TVS Apache RTR 200 4V Installation guide

NOTICE
All information included in this publication is based on the latest product information available at the time of approval for
printing.
All the illustrations given in this manual may vary from the actual vehicles.
TVS MOTOR COMPANY LIMITED reserves the right to make changes at any time without prior notice and without
incurring any obligation whatsoever.
No part of this publication should be reproduced without written permission from TVS MOTOR COMPANY LIMITED.
TRAINING HAND BOOK

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TVS APACHE RTR 200 4V
RIGHT SIDE VIEW
LEFT SIDE VIEW

-2-
FEATURES OF TVS APACHE RTR 200 4V
Head Lamp:
Power full 60W head lamp
Turn signal indicators:
Clear lens octagonal turn signal
lamps for better clarity and visibility
Pilot lamp:
Robotic eyes pilot lamp
Rear view mirrors:
Stylish Apache razor mirrors
with more visibility at the edges
Petrol tank:
Massive fuel tank
Pillion grab rail:
PDC grab handle
Spilt seats:
Foam - in- place
racing seats
Rear Shocks:
Race tuned KYB
monoshock
Exhaust:
Racing double -
barrel exhaust
Disc brake:
270 mm disc with
premium look
Engine cowl:
Cools the
engine
Y Spoke
10 Spoke alloy
wheels
Front fender:
3 piece sculptured
front fender

FEATURES OF TVS APACHE RTR 200 4V
Battery
Saver Feature
Head lamp dims automatically if the
vehicle is in idle for more than 20
seconds. It gets life back immediately
on giving the throttle
Battery
Saver Feature
The head lamp will glow only for
10 secs. at 50% intensity. If engine in
OFF condition.
Battery
Saver Feature
When ES switch is pressed in head
lamp ON condition. The head lamp goes
OFF and turn ON after the engine is
started.
Night
Flasher Feature
When head lamp pass-by is operated
at night time the opposite beam of head
lamp flashes for safety.
TCI
Controlled
All functions of head lamp are
controlled through TCI for better battery
life.
Brighter
Head lamp
DC Supply. No fluctuations
during engine deceleration for better
visibility.
Better
Switch Life
Voltage to the head lamps is routed
through TCI therefore better switch
life.
Day
Flasher Feature
When the head lamp pass-by is
operated in day time the high beam flashes
for better visibility.
Intelligent DC Head Lamp
• Flicker-free constant beam headlamp, every single ride is a blessing on the roads. Furthermore, for safety with
a nifty pass-by switch operation for day and night.
Note:
Head lamp will not work if the engine cut off switch is in ‘OFF’ condition.
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-4-
FEATURES OF TVS APACHE RTR 200 4V
Digital speedometer :
012345 6 7 8910 11 12
Turn signal indicator left
Service reminder
Low battery indicator
Turn signal indicator right
Fuel gauage
Speedometer
Shift RPM indicator
High beam indicator lamp
Digital clock
Gear shift indicator Tachometer
Low fuel indicator
Neutral indicator lamp
1. Digital clock
Indicates the time in 12 hour time format.
2. Turn signal indicator left ( )
Flashes when the ‘left’ side turn signal indication is activated.
3. High beam indicator lamp ( )
Glows when the head lamp is activated in high beam.
4. Neutral indicator lamp ( N )
Glows when the vehicle is in neutral and goes ‘OFF’ if the gear is shifted from neutral.
5. Low fuel indication ( )
Blinks when the fuel level reaches to minimum safe fuel level. It glows continuously when the fuel comes
below minimum safe level.
6. Turn signal indicator right ( )
Flashes when the ‘right’ side turn signal indication is activated.
7. Fuel gauge
Digital bars indicate the approximate quantity of fuel available in the fuel tank. There are eight bars to indicate
the quantity of fuel available in the fuel tank.
All the eight bars will be displayed when the fuel in the tank reaches above 10.5 liters approximately (full tank).
When the fuel reaches half tank (6 liters approx.) the fuel gauge displays only four bars as shown.
The fuel gauge shows only single bar when the fuel reaches minimum safe fuel level (2.5 liters approx.)

Low fuel indication (serial no. 5) starts blinking and one bar will be visible when the fuel reaches to the
minimum safe level 1.8 liters approximately. Refill the fuel immediately. Once the fuel level reaches 1.1 liters
approximately, no bar will be visible and low fuel indication (serial no. 5) glows continuously.
If all the fuel level bars in the speedometer are blinking and an error message ‘CHECK FUEL SENSOR’ scrolls
at bottom check wiring harness couplers for any loose connection and the proper working of fuel sender unit.
8. Speedometer
Indicates the vehicle speed in kilometer per hour by default when turning the ignition to ON position. This can
be changed to mile per hour. Change the mode between kilometer per hour and mile per hour using the mode
and set switch buttons. If you leave the ignition key in ‘ON’ position and vehicle is kept without moving for
more than 3 minutes, an error message ‘CHECK SPEED SENSOR’ will scrolls which is normal. If this error
message continue to appear even in running and there is not speed indication, check the wiring harness
couplers and speed sensor for proper working.
10. Shift RPM indicator
Shift RPM indicator alerts the user to shift the gears when engine reaches the specified RPM. Users can set
the RPM indication levels as per their riding convenient in multiples of 1000 up to 12000 RPM. When the
engine reaches the set RPM, red indicator in the digital speedometer glows and indicates the user to shift to
next higher gear.
11. Tachometer
Tachometer indicates the engine speed in multiples of 1000 RPM (Revolutions Per Minute).
12. Gear shift indicator
The gear shift indicator in the digital display indicates the position of the gears.
13. Service reminder
If the service is due, whenever the ignition lock is turned ‘ON’, an icon with spanner symbol ‘ ’ blinks for
10 seconds after the speedometer’s self diagnostic cycle and continues to glow till the vehicle is serviced and
reset.
14. Low battery indicator
An icon with battery symbol ‘ ’ glows when the battery charge is too low.
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Odometer / Trip meter 1 & 2 / Lap indicator / High speed indicator / Shortest time indicator
A. Odometer
Odometer registers the total distance covered by the vehicle in kilometer or mile as per the user’s preferred
setting. The digit after the dot mark denotes one tenth of a kilometer or mile. Set the meter in ‘ODO’ mode to
know the odometer reading.
KMPH and MPH setting
lEnsure the display is in ‘ODO’ mode.
lPress and hold the ‘Mode’ button till ‘MPH’ blinks in display. Press ‘Set’ button to select the ‘MPH’ mode,
the ‘MPH mode’ icon scrolls in running display for one full cycle.
lTo change the display to ‘KMPH’ mode again, press and hold the ‘Mode’ button till ‘KMPH’ blinks in
display. Press ‘Set’ button to select the ‘KMPH’ mode, the ‘KMPH’ icon scrolls in running display for one
full cycle.
B. Trip meter
In ODO mode, Press mode button once and twice to enter ‘TRIP 1’ and ‘TRIP 2’ meters respectively. Trip
meter indicates the trip distance travelled in kilometer or mile (as per the preferred settings). The digit after the
dot mark denotes the one tenth of a kilometer or mile.
Provision to measure two different distance ‘TRIP 1’ or ‘TRIP 2’ is provided for the users to use as per their
convenience. To reset any of the trip meter while ensuring the display is in ‘TRIP 1’ or ‘TRIP 2’, press and hold
the set button for a few seconds
C. Trip F
This function shows the distance travelled when the low fuel indication symbol ( ) starts blinking and fuel
gauge shows only one bar or glows continuously with fuel gauge showing no segment, the display
automatically switches to the ‘TRIP F’ indicator after 1km or 0.6 miles as per preferred settings and ‘TRIP F’
meter starts counting from 1 km in km/h mode and 0.6 miles in mph mode.
If the fuel level remains in minimum safe level, the reading is saved even after the ignition key is turned ‘OFF’.
The count stops and clears automatically after a certain distance covered when the fuel level rises above
minimum safe level. ‘TRIP F’ meter cannot be activated or deactivated manually. At every ignition ON, ‘TRIP F’
meter will get enabled automatically until fuel level is reached above minimum safe level (2.5 L).
Odometer
Trip meter
Shortest time indicator
Set button
Mode button
Lap
Alpha numeric display
High speed indicator
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D. Lap timer
Lap timer indicates the time taken to complete the lap.
In ‘TRIP 2’ meter mode, Press mode button once to enter lap timer mode. After speedometer enters lap timer
mode, press SET button for more than 1 sec. After set button input, lap timer indicating digit blinks. Lap timer
will start counting when the vehicle speed is more than 3 km/h and stops blinking once it starts counting . Lap
timer will stop counting and starts blinking once the vehicle speed reduces below 3 km/h. Blinking will stop
once the vehicle comes to neutral. New lap can be started once the data is cleared by changing the mode or by
turning ‘OFF’ and ‘ON’ the ignition.
E. Alpha numeric display
The self diagnostic alpha numeric display indicates the information about current mode and error messages
when the ignition key is turned ON.
F. High speed indicator
High speed indicator records the maximum speed (top speed) achieved by the rider so far either in km/h or
mph as per preferred setting. You can reset and record the new speed if required. Set the meter in
‘HIGHSPEED’ mode to know the maximum speed achieved by any user so far.
Whenever the vehicle speed crosses the previous achieved high speed then speedometer will scroll
‘ACHIEVED HIGH SPEED’ in display and flash the high speed data at the rate of 2 Hz till the scrolling completes
when speed comes less than 3 km/h. This will happen in all modes except shortest time mode. Maximum
speed recorded so far will be displayed whenever the meter is set in ‘HIGH SPEED’ mode. This display will go
off automatically once the vehicle starts moving (>1 km/h) and it will continue the normal operation. Max
speed recorded will be stored until its reset. To reset the high speed recorded, keep the display in ‘HIGH
SPEED’ mode and press the ‘Set’ button for a few seconds. If the high speed is reset, the speed value will be
shown as ’0’.
G. Shortest time indicator
Shortest time indicator records the minimum time taken so far to reach 60 km/h or 40 mph speed (according to
the preferred setting). You can reset and record new time if required. Set the meter in ‘SHORTEST TIME’
mode to know the time taken by a rider to reach the specific speed from starting. Minimum time taken
recorded so far to reach 60 km/h or 40 mph speed will be displayed when the ignition is turned 'ON' and the
meter is set in ‘SHORTEST TIME’ mode. Once the speed reaches 60 km/h or 40 mph, then the time will stop
at the exact point.
The best time achieved by any user and the last time taken to reach 60 km/h or 40 mph speed will be displayed
in ‘SHORTEST TIME’ mode as shown below. You can only reset the last time taken and record new time. The
‘best record’ time will be automatically replaced by next best time and the new best time recorded will be
flashed and ‘BEST SHORTEST TIME’ scrolls in running display when the vehicle comes less than 3 km/h. To
reset the ‘LAST RECORD’ of the shortest time, press and hold the ‘Set’ button for few a seconds. Please
remember only current record will be reset and best time display will remain same.
Mode and set buttons will not work when the vehicle speed exceeds above 10 km/h or 6 mph in the
respective modes.
BEST RECORD
LAST RECORD
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Digital clock setting
lPress and hold the ‘Mode’ button till ‘MPH’ icon blinks in display.
lRelease and press the ‘Mode’ button once again so that the ‘Clock’ icon blinks.
lOn pressing the ‘Set’ button, ‘CLOCK MODE’ scrolls in running display and the hour digit of the clock blinks.
l Now, press the ‘Mode’ button to increase the hours while hour digits are blinking.
lOn pressing the ‘Set’ button again the hours of the clock is set and the minute digit blinks.
lNow, press the ‘Mode’ button to increase the minutes while minute digits are blinking.
lElse, on pressing the ‘Set’ button again the minutes of the clock is set and the hour format ‘AM’ or ‘PM’
blinks.
lPress the ‘Mode’ button to change the hour format ‘AM’ or ‘PM’.
lPress the ‘Set’ button once again to set hour format and to come out from clock setting.
Setting the Shift RPM
lPress and hold the ‘Mode’ button till ‘MPH’ icon blinks in display.
lRelease and press the ‘Mode’ button twice so that the ‘RPM’ icon blinks.
lPress the ‘Set’ button to reach shift RPM setting mode the ‘SHIFT RPM’ icon scrolls in running display for
one cycle. Previous RPM setting value is displayed in the bar display and LED will glow.
lNow, press the ‘Mode’ button to increase the RPM (multiples of 1000) in cyclic fashion. Once the user
starts updating, the LED stops glowing.
lPressing the ‘Set’ button exits the setting. Once the shift RPM is set, the LED again glows and mode is exit.
-8-

DIMENSIONS AND WEIGHT
Overall length 2050 mm
Overall width 790 mm
Overall height 1105 mm
Wheel base 1353 mm
Ground clearance 180 mm
Kerb weight (with toolkit and 90% of fuel) 148 kg
Pay load 130 kg
Maximum laden weight 278 kg
Steering angle 34º
Caster angle 25.5º
ENGINE
Type 4 stroke, oil cooled, Single cylinder OHC
Cylinder bore 66 mm
Stroke 57.8 mm
Piston displacement 197.75 cc
Compression ratio 9.7 : 1
Carburettor Keihin CV 30VE
Air filter Viscous Paper filter element
Oil filter Wire mesh and micronic paper filter
Lubrication system Forced lubrication
Maximum power in kW 15.09 (20.5 PS) @ 8500 rpm
Maximum torque in Nm 18.1 Nm @ 7000 rpm
Maximum speed Around 128 km / hr
Engine idling rpm 1500 ± 100 rpm (Under warm condition)
Starting system Electric starter
TRANSMISSION
Clutch Wet - multi plate type
Transmission 5 speed constant mesh
Gear shift pattern 1 down and 4 up
Primary transmission Helical gears
Secondary transmission Chain and sprockets
GEAR RATIOS
I Gear 2.917
II Gear 1.857
III Gear 1.333
IV Gear 1.050
V Gear 0.880
Primary reduction 2.818
Final reduction 3.461
Specifications are subject to change without notice
TECHNICAL SPECIFICATIONS
-9-

CHASSIS
Frame Double Cradle Split Synchro STIFF (DCSSS)
Front suspension Telescopic oil damped
Rear suspension Gas charged Mono shock absorber, 7 step adjustable
with rectangular swing arm
Brakes Front Disc Hand operated, 270 mm dia.
Rear Disc Hand operated, 240 mm dia.
Tyre Front 90/90 x 17 Tubeless
Rear 130/70 x 17 Tubeless
Tyre pressure Front 1.75 kg/cm² (25 PSI)
Rear Solo 2.00 kg/cm² (28 PSI)
Pillion 2.25 kg/cm² (32 PSI)
ELECTRICAL
Type AC generator
Ignition system IDI - Engine load based digital ignition
Spark plug BOSCH - UR4KE
Spark plug gap 0.7 mm
Battery type 12V, 9 Ah
Generator Fly wheel magneto 12V, 200W
Body earthing Negative terminal
Head lamp 12V, H4 - 60/55W x 1 (Halogen)
Position lamps LED lamp (2W) x 2
Tail / brake lamp LED indicators (1W max. / 2.5W max.)
Turn signal lamp 12V, 10W x 4
Number plate lamp 12V, 5W x 1
Instrument panel LCD / LED Indicators
Horn 12V DC x 2
Main fuse 12V,15A and 12V, 10A (each one)
CAPACITIES
Fuel tank capacity** 12 litres (including reserve)
Reserve 2.5 litres (approx.)
Fuel type Unleaded petrol
Engine cum transmission oil grade TVS TRU4 FULLY SYTHENIC oil
(SAE 10W30 API-SL, JASO MA2 )
Engine cum transmission oil capacity 1200 ml (after draining)
1400 (after disassembly)
Front fork oil grade KYB G10 oil
Front fork oil capacity 352 ± 2 ml per leg
Brake fluid TVS Girling, DOT 3 / DOT 4
Specifications are subject to change without notice
TECHNICAL SPECIFICATIONS
** The fuel tank is not a measuring instrument and the capacity of fuel tank may slightly vary from the
indicated capacity.
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PERIODIC MAINTENANCE SCHEDULE
Item In free service After free service
Service 1st 2nd 3rd 4th 5th Remarks
Every Every
km 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000 km
Period from the date of sale 1 month 3 months 6 months 9 months 12 months
Engine cum transmission oil R I&T R I&T R I&T R
Oil filter (strainer) C – C – C – C
Oil filter (paper filter) R – R – R – R
Spark plug I & C – – – R – – Replace every 12000 km
Air cleaner element – – – – R – – Replace every 12000 km
Carburettor assembly C & A – – – C & A – – C & A every 12000 km
Tappet clearance I & A – I & A – I & A – I & A
Oil cooler fins – – I & C I & C I & C I & C –
Oil cooler pipes – I I I I I – Inspect & replace if
required every 15000 km
Clutch plates – – – – – – – Inspect & replace if
required every 21000 km
Engine breather hose I I I I I I – Replace every 21000 km
if required
Carburetor rubber ducts – I I I I I – Replace every 21000 km
if required
Fuel cock sediment bowl C C C C C C C –
Hose fuel I I I I I I – Replace every three years
Clutch and throttle I, A & L I, A & L I, A & L I, A & L I, A & L I, A & L –
1
cable play
Throttle grip – – L – L – L Lubricate using grease
Choke operation I I I I I I –
Steering smooth operation / play I & A – – – C, L & A – – C & L with fresh Bechem
2
premium grade 3 grease
every 12000 km
Front fork oil – – – – – – – Replace every 18000 km
Front and rear suspension I I I I I I –
3
All fasteners I & TI I & TI I & TI I & TI I & TI I & TI – Tighten if necessary
Drive chain** C, L & A C, L & A C, L & A C, L & A C, L & A C, L & A – Adjust if necessary
4
Retainer oil seal I I I R I I – Replace every 9000 km
5
Chain guide bottom I I I R I I – Replace every 9000 km
All bulbs, horn and switches I I I I I I – Inspect for proper
functioning
Head lamp beam I & A I & A I & A I & A I & A I & A –
Battery electrolyte level I & T I & T I & T I & T I & T I & T –
6
Specific gravity and voltage I I I I I I –
Brake effectiveness I I I I I I –
Brake pedal shaft L L L L L L – Lubricate using TRU4 oil
R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set
1 Inspect for proper operation and adjust play. Lubricate ends using grease.
2 Inspect for smooth steering rotation, steering shake / noise. Adjust the steering if necessary.
3 Inspect for smooth and proper function of front and rear suspension. Also inspect for any visual damage and oil leakage.
4&5 Inspect at every service. Replace if found damaged. However the retainer oil seal and the chain guide bottom need to be replaced every
9000 km.
6 Recharge if necessary.
** Clean the drive chain with dry cloth and apply TRU SPRAY / TRU 4 oil as frequently as every 500 km for better chain life and smooth
vehicle running.
-11-

PERIODIC MAINTENANCE SCHEDULE
Item In free service After free service
Service 1st 2nd 3rd 4th 5th Remarks
Every Every
km 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000
Period from the date of sale 1 month 3 months 6 months 9 months 12 months
Brake pad wear I I I I I I – Replace if necessary
Brake fluid I & T I & T I & T I & T I & T I & T – Replace every 21000 km
Brake hose I I I I I I – Replace every three years
Master cylinder cups – – – – – – – Replace every 21000 km
Wheel freeness I I I I I I –
Tyre pressure at cold condition I & S I & S I & S I & S I & S I & S –
Engine idling RPM I & S I & S I & S I & S I & S I & S –
7
Idling CO% I & S – – – – – – I & S every 12000 km
Ball joint gear shift lever – – L – L – L Lubricate using grease
Centre / side stand pivot L L L L L L – Lubricate using TRU4 oil
Swing arm bearings – – – – – – – C & L with fresh Bechem
premium grade 3 grease
every two years
8
Wheel balancing – – – – I – –
R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set
7 Idling CO% should be set with the help of exhaust gas analyser and tachometer only
8 Wheel balancing to be done every 1 year or every 12000 km. In addition, after every tyre puncture repair or tyre replacement, wheel
balancing to be done.
RECOMMENDED LUBRICANTS
Application Qty Manufacturer Brand
Engine cum transmission oil 1200 ml (after draining) TVS Motor Company TVS TRU4 FULLY SYNTHETIC oil,
1400 ml (after disassembly) (SAE 10W30 API-SL, JASO MA2)
Front fork oil 325 ± 2 ml / leg KYB G10 oil
Disc brake fluid – TVS Girling DOT 3 / DOT 4
Grease – Bharath petroleum MP Grease no. 3
IOC Servo Gem no. 3
Bechem Bechem premium grade 3
Chain lubricant – TVS Motor Company TRU SPRAY
Fuel additives As recommended IFTEX
-12-

LUBRICATION POINTS
SERVICE SCHEDULE
WARRANTY
TVS Apache RTR 200 4V comes with a 24 months or 24000 Kms from the date of purchase, whichever is earlier.
Service
I
II
III
IV
V
Free service Pay service
Service
VI
VII
VIII
IX
X
XI
Kms
500 - 750
2500 - 3000
5000 - 6000
8500 - 9000
11500 - 12000
Kms
14500 - 15000
17500 - 18000
20500 - 21000
23500 - 24000
26500 - 27000
29500 - 30000
Month
1 month
3 Months
6 Months
9 Months
12 Months
Month
15 Months
18 Months
21 Months
24 Months
27 Months
30 Months
DRIVE CHAIN
(TRU SPRAY)
CENTRE STAND AND
SIDE STAND PIVOTS (TRU4 oil)
BRAKE PEDAL SHAFT
(TRU4 oil)
THROTTLE GRIP
(Grease)
STEERING BEARINGS
(Grease)
Dotted line indicates RH side lubricating points
Lubricate all cable ends using grease
SWING ARM BEARINGS
(Grease)
-13-

THROTTLE GRIP FREE PLAY
1 ~ 2 mm
CLUTCH PLAY
8 ~ 15 mm
DRIVE CHAIN SLACKNESS
20 - 25 mm
IDLING CO %
< 1 ~ 3 %
IDLING RPM
1500 ± 100
AIR SCREW TURNS
1 ~ 4
ADJUSTMENTS
Dotted line indicates RH side lubricating points
Lubricate all cable ends using grease
-14-
CARBURETTOR ASSEMBLY
S.No. DESCRIPTION SPECIFICATION
1 Carburettor type Keihin CV 30 VE
2 Main Jet 112
3 Needle jet NA
4 Jet needle NUQA
5 E - Ring position NA
6 Pilot Jet 38
7 Piston valve NA
8 Mixture control screw turns 1~ 4 turns
9 Idling rpm 1500 ± 100
10 Idling CO % (with SAI and CAT) < 1.0 ~ 3 % by volume
11 Cable assembly throttle free play 1 ~ 2 mm

SPECIAL TOOLS
Sl. no. Part no. Description
1 M131 002 0 Magneto puller
2 M131 007 0 Tappet adjuster
3 M131 011 0 Puller assembly - crankcase
4 N231 001 0 Clutch holder tool
5 N231 002 0 Clutch nut tightening tool
6 N931 009 0 Front fork oil seal installer
7 N931 011 0 Tool fork cylinder holder
8 N931 012 0 Tool pre-load adjuster
9 N931 013 0 Tool cone bottom installer
10 N931 014 0 Tool steering nut
11 N931 015 0 Tool swing arm service
12 N931 016 0 Tool steering cup remover
13 N931 017 0 Magneto tool assembly
14 NB31 004 0 Tool assembly steering cups adjuster
15 S131 002 0 Extractor inlet and exhaust valve
16 S131 050 0 Bearing installer set
7 S131 111 0 Main bearing extractor1
18 T215 099 9 Dismantling tool (damper)
19 031 240 1 Universal oil seal remover
Exclusive special tools
Front fork oil seal installer - N931 009 0
l Used to assemble the front fork oil seal and dust cap.
Tool fork cylinder holder - N931 011 0
l Used to hold the front fork cylinder during fork leg
assembly dismantling.
-15-

Tool pre-load adjuster - N931 012 0
l Used to adjust the rear mono-shock spring pre-load.
Tool cone bottom installer - N931 013 0
l Used to assemble the cone bottom to the steering
stem.
Tool steering nut - N931 014 0
l Used to remove / assemble the steering lock nut and
arrester steering stem.
Tool swing arm service - N931 015 0
l Used to remove and reassemble the swing arm
needle bearings.
-16-

Tool steering cup remover - N931 016 0
l Used to remove the top and bottom steering cups.
Tool assembly steering cups adjuster -NB31 004 0
lUsed to assemble the cup bottom and race steering
inner during servicing of steering.
COMMON TOOL
Magneto tool assembly - N931 017 0
lt o r o t o r w h i l e U s e d t o h o l d t h e m a g n e
removing/assembling the primary drive gear and
magneto rotor nuts.
-17-

PERIODIC MAINTENANCE
ENGINE CUM TRANSMISSION OIL
Oil replacement / Oil filter (strainer) cleaning:
Replace oil at initial 500 km and every 6000 km
thereafter. Inspect the oil level every 3000 km
and top-up if necessary.
l Place the vehicle on center stand. Start the engine
and warm to the normal operating temperature and
switch ‘OFF’.
l Remove the gauge oil level to facilitate easy draining
of oil.
l Keep a measuring jar under the engine and cap oil
strainer along with ‘O’ ring and drain the engine cum
transmission oil
8 mm spanner
l Remove the oil strainer from the crankcase
assembly.
Philips head screw driver
l Clean the oil filter (strainer) using suitable solvent and
blow off any dirt / sediment. Inspect the filter for any
abnormality. Replace if required.
l Assemble back the oil filter and plug oil drain along
with a ‘O’ ring.
lFill TVS TRU4 FULLY SYNTHETIC oil (SAE 10W30
API-SL, JASO MA2).
1200 ml (after draining)
Capacity
1400 ml (after disassembly)
Oil level inspection / top-up:
l Remove the gauge oil level and wipe off the gauge
with a clean cloth.
l To measure the oil level, insert the gauge into its
mounting hole by screwing it in.
lThe oil level should be between minimum and
maximum marking on the gauge. If the oil level is
below the minimum marking, top-up with the
recommended oil upto the maximum marking of the
gauge and refit the gauge.
MAXIMUM
MINIMUM
-18-

SPARK PLUG
Clean the gap at initial 500 km if necessary.
Replace the spark plug every 12000 km.
l Disconnect the spark plug cap and remove the spark
plug.
Plug spanner
l Carbon deposits on the spark plug gap will prevent
good sparking and cause misfiring. Clean the
deposits by sand blasting and cleaning with
compressed air in the spark plug cleaning machine.
(Refer service manual for cleaning and checking
procedure)
l Check for the wear of ground (A) and central (B)
electrode. If either of them are worn-out replace the
plug with a new one.
Sparkplug BOSCH UR4KE
l Visually inspect the spark plug gap. If the gap isfound
more, replace the plug with a new.
Spark plug gap 0.7 mm
AIR CLEANER ELEMENT (PAPER FILTER)
Replace every 12000 km.
• Remove the cover frame R to access the Filter.
• Remove the cover air cleaner and air cleaner
element.
• Clean the air filter box with a clean cloth.
• Inspect the sealing rubber seal before reassembly.
Caution:
Do not wash or clean the paper filter. It needs
only replacement.
Inspect the paper filter for any block / damage. If
found any, replace with a new one. However, the
paper filter must be replaced at every 12000 km.
0.7 mm
B
A
-19-