
All information, illustrations, photographs and specifications contained in this owner’s manual are based on the
latest product information available at the time of this publication. TVS Motor Company Limited may, however,
incorporate modifications or improvements on its vehicles at any time without notice, and therefore, in such
events it is possible that the relevant part of the owner‘s manual does not apply to your vehicle.
Part Number : NF210650 Revision 1, June 2020
NOTICE
II

Disregarding this message might result in injury to the rider or deadly accidents.
This message provides further clarification for clear understanding of any particular information.
This message indicates special procedures or precautions to be followed to avoid damage to the vehicle.
Caution
Warning
Note
Operating this vehicle safely is an important responsibility of the rider. To help you make decisions on safety, we have
provided necessary operating procedure and other information in this manual. This information alerts you on potential
hazards that could hurt you or others. Since it is not possible to warn you about all the hazards associated with operating
or maintaining the vehicle, you must use your own judgement.
You will find important safety information in following form in this manual. These words carry the following connotations:
SAFETY INFORMATION
III

CONTENTS
IV
Know your TVS Apache RTR 200 4V 10
Technical specifications 87
Running-in information 01
Antilock braking system 02
Safe riding tips 06
Riding your TVS Apache RTR 200 4V 55
Maintenance 61
Service record sheet 84

The first 1000 km is a crucial part of your motorcycle. Proper running-in operation during this period helps in ensuring a
maximum life and smooth performance of your motorcycle.
Maximum 50 km/h speed upto 750 km (vary the engine speed for better mating of parts).
The first service at 500 ~ 750 km is most important. During running-in period all the engine components and other parts
will have set in. All adjustments to be restored, all fasteners to be tightened. Engine cum transmission oil to be replaced.
Timely performance of the first service will ensure optimum service life and performance from the engine.
The reliability and performance of your motorcycle depends on the special care and restrain exercised during the
running-in period. It is especially important that you avoid operating the engine in high speed (RPM), which could expose
the engine parts to excessive stress. Recommended speed during the running-in is:
Since your motorcycle is fitted with Evaporative Emission Control System, the motorcycle should not be laid on the
floor during water wash. Else it may lead to difficulty in starting and improper running of the motorcycle.
Replacing the engine cum transmission oil during first service is most important for better life of engine. Always use TVS
TRU4 FULLY SYNTHETIC oil (SAE 10W30 API-SL, JASO MA2) for better performance and life.
RUNNING-IN INFORMATION
01
Caution

SINGLE CHANNEL ANTI-LOCK BRAKING SYSTEM
The slipping wheels on a riding surface results in losing control of whole motorcycle which usually occurs in fractions of a
second. Restoring traction while keeping the bike balanced is only a result of luck, or extreme training, as is the case of
professional stunt riders who drift. Preventing the wheels from slipping due to excessive braking force compensates
losing control and help the rider to maneuver the vehicle and to avoid accidents.
So what the ABS does is actually limiting the braking force exerted by the rider by either squeezing the lever and keep the
wheel spinning. Once the imminence of the locking (and therefore skidding) is avoided, the system re-applies the
maximum braking force until the next skid is anticipated. By limiting the max force of the braking maneuver, the ABS
systems practically allow riders to use the greatest stopping force possible without locking the front wheels.
During normal operation the ABS works similar to a normal brake, but functions only when the wheel tends to lock up.
The speed sensors fitted on front wheel measures the rotational speed of the wheel, when the wheel speed reduces
rapidly i.e. wheel tends to lock, the HECU modulates the pressure in the brake circuit and thereby prevents the wheel
from locking.
Your motorcycle is fitted with a single channel Anti-Lock Braking System (ABS) in the front brake system which is
designed to prevent skidding and help riders to maintain steering control during emergency-stopping situation in dry or
wet roads, loose gravels etc.
When a rider applies the front brakes continuously as he detects a dangerous obstacle in dry or wet roads, loose gravels
etc. transmits an excessive brake force to the wheel. This excessive force may cause the wheel to stop spinning and
leads to lose of road grip. With no firm contact between the tire’s contact patch and the road surface, the bike becomes
unstable and a crash is imminent.
How does the ABS understands the wheel locking?
The ABS uses continuous wheel speed monitoring system; wheel speed sensor and toner ring and a Hydraulic
Electronic Control Unit (HECU).
ANTI-LOCK BRAKE SYSTEM (ABS)
How does ABS work?
02

03
Humps and irregular surfaces of the road can cause
the wheels to lose contact temporarily with the road
surface; if this happens the braking force that can be
transmitted to road surface is zero.
If the brakes are applied under these condition, the
ABS has to reduce the braking force to ensure and
maintain the directional stability when the wheels
regains its contact with the road surface. At this
instant the ABS must reduce the traction, so that the
wheels will continue to rotate under all imaginable
circumstances, because this is the precondition for
ensuring directional stability.
How the irregular road surface affects the
braking?
As soon as the actual circumstances arises, the
system reacts instantly and adjusts braking force
accordingly to achieve optimum braking.
Vehicles fitted with ABS uses the conventional brake
system during normal operation. But during hard
stop the brake lever feels different, i.e., a rapid
pulsation in the brake lever; This is absolutely
normal.
Why does brake lever pulsate during brake
application?
The ABS can apply and release the pressure in the
brake circuit much faster than that rider can do with
brake lever to avoid wheel locking. So there is no
need to pump the brake, it requires only
continuous application.
Only the front brake of your motorcycle is
fitted with ABS not the rear brake. Applying
rear brake alone can cause wheel skidding just
like normal braking system. Always apply both
front and rear brake for better performance.
Warning
SINGLE CHANNEL ANTI-LOCK BRAKING SYSTEM
HECUHECU
Wheel speed sensorWheel speed sensor

The Apache RTR 160 4V with ABS does an automatic
self check every time the ignition switch is turned
‘ON’. The ABS warning lamp provided at the
speedometer console blinks and informs you that the
ABS is under check.
It is not necessary to have this pulsation feel every
time the brake is applied. Pulsations are felt only
during wheel locking tendency, occurs due to the
modulation of pressure in the brake circuit by HECU.
Pulsation means that the vehicle is in limit. This
pulsation feel also depends on the road condition.
t Perform the periodic maintenance as per the
schedule.
DO‘S AND DON'T‘S
Do’s
This ABS warning lamps goes ‘OFF’ once the bike
reache 6 km/hs speed and above and ABS warning
lamp will blink whenever vehicle speed is less than
6 km/h indicating that the ABS is working fine. If the
warning lamp is continuously ‘ON’ even after the
vehicle crossing speed then ABS has an error 6 km/h
and your bike should be taken to any of your nearest
TVS Motor Company Authorised Distributors or
Dealers / Authorised Service Centers.
t Check the ABS warning lamp for any warning
before driving the vehicle.
t Apply both front and rear brake for better
performance.
t Apply continuous brake in ABS mode for better
performance. Do not pump.
t ABS should be serviced only at TVS Motor
Company Authorised Distributors or Dealers /
Authorised Service Centers.
t Carefully remove the front wheel during puncture
/ tyre replacement to prevent toner ring damage /
bend.
04
SINGLE CHANNEL ANTI-LOCK BRAKING SYSTEM

05
t Do not try to service HECU or open to separate
parts..
t Do not use non-genuine spares like pads,
discs, tyres etc.
t Do not test the ABS on road!!, but use ABS (it is
already tested).
t Keep the wheel in such a way that the toner
ring is facing upwards.
t Always use recommended brake fluid. Use fresh,
clean brake fluid.
Don't’s
t Do not use non-standard tyres.
t Do not ignore any warning lamp on speedometer.
t Do not adjust the wheel speed sensor air gap your
self.
t Do not attempt to correct the toner ring teeth by
bending manually or by any other method.
t Do not use different toner ring.
t Do not insert any metallic parts near wheel speed
sensor.
t Use only the recommended make, type and size
of tyre (ABS is tuned with tyre specified by the
TVS Motor Company).
Incase of ABS failure, the braking system will work
like a non ABS braking system and provides normal
stopping distance.
This motorcycle is equipped with ABS and Tubeless
tyres. For repair or replacement please contact
nearest TVS Motor Company Authorised Distributors
or Dealers / Authorised Service Centers.
As a general riding practive it is advisable to apply
more front brake and less of rear brake.
Never open HECU on your own, it is a very sensitive
part of ABS and needs to be handled only by the
trained personnel. Contact your nearestTVS Motor
Company Authorised Distributors or Dealers /
Authorised Service Centers.
Use of non-genuine brake pads, tyres, disc etc. leads
to poor braking performance and unsafe riding
conditions.
Note
SINGLE CHANNEL ANTI-LOCK BRAKING SYSTEM

To prevent or minimize accident, never consume alcohol or drugs before or during the operation of your vehicle. Even
minimal consumption of these will affect the rider’s ability to control the vehicle.
Two wheeler safety starts with wearing a good quality helmet. One of the most serious injuries that can happen is a
head injury. Always wear an good quality helmet that should fit your head comfortably and securely. You should also
have good quality goggles to protect your eyes and help your vision.
Riding skill and your mechanical knowledge forms the foundation of safe riding practices. We suggest you to practice
riding TVS Apache RTR 160 4V in a low-traffic condition until you are thoroughly familiar with your vehicle and its controls.
Remember practice makes you perfect.
Any two wheeler riding requires some precautions to be taken to ensure the safety of the rider, pillion rider and other
road users. These precautions are:
Familiarise yourself with new TVS Apache RTR 160 4V
Riding apparel
SAFE RIDING RECOMMENDATIONS
Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you avoid
accidents.
Loose, fancy clothing can be uncomfortable and unsafe when riding a two-wheeler. Choose good quality two wheeler
riding apparel.
Know your limits
SAFE RIDING TIPS
Warning
06

Avoid use of mobile phones while riding as it
could lead to fatal accident.
Do not downshift the gears in the midst of cornering.
Slow down to a safe speed before negotiating a
corner. If this is the first time that you are riding a
vehicle of this type, we suggest that you practice on a
safe, open area to thoroughly familiarise with the
operation of the vehicle.
One-hand riding is dangerous. Keep both hands
firmly on the handle bar and both feet securely on the
foot rest. Under no circumstances should both the
hands be removed from the handle bar, as it is very
dangerous.
2. Sit and adjust yourself on seat so that arms and
shoulders are relaxed.
Cornering
Posture
3. Look widely instead of gazing at one point.
During cornering, reduce speed so as to reduce the
effects of centrifugal force. Avoid abrupt application
of brake or sudden steering by all means.
4. Keep the knees close to the fuel tank.
Proper vehicle riding starts with proper posture.
1. Keep your elbows relaxed and flexible.
When cornering, centrifugal force works in a direction
perpendicular to the direction in which the vehicle is
moving. Centrifugal force increases in proportion with
speed and the radius of the corner.
Warning
Warning
SAFE RIDING TIPS
2. Hold the vehicle upright as you apply the brake.
Braking
6. Riding down hills, while cornering and wet roads
close throttle and down shift the gear to take
advantage of gearbox and engine which acts as an
additional brake. This will avoid the loss of control
3. Progressive application of brakes is safer.
For safe riding, it is very important to master the
braking techniques.
4. Never depress the clutch lever while braking at
higher speeds.
5. Apply both the brakes.
1. Close / release the throttle.
07

ACCESSORY INSTALLATION AND SAFETY
TIPS
Use extreme caution while selecting and installing the
accessories for your motorcycle.
While selecting the accessories, make sure the
accessories should not obstruct lighting, steering,
suspension level and ground clearance. Please
ensure that if the tank cover is used, it is not getting
en-trapped between fuel tank and fuel tank cap.
Additional electrical equipments and controls
should not exceed the specified electrical system
load of the vehicle (capacity of battery and
magneto).
The addition of unsuitable accessories can lead to
unsafe operating conditions. Your friendly Dealer
will assist you in selecting quality accessories and
installing them correctly.
Any abrupt braking on slippery or irregular roads can
cause loss of rider control.
Using only the front or rear brake is dangerous and can
cause skidding and loss of control. Apply both
the brakes together and with great care on a wet
road or other slippery surfaces.
As the vehicle speed increases, the stopping distance
also increases progressively. Be sure that, you have
sufficient distance between you and the vehicle or
obstruction ahead of you.
2. Even when the brake works normally, if the road
surface is wet or the tyre surface is worn-out,
tyres do not take a firm hold on the surface,
increasing the stopping distance.
over the vehicle due to over speed.
1. If the brake shoes / pads or drum / disc are worn
out or if there is water or oil on them, sufficient
friction does not develop and brakes do not work
well.
Causes for poor braking
3. Approximately 60% braking effect is from front
brake. Non-usage of front brake causes poor
braking.
08
SAFE RIDING TIPS
Warning
Warning

Evaporative Emission Control System
The TVS Apache RTR 160 4V is fitted with Evaporative
Emission Control System which consists of a canister
and associated piping. This system prevents the
escape of fuel vapors from the fuel tank.
All the TVS motorcycles are tested in the factory for
optimum fuel efficiency and CO levels.
Do not disturb the Carburettor settings as this
may lead to higher fuel consumption and also
higher CO levels.
While adequate care is exercised at the factory to
ensure that the emissions are within the limits, it is
essential for the owner to always maintain the
motorcycle in good condition by getting it periodically
checked and serviced by TVS Motor Company
Authorised Distributor or Dealer / Authorised Service
Center so that the emission and fuel consumption
levels are maintained as per norms.
Crankcase emission control system
The engine of TVS Apache RTR 160 4V is equipped
with a closed crankcase system to prevent
di s c h a rgi n g c ran k c a s e e m i s s i ons i n t o t h e
atmosphere. Blow-by gas is returned to the
combustion chamber through the air cleaner and the
carburettor.
EMISSION CONTROL
If the vehicle needs any adjustments, please consult
nearest TVS Motor Company Authorised Distributor
or Dealer / Authorised Service Center.
09
SAFE RIDING TIPS
If there is any abnormal jerk, startability issue are felt
in the vehicle or noise due to sudden escape of gas
during opening of fuel tank cap, immediately report to
the TVS Motor Company Authorised Distributor or
Dealer / Authorised Service Center.
Warning

The frame and engine serial numbers are the only means of identifying your vehicle from others of the same model and
type. They are also required to assist your Dealer for ordering parts or referring to special information.
VEHICLE IDENTIFICATION NUMBER
Please fill the above boxes now for future reference
Frame number
Engine number
Control key number
Frame serial number is engraved on the right side of
the steering head tube as shown in the above figure.
Engine serial number is engraved on the left side
crankcase assembly near cylinder block as shown in
the above figure.
KNOW YOUR TVS Apache RTR 160 4V
10

LOCATION OF PARTS - HANDLE BAR
KNOW YOUR TVS Apache RTR 160 4V
11
2
1 3 54
8
11
1514
7
9
10
12
13 67. Throttle grip
9. Fuel tank cap
3. Master cylinder (front)
15. Pass by switch
11. Turn signal lamp switch
12. High / low beam switch
4. Engine cut off switch
8. Electric starter switch
10. Horn switch
1. Connected instrument cluster
5. Rear view mirror R
6. Front brake lever
13. Clutch lever
2. Ignition cum steering lock
14. Rear view mirror L

LOCATION OF PARTS - VEHICLE LEFT SIDE
KNOW YOUR TVS Apache RTR 160 4V
12
1. Wheel hugger rear
3. Rear wheel axle
4. Pillion foot rest L
5. Rider foot rest L
2. Saree guard
7. Centre stand
6. Side stand
8. Gear shift lever
9. Front wheel axle
10. Cover frame L
10
3
97 6 58 4 2 1

LOCATION OF PARTS - VEHICLE RIGHT SIDE
KNOW YOUR TVS Apache RTR 160 4V
13
1. Disc plate front
3. Front wheel axle nut
5. Toner ring front
7. Location of spark plug
2. Cover toner ring
4. Wheel speed sensor front
11. Pillion foot rest R
12. Muffler assembly
13. Rear wheel axle nut
14. Disc plate rear
15. Caliper assembly rear
16. Cover frame R
17. Location of ram air duct
6. Caliper assembly front
8. Gauge oil level
10. Rider foot rest R
9. Rear brake pedal
1
16 17
2
11
1213 7
10 9 8 3
45615 14

LOCATION OF PARTS - VEHICLE FRONT AND REAR
KNOW YOUR TVS Apache RTR 160 4V
14
1
2
3
4
6
5
2
1
3
4
6
5
1. Turn signal lamp front L
REAR
2. Reflex reflector
3. Number plate lamp
2. Head lamp assembly
5. Tail lamp assembly
4. Crash guard
5. Position lamps
6. Turn signal lamp front R
FRONT
3. Oil cooler
1. Turn signal lamp rear R
4. Turn signal lamp rear L
6. Pillion handle