TVS Apache RTR 200 4V User manual

SER.MAN/TVS APACHE RTR 200 4V - REVISION - 0
SERVICE MANUAL

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.

FOREWORD
We are happy to provide you the first edition of new TVS APACHE RTR 200 4V motorcycle’s service
manual.
This manual is prepared to provide the assistance during the process of servicing the new TVS
APACHE RTR 200 4V motorcycle. This manual describes about the basic operations of this new
product, do‘s and don‘t‘s, service limits of individual components and sub systems while servicing the
TVS APACHE RTR 200 4V motorcycle. We request you to carefully go through this manual and follow
the instructions given.
All the instructions and illustrations of this manual is prepared based on the recent information available
during the preparation of manual. Modifications or any improvements on product will be
communicated through ‘SERVICE INFORMATION BULLETINS’ from time to time.
This manual will help to the technicians who already have technical knowledge about motorcycles.
While servicing, certain parts may require replacement. For ordering spares please refer Parts
catalogue of TVS APACHE RTR 200 4V motorcycle. The illustrations in this manual may not give you
the exact name, part number and quantities.
Incase, you face any critical problems during the course of servicing and if you need any further
clarifications or technical assistance you may contact our area service personal.
You may also contact us at
TVS Motor Company Limited,
Marketing (Service) Department,
Post box No.4, Harita, Hosur - 635 109,
Tamilnadu, India.

Caution / warning :- This indicates special procedures of precautions to be followed by the mechanics during
the service. Avoiding these messages may cause injury to them as well as damage to the
components.
This service manual is split into seven chapters as “General information“, “Periodic maintenance“, “Servicing of
engine”, “Fuel, Lubrication and Exhaust system“, “Electrical system“, “Chassis” and “Service information”.
Mostly the pages run through two columns in the inside pages with instructions on left side and the illustrations on
the right side. Some of the exploded views occupy full pages. In between the running instructions we have used the
notations as per the examples given below:
Note:
Inspect and set the idling speed after
completing all other maintenance actions.
HOW TO READ THIS MANUAL
Heading:- CHAIN ASSEMBLY DRIVE
Sub heading:- Chain slackness
Note :- This provides further clarification for clear understanding of any particular information/operation/data.
Hand tools :-17 mm spanner
Special tools :- N231 002 0 Clutch nut tightening tool
Service limits :- Service limit 0.05 mm
Partnumber Description
Caution:
Check that the gasket inlet is intact and in
good condition.

1 GENERAL INFORMATION Page 1-1 to 1-14
2Page 2-1 to 2-52 PERIODIC MAINTENANCE
3Page 3-1 to 3-58 SERVICING OF ENGINE
4Page 4-1 to 4-19 FUEL, LUBRICATION AND EXHAUST SYSTEM
5Page 5-1 to 5-28 ELECTRICAL SYSTEM
6Page 6-1 to 6-51 CHASSIS
7Page 7-1 to 7-15 SERVICE INFORMATION
TVS APACHE RTR 200 SERVICE MANUAL
GROUP INDEX

TVS APACHE RTR 200 SERVICE MANUAL
DESCRIPTION PAGE NO
VIEW OF TVS APACHE RTR 200 4V 1
VEHICLE IDENTIFICATION NUMBERS 2
FRAME NUMBER LOCATION 2
ENGINE NUMBER LOCATION 2
FRAME AND ENGINE NUMBER CODES 2
YEAR AND MONTH CODES 3
CODE FOR THE PRODUCTION YEAR 3
CODE FOR THE PRODUCTION MONTH 3
TECHNICAL SPECIFICATIONS 4
DIMENSIONS AND WEIGHT 4
ENGINE 4
TRANSMISSION 4
GEAR RATIO 5
CHASSIS 5
ELECTRICAL 5
CAPACITIES 6
ADVANTAGES AND SPECIAL FEATURES OF TVS APACHE RTR 200 4V 7
WARRANTY TERMS 7
RUNNING- IN PERIOD 7
FUEL AND OIL RECOMMENDATIONS 8
PRECAUTIONS AND GENERAL INSTRUCTIONS 8
LIST OF HAND TOOLS REQUIRED 9
LIST OF SPECIAL TOOLS REQUIRED 9
SPECIAL TOOLS AND ITS APPLICATION 10
Chapter 1
GENERAL INFORMATION
CONTENTS

TVS APACHE RTR 200 4V
RIGHT SIDE
LEFT SIDE
Fig. 1.1
Fig. 1.2
TVS APACHE RTR 200 SERVICE MANUAL
GENERAL INFORMATION
1-1

FRAME AND ENGINE NUMBER CODES
FRAME NUMBER
ENGINE NUMBER
4
2
Manufacturing serial no.
Manufacturing serial no.
0 0 3 9
000 8
Month code
F 2 P
F 2 0
Year code
Year code
Plant code
Plant code
A R 1 6
0R1 P
Engine type
Engine type
Variant identifier
Month code
Filler
Check digit
VEHICLE IDENTIFICATION NUMBERS
LOCATIONS
FRAME NUMBER
l The frame serial number is stamped on the
right side of the steering head tube. (Fig. 1.3)
ENGINE NUMBER
l The engine serial number is stamped on the
left side crankcase assembly near cylinder
block. (Fig. 1.4)
6 3 7
Frame type
Vehicle type
M D
World manufacturer
identifier
Fig. 1.3
Fig. 1.4
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-2

1 2001
2 2002
3 2003
4 2004
5 2005
6 2006
7 2007
8 2008
9 2009
A 2010
B 2011
C 2012
D 2013
E 2014
F 2015
G 2016
H 2017
J 2018
K 2019
L 2020
M 2021
N 2022
P 2023
R 2024
S 2025
T 2026
V 2027
W 2028
X 2029
Y 2030
A JANUARY
B FEBRUARY
C MARCH
D APRIL
E MAY
F JUNE
G JULY
H AUGUST
K SEPTEMBER
L OCTOBER
N NOVEMBER
P DECEMBER
CODE FOR THE PRODUCTION YEAR
CODE CODE YEAR
CODE FOR THE PRODUCTION MONTH
MONTH
YEAR AND MONTH CODES
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-3

DIMENSIONS AND WEIGHT
Overall length 2050 mm
Overall width 790 mm
Overall height 1105 mm
Seat height 800 mm
Ground clearance 180 mm
Wheel base 1353 mm
Kerb weight (with toolkit and 90% of fuel) 148 kg
Pay load 130 kg
Maximum laden weight 278 kg
ENGINE
Type 4 stroke, Oil cooled, Single cylinder OHC
Bore 66 mm
Stroke 57.8 mm
Piston displacement 197.75 cc
Compression ratio 9.7 : 1
No. of valves 4
Carburettor type Keihin CV 30 VE
Air filter Viscous Paper filter
Oil filter Wire mesh and micronic paper filter
Lubrication system Forced wet sump
Maximum power in kW 15.09 kW (20.5 PS) @ 8500 rpm
Maximum torque in Nm 18.1 Nm @ 7000 rpm
Maximum speed Around 128 km / h
Engine idling rpm (under warm condition) 1500 ± 100 rpm
Starting system Electric starter
TRANSMISSION
Clutch Wet - multiplate type
Gear shift pattern 1 down and 4 up
Primary transmission Helical gears
Secondary transmission Chain and sprockets
TECHNICAL SPECIFICATIONS
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-4

TECHNICAL SPECIFICATIONS
GEAR RATIO
First gear 2.917
Second gear 1.857
Third gear 1.333
Fourth gear 1.050
Fifth gear 0.880
Primary reduction 2.818
Secondary reduction 3.461
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
Steering angle 34°
Caster angle 25.5°
Trail length 95.5 mm
Brakes Front Hand operated, 270 mm petal disc
Rear Foot operated, 240 mm petal disc
Tyre* Front 90/90 x 17 Tubeless
Rear 130/70 x 17 Tubeless
2
Tyre pressure Front 1.75 kg/cm (25 PSI)
2
Rear Solo 2.00 kg/cm (28 PSI)
2
Dual 2.25 kg/cm (32 PSI)
ELECTRICAL
Type AC generator
Ignition system IDI - Engine load based digital ignition
Spark plug BOSCH - UR4KE
Battery type 12V, 9 Ah
Body earthing Negative terminal
Generator Fly wheel magneto 12V, 200W
Head lamp 12V, 60/55W H4 x 1
Position lamp LED lamp (2W) x 2
Tail / brake lamp LED indicator (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
Fuse 12V, 15A and 10A (each one)
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-5
* The pneumatic tyres fitted in this vehicle meet the requirements specified by BIS and comply with
the requirements under Central Motor Vehicles Rules (CMVR), 1989.

Note:
Specification are subject to change on account of continuous improvements in the product.
* The fuel tank is not a measuring instrument and the capacity of the fuel tank may vary from the
indicated capacity.
TECHNICAL SPECIFICATIONS
CAPACITIES
Fuel type Unleaded petrol
Fuel tank capacity* 12 litres (including reserve)
Reserve 2.5 litres
Engine cum transmission oil grade TVS TRU4 FULLY SYNTHETIC oil
(SAE 10W30 API-SL, JASO MA2)
Engine cum transmission oil capacity 1200 ml (after draining)
1400 ml (incase of disassembly)
Front fork oil grade KYB G10 oil
Front fork oil quantity 325 ± 2 cc
Brake fluid TVS Griling DOT 3 / DOT 4
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-6

ADVANTAGES AND SPECIAL FEATURES OF TVS APACHE RTR 200 4V
l 200 CC, 4 valve, learn burn engine with the peak power of 20.5 PS @ 8500 rpm and peak torque of 18.1 Nm
@ 7000 rpm helps to achieve 0 to 60 kmph speed in 3.9 secs.
l IDI - Engine load based digital ignition, tuned for smooth power delivery
l High combustion nanofriks-coated piston
l6 plate clutch for racing launch
l 5 speed gear box for high speed
lLarge intake resonator - boosts low-end torque
l Paper filter in air cleaner for increased durability
lOil cooled along with ram air assisted cooling for optimum engine performance
lStainless steel exhaust pipe exhaust system
lDouble barrel exhaust engineered with European sound design techniques
l Race origin double cradle split syncro stiff frame
lDouble check valve bush front fork for excellent and smooth front suspension
lKYB mono tube suspension for aggressive racing
lRoto petal disc brakes
lRace grip Remora tyres (Pirelli tyres optional)
lAluminium forged handle bars
lInteractive racing display
lAll new - Day LED lamp
lAggressive tank cowl
l Racing ergo split seat assembly
l Longer wheel base for better stability
WARRANTY TERMS
TVS APACHE RTR 200 4V
24 months from the date of sale or 30,000 km, whichever of the two occurs earlier
RUNNING - IN PERIOD
The first 1000 km is a crucial part. Proper running-in operation during this period helps in ensuring a longer life and
smooth performance of TVS APACHE RTR 200 4V.
The reliability and performance of TVS APACHE RTR 200 4V depends on special care and restrain exercised during
running-in period. It is especially important that you avoid operating the engine in a manner, which could expose the
engine parts to excessive heat. Maximum recommended speed upto 750 km is 50 km/h.
Do not ride at constant low speed for a longer time during any portion of the running-in period. Keep varying the
engine speed for better mating of parts.
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-7

FUEL AND OIL RECOMMENDATIONS
TVS APACHE RTR 200 4V has a four stroke engine. Do not mix oil with petrol. Be sure to use the following specified
fuel and oil.
Fuel:
l Unleaded petrol with octane number between 85 to 95 by research method.
l Use fuel additives IFTEX in petrol as recommended by the manufacturer for low carbon deposition.
Oils:
Application Qty Manufacturer Brand
Engine cum transmission oil 1200 ml (during regular service) TVS-M TVS TRU4 FULLY SYNTHETIC oil
1400 ml (incase of disassembly) (SAE 10W30 API-SL, JASO MA2)
Front fork oil 325 ± 2 cc KYB KYB G10 oil
Disc brake oil TVS Girling DOT 3 / DOT 4–
Other lubricant:
Application Qty Manufacturer Brand
Grease – Bharat petroleum MP Grease no. 3
IOC Servo Gem no. 3
Bechem Bechem premium grade 3
Kluber Lubrication Kluber Centoplex 2
Chain lubricant – TVS Motor Company TRU SPRAY
PRECAUTIONS AND GENERAL INSTRUCTIONS
Observe the following precautions without fail when dismantling and reassembling.
l Do not run the engine indoors with little or no ventilation.
l Be sure to replace gaskets, O-rings, circlips and cotter pins with new ones, for safety.
l When tightening nuts and bolts, start first with the larger or centre ones. Tighten these to the specified torque
using a crisscross pattern.
l Use specified special and common tools only.
l When engine and final drive components are disassembled and inspected, coat the mating surfaces with a
lubricant to prevent corrosion.
l When assembling components, use recommended lubricants.
l After assembling, check every part for proper installation, movement and operation.
l Always ensure mutual safety when working with the partners.
l Use only genuine TVS Motor Company parts and recommended lubricants.
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-8

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
18 031 180 0 Front fork oil level gauge
19 031 240 1 Universal oil seal remover
LIST OF SPECIAL TOOLS REQUIRED
1. Flat head spanners:
7 mm, 8 mm, 10 mm, 12 mm, 14 mm and 21 mm
2. Ring spanners:
8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm , 17 mm, 22 mm, 24 mm, 27 mm and 32 mm
3. Tubular spanners:
8 mm, 10 mm, 12 mm, 14 mm, 16 mm and 17 mm
4. Socket spanners:
12 mm, 14 mm, 17 mm, 22 mm, 27 mm and 32 mm
5. Allen keys:
4 mm, 6 mm, 8 mm, 10 mm and 12 mm
6. Screw drivers:
Flat screw driver-small, flat screw driver, phillips head screw driver no.1, phillips head screw driver no. 2 and
phillips head screw driver no. 3
7. Hammers:
Nylon hammer, rubber mallet and metal hammer
8. Pliers:
Straight nose plier, combination plier, water pump plier, external circlip plier-6 inch and snap ring circlip plier-7
inch
9. Others:
Drift, chisel, plug spanner, compression gauge, special adopter, micrometer, vernier calliper, dial gauge, surface
plate and hot plate
LIST OF HAND TOOLS REQUIRED
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-9

SPECIAL TOOLS & ITS APPLICATION
1. Magneto puller - M131 002 0 (Fig. 1.5A)
l Used to remove the magneto rotor from the
crankshaft assembly. (Fig.1.5B)
2. Tappet adjuster - M131 007 0 (Fig.1 .6A)
l Used to adjust the valve tappet clearance.
(Fig. 1.6B)
3. Puller assembly crankcase - M131 011 0
(Fig. 1.7A)
lUsed to separate the LH and RH side
crankcases. (Fig. 1.7B)
4. Clutch holder tool - N231 001 0 (Fig.1.8A)
l Used to hold the clutch assembly during
clutch assembly mounting nut removal.
(Fig. 1.8B)
Fig. 1.5BFig. 1.5A
Fig. 1.6B
Fig. 1.7B
Fig. 1.6A
Fig. 1.7A
1-10
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
Fig. 1.8BFig. 1.8A

5. Clutch nut tightening tool - N231 002 0
(Fig.1.9A)
l Used to remove / reassemble the clutch nut
during clutch servicing. (Fig. 1.9B)
6. Front fork oil seal installer - N931 009 0
(Fig. 1.10A)
l Used to assemble the front fork oil seal and
dust cap. (Fig. 1.10B)
7. Tool fork cylinder holder - N931 011 0
(Fig. 1.11A)
l Used to hold the front fork cylinder during fork
leg assembly dismantling. (Fig. 1.11B)
8. Tool pre-load adjuster - N931 012 0
(Fig. 1.12A)
l Used to adjust the rear mono-shock spring pre-
load. (Fig. 1.12B)
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-11
Fig. 1.9B
Fig. 1.10B
Fig. 1.11B
Fig. 1.12B
Fig. 1.9A
Fig. 1.10A
Fig. 1.11A
Fig. 1.12A

Fig. 1.14B
Fig. 1.15B
Fig. 1.16B
Fig. 1.14A
Fig. 1.15A
Fig. 1.16A
9. Tool cone bottom installer - N931 013 0
(Fig. 1.13A)
l Used to assemble the cone bottom to the
steering stem. (Fig. 1.13B)
10. Tool steering nut - N931 014 0 (Fig. 1.14A)
l Used to remove / assemble the steering lock
nut and arrester steering stem. (Fig. 1.14B)
11. Tool swing arm service - N931 015 0
(Fig. 1.15A)
l Used to remove and reassemble the swing
arm needle bearings. (Fig. 1.15B)
12. Tool steering cup remover - N931 016 0
(Fig. 1.16A)
l Used to remove the top and bottom steering
cups. (Fig. 1.16B)
GENERAL INFORMATION TVS APACHE RTR 200 SERVICE MANUAL
1-12
Fig. 1.13BFig. 1.13A