TVS Apache RTR 200 Fi4V with ABS User manual

FOREWORD
I
Dear Racer,
Thank you for choosing the TVS Apache RTR 200 Fi4V with ABS.
The newest member of the Apache family now comes with Dual-Channel ABS for unmatched control on the track. Every
feature on the Apache is honed on the race track to deliver the best in racing performance.
The motorcycle has a rich racing pedigree, with the Apache Series RTR winning 16 national championships in 2016
alone. As a proud owner of the TVS Apache RTR 200 Fi4V with ABS, you are now part of the two million strong TVS
Racing family.
This manual explains the features and operations of your TVS Apache RTR 200 Fi4V with ABS. Please read it carefully and
follow the instructions to enjoy the ultimate racing experience.
To prolong your journey on the TVS Apache RTR 200 Fi4V with ABS, we urge you to get your TVS Apache RTR 200 Fi4V
with ABS services only at TVS Motor Company Authorised Distributor or Dealer / Authorised Service Centers.
Here's to your new lap on the Apache RTR 200 Fi4V with ABS.
TVS MOTOR COMPANY LIMITED

Always keep your Owner‘s Manual in the motorcycle and give it to the new owner if you ever transfer your TVS Apache
RTR 200 Fi4V with ABS.
Take time to familiarize yourself with your TVS Apache RTR 200 Fi4V with ABS 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 200 Fi4V with ABS. 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 200 Fi4V with ABS 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.
Prior permission of TVS Motor Company Limited is required for quoting, copying or reproducing any part of this owner's
manual.
Part Number : Revision 0, July 2018
NOTICE
II
Note

Disregarding this message might result in injury to the rider or deadly accidents.
This message indicates special procedures or precautions to be followed to avoid damage to the vehicle.
This message provides further clarification for clear understanding of any particular information.
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

Running-in information 01
Antilock braking system 02
Safe riding tips 08
Know your TVS Apache RTR 200 Fi4V with ABS 12
Riding your TVS Apache RTR 200 Fi4V with ABS 33
Maintenance 39
Service record sheet 59
Technical specifications 62
CONTENTS
IV

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.
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:
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.
RUNNING-IN INFORMATION
01
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) or recommended equivalent oil for better performance
and life.
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.
Caution

ANTI-LOCK BRAKE SYSTEM
Anti-Lock Brake System (ABS)
Your motorcycle is fitted with an Anti-lock braking system (ABS) 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.
How does ABS work?
When a rider applies the 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.
02

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 or pressing the brake pedal 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
wheels.
How does the ABS understands the wheel
locking?
The ABS uses continuous wheel speed monitoring
system; wheel speed sensors and toner rings and a
Hydraulic Electronic Control Unit (HECU).
ANTI-LOCK BRAKE SYSTEM
03
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 both the
wheels 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.
How the irregular road surface affects the
braking?
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.
Toner ring
Wheel speed sensor

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. As soon as the actual
circumstances arises, the system reacts instantly and
adjusts braking force accordingly to achieve optimum
braking.
ANTI-LOCK BRAKE SYSTEM
04
Why does brake pedal / lever pulsate during brake
application?
Vehicles fitted with ABS uses the conventional brake
system during normal operation. But during hard
stop the brake pedal / lever feels different, i.e., a
rapid pulsation in the brake pedal / lever; This is
absolutely normal.
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.
Rear wheel lift
Under very severe and sudden deceleration,
however, under certain circumstances it is possible
that the ABS unit fitted in your vehicle will be unable to
prevent the rear wheel from lifting clear of the ground
and flip over.
Severe braking can cause the rear wheel to lift off the
ground. When you brake, bear in mind that ABS
control cannot always be relied on to prevent the rear
wheel from lifting clear of the ground.
HECU

The Apache RTR 200 Fi4V 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.
This ABS warning lamps goes ‘OFF’ once the bike
reaches 10 km/h speed and above, indicating that the
ABS is working fine. If the warning lamp continuously
‘ON’ even after the vehicle crossing 10 km/h speed
then ABS has an error and your bike should be taken to
any of your nearest TVS Motor Company Authorised
Distributor or Dealer / Authorised Service Center.
DO‘S AND DON'T‘S
Do’s
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 Perform the periodic maintenance as per the
schedule.
t ABS should be serviced only at TVS Motor
Company Authorised Distributor or Dealer /
Authorised Service Center.
t Carefully remove the wheel during puncture / tyre
replacement to prevent toner ring damage / bend.
ANTI-LOCK BRAKE SYSTEM
05
The ABS can apply and release the pressure in the
brake circuit much faster than that rider can do with
brake pedal / lever to avoid wheel locking, so there is
no need to pump the brake, it requires only
continuous application.
Warning

06
ANTI-LOCK BRAKE SYSTEM
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.
t Use only the recommended make, type and size
of tyre (ABS tuned with tyre specified by the TVS
Motor Company).
Don't’s
t Do not use non-standard tyres.
t Do not pump the brakes. Apply the brakes
continuously
t Do not ignore any warning lamp on speedometer.
t Do not adjust the wheel speed sensor air gap your
self.
t Do not run the engine and ride or rotate the rear
wheel alone in gear with vehicle on centre stand,
for drive chain lubrication, during water wash etc.,
t Do not attempt to correct the toner ring teeth by
bending manually or by using any other mode.
t Do not use different toner ring.
t Do not insert any metallic parts near wheel speed
sensor.
t Do not test the ABS on road!!, but use ABS (it is
already tested).
t Do not use non-genuine spares like pads,
discs, tyres etc.
t Do not try to service HECU or open to separate
parts..
ABS only helps in improving the vehicle control. It is
always good to remember not to exceed the physical
limits of the vehicle stability. It is rider’s responsibility
to ride at a suitable speed, while taking care of
conditions and road surface. ABS will not compensate
for errors in the judgement or improper brake use in
the various situation. ABS never eliminates the danger
of falling while turning.
Hard braking during sharp cornering on slippery
surface may lead to vehicle instability. Under such
circumstances gradual braking is recommended.
Use of non-genuine brake pads, tyres, disc etc. leads
to poor braking performance and unsafe riding
conditions.
Warning

This motorcycle is equipped with ABS and tubeless
tyres. For repair or replacement please contact
nearest TVS Motor Company Authorised Distributor
or Dealer / Authorised Service Center.
As a general riding practice 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 nearest TVS Motor
Company Authorised Distributor or Dealer /
Authorised Service Center.
Note
ANTI-LOCK BRAKE SYSTEM
07
Do not ride the vehicle in conditions like wheelie,
stoppie, on-stand engine revving in gear for chain
lubrication and during water wash etc... for more than
three minutes as it will result in ABS error and ABS
warning lamp glowing continuously. In such cases,
just switch ‘OFF’ and switch ‘ON’ the ignition key
once. ABS warning lamp may glow continuously if any
ABS error had occurred before.
This error gets cleared automatically and ABS warning
lamp goes ‘OFF’ after riding the vehicle above 10 kph
speed. If ABS warning lamp is still ‘ON’, then contact
the nearest TVS Motor Company Authorised
Distributor or Dealer / Authorised Service Center.
Warning
Incase of ABS failure, the braking system will work
like a non ABS braking system and provides normal
stopping distance.
Note

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 a 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.
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.
SAFE RIDING RECOMMENDATIONS
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 200 Fi4V with ABS
Riding skill and your mechanical knowledge forms the foundation of safe riding practices. We suggest you to practice
riding TVS Apache RTR 200 Fi4V with ABS in a low-traffic condition until you are thoroughly familiar with your vehicle and
its controls. Remember practice makes you perfect.
Riding apparel
Loose, fancy clothing can be uncomfortable and unsafe when riding a two-wheeler. Choose good quality two wheeler
riding apparel.
Know your limits
Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you avoid
accidents.
SAFE RIDING TIPS
08
Warning

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.
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.
Posture
Proper vehicle riding starts with proper posture.
1. Keep your elbows relaxed and flexible.
2. Sit and adjust yourself on seat so that the arms
and shoulders are relaxed.
3. Look widely instead of gazing at one point.
4. Keep the knees close to the fuel tank.
Cornering
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.
During cornering, reduce speed so as to reduce the
effects of centrifugal force. Avoid abrupt application
of brake or sudden steering by all means.
09
Warning
SAFE RIDING TIPS

3. Approximately 60% braking effect is from front
brake. Non-usage of front brake causes poor
braking.
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.
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. Any abrupt braking
on slippery or irregular roads can cause loss of rider
control.
Braking
For safe riding, it is very important to master the
braking techniques.
1. Close / release the throttle.
2. Hold the vehicle upright as you apply the brakes.
3. Progressive application of brakes is safer.
4. Never depress the clutch lever while braking at
higher speeds.
5. Apply both the brakes.
6. Do not pump the brakes.
7. While riding down hills, cornering and wet roads
close the 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
over the vehicle due to over speed.
Causes for poor braking
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.
2. Even when the brakes work 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.
10
SAFE RIDING TIPS
Warning

Do not disturb the fuel supply settings as this may
lead to higher fuel consumption and also higher
CO levels.
If the vehicle needs any adjustments, please consult
nearest TVS Motor Company Authorised Distributor
or Dealer / Authorised Service Center.
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.
ACCESSORY INSTALLATION AND SAFETY
TIPS
Use extreme caution while selecting and installing the
accessories for your motorcycle.
The addition of unsuitable accessories can lead to
unsafe operating conditions. Your friendly
Distributor / Dealer will assist you in selecting quality
accessories and installing them correctly.
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).
EMISSION CONTROL
All the TVS motorcycles are tested in the factory for
optimum fuel efficiency and lowest possible CO
levels.
11
SAFE RIDING TIPS

SAFE RIDING TIPS
Crankcase emission control system
The engine of new Apache RTR 200 Fi4V with ABS is
equipped with a closed crankcase system to prevent
dis c h a r g i n g c r a n k c a s e e m i s s i o n s i n t o the
atmosphere. Blow-by gas is returned to the
combustion chamber through the air cleaner and the
throttle body.
Evaporative Emission Control System
The Apache RTR 200 Fi4V with ABS is equipped with
an evaporative emission control system which
consists of a canister and associated piping. This
system prevents the escape of fuel vapors from the
fuel tank.
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
12

VEHICLE IDENTIFICATION NUMBER
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.
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 200 Fi4V with ABS
13

LOCATION OF PARTS - HANDLE BAR
1. Horn switch
2. Turn signal lamp switch
3. Clutch lever
4. Pass by switch
5. Rear view mirror L
6. High / low beam switch
7. Digital speedometer
8. Ignition cum steering lock
9. Master cylinder (front)
10. Rear view mirror R
11. Engine cut off switch
12. Front brake lever
13. Throttle grip
14. Electric starter switch
15. Fuel tank cap
13
14
15
12
11
4
3
2
1
97 8
6
5
10
KNOW YOUR TVS APACHE RTR 200 Fi4V with ABS
14

LOCATION OF PARTS - VEHICLE LEFT SIDE
KNOW YOUR TVS APACHE RTR 200 Fi4V with ABS
15
1. Front wheel axle
2. Cover fuel filter EFI
3. Gear shift lever
4. Centre stand
5. Side stand
6. Rider foot rest L
7. Pillion foot rest L
8. Rear wheel axle
9. Saree guard
10. Wheel hugger
11. Cover frame L
1 2 35 6 7 8 9 10
11
4

LOCATION OF PARTS - VEHICLE RIGHT SIDE
KNOW YOUR TVS APACHE RTR 200 Fi4V with ABS
16
1. Disc plate front
2. Front wheel axle nut
3. Caliper assembly front
4. Spark plug
5. Gauge oil level
6. Rear brake pedal
7. Rider foot rest R
8. Pillion foot rest R
9. Muffler assembly
10. Disc plate rear
11. Rear wheel axle nut
12. Caliper assembly rear
13. Cover frame R
14. Location of ram air duct
2
378910 1
5
64
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