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