SERVICE INFORMATION

SERVICE DATA
VALVE AND VALVE GUIDE

Unit : mm

[Link].

DESCRIPTION

STANDARD

SERVICE LIMIT

Valve diameter

Inlet
Exhaust

27.220
24.220

Valve clearance

Inlet
Exhaust

0.06
0.08

Valve stem (OD)

Inlet
Exhaust

4.990 - 4.975
4.970 - 4.955

Guide valve (ID)

Inlet
Exhaust

5.000 - 5.012

0.035

Guide valve to valve stem clearance

Inlet
Exhaust

Valve stem runout

Inlet
Exhaust

0.01

0.05

Valve head thickness

Inlet
Exhaust

0.75
0.70

0.5

Valve head radial runout

Inlet
Exhaust

0.03

0.075

Spring valve free length

Inner
Outer

30.00
33.80

0.50

CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER (CYLINDER HEAD)

[Link].
1

DESCRIPTION
Cam lobe height

Unit : mm
STANDARD

SERVICE LIMIT

Inlet
Exhaust

33.790 - 33.830
33.670 - 33.710

33.510
33.390

0.003

0.080

Cam shaft complete runout

Arm complete valve rocker (ID)

Inlet
Exhaust

12.000 - 12.018

Shaft valve rocker arm (OD)

Inlet
Exhaust

11.996 - 11.984

Head complete cylinder distortion

0.05

Cover cylinder head distortion

0.05

7
Service information 7-1

SERVICE INFORMATION
CYLINDER, PISTON AND RINGS PISTON

[Link].

Unit : mm

DESCRIPTION

STANDARD

SERVICE LIMIT

Compression pressure

10-13 kg/cm2

8 kg/cm2

Cylinder to piston clearance

0.025 - 0.035

0.120

Cylinder bore diameter

62.000 - 62.015
62.500 - 62.515

62.110
62.610

Piston diameter (measure 10mm from skirt end)

RTR 160cc
RTR 180cc

61.970 - 61.985
62.475 - 62.490

61.875
62.380 - 62.395

Cylinder complete distortion

0.05

Ring piston free end gap

Top
2nd

approx 7.0
approx. 5.5

5.5
4.4

Ring piston closed end gap

Top
2 nd

0.20 - 0.350
0.350 - 0.50

0.70
0.70

Ring to piston groove clearance

Top
2 nd

0.015 - 0.045
0.015 - 0.045

0.15
0.15

Ring piston groove width

Top
2 nd
Oil ring

0.805 - 0.820
0.805 - 0.820
1.505 - 1.520

Top
2 nd

0.775 - 0.790

RTR 160cc
RTR 180cc
4

10

Ring piston thickness

11

Piston pin hole (ID)

15.002 - 15.008

15.030

12

Pin piston (OD)

14.996 - 14.998

14.980

CRANKSHAFT COMPLETE

[Link].

Unit : mm

DESCRIPTION

Connecting rod small end (ID)

Connecting rod deflection

Connecting rod big end side clearance

Connecting rod big end width

Crank web to web width

Crankshaft complete runout

Service information 7-2

STANDARD

SERVICE LIMIT

15.006 - 15.014

15.040

3.00

0.20 - 0.40

0.65

16.95 - 17.00

46.3 0.1

0.05

0.10

SERVICE INFORMATION
CLUTCH

Unit : mm

[Link].

DESCRIPTION

STANDARD

SERVICE LIMIT

5 - 15

2.920 - 3.080

2.60

Lever assembly gear shift play (to adjust clutch play at cover)

Plate clutch drive thickness

Plate clutch drive claw width

15.750 - 15.850

15.20

Plate clutch driven distortion

0.10

Spring clutch free length

29.5

28.7

TRANSMISSION SPECIFICATION
[Link].

DESCRIPTION

Primary reduction ratio

Final reduction ratio

Gear ratio

SPECIFICATION
3.095 (65/21)
RTR 160cc
RTR 180cc

3.384 (44/13)
3.286 (46/14)

First gear

2.917 (35/12)
1.875 (26/14)
1.333 (24/18)
1.050 (21/20)
0.880 (22/25)

Second gear
Third gear
Fourth gear
Fifth gear

TRANSMISSION
[Link].
1

Unit : mm
DESCRIPTION

Shift fork roller to groove clearance

Drive chain - 20 pitch length

Drive chain slack

Fork low speed

Fork high speed
Fork high speed

STANDARD

SERVICE LIMIT

0.050 - 0.200

0.3

254

259.4

20 - 30

SUSPENSION
[Link].

Unit : mm
DESCRIPTION

Front fork stroke length

Front fork spring length

Front fork oil grade

Front fork oil capacity (each leg)

(GIL make)
(TOP make)

STANDARD

SERVICE LIMIT

105

445
403.5

435
393.5

Teleshockab oil
(GIL make)
(TOP make)

140 2 ml
152 2.5 ml

140 2.5 ml

Service information 7-3

SERVICE INFORMATION
BEARING SPECIFICATION

6301/RS1/C3 (12x37x12)
(ON ALLOY WHEEL HUB L)

6301/RS1/C3 (12x37x12)
(ON ALLOY WHEEL HUB R)

AXLE FRONT

6003/C3H (17x35x10)
(L SIDE)

6003/Z/C3H (17x35x10)
(R SIDE )

CAM SHAFT

6207/C3 (35X72X17)
(ON CRANKSHAFT L)

63/28/C3 (28X68X18)
(ON CRANKSHAFT R)

CRANKSHAFT
6006/C3 (30x55x13)
(ON CRANKCASE R)
6001/C3/RS (12x28x8)
(ON CRANKCASE L)

CLUTCH SHAFT ASSEMBLY

(Counter shaft)
6204/C3/RS (20x47x14)
ON CRANKCASE L)

DRIVE SHAFT ASSEMBLY

(Shaft drive)
6202/Z/C3 (15x35x11)
(ON WHEEL HUB L)

AXLE REAR
6205/RS1/C3 (25x52x15)
(ON DRUM REAR SPROCKET)

Service information 7-4

6001/C3 (12x28x8)
(ON CLUTCH RELEASE PLATE)

6201 (12x32x10)
ON CRANKCASE R)
6302/Z/C3 (15x42x13)
(ON WHEEL HUB R)

SERVICE INFORMATION
CARBURETTOR ASSEMBLY

[Link].

DESCRIPTION

SPECIFICATION
RTR 160

RTR 180

BS26-X39

BS29

Carburettor type

Carburettor identification number

Z1

-----

Main Jet

105

125

Needle Jet

P-2

P-0

Jet Needle

4DHZ56

4DHL42

E - Ring position

2nd from top

2nd from top

Pilot Jet

15

20

Pilot air jet (1)

145

145

Piston valve

120

120

Mixture control screw

21

32

10

Idling rpm

1400 100

1400 100

11

Idling CO%

3.5 % By Volume

2 ~ 3 % By Volume

7
Service information 7-5

SERVICE INFORMATION
ELECTRICAL

[Link].
1

DESCRIPTION

SPECIFICATION

Ignition timing
At coinciding mark
Full advance

5 2 BTDC @ 1500 rpm,

34 2 BTDC @ 10000 rpm

Pulsar coil resistance

175 - 275 ohms

Ignition coil resistance

Primary winding
Secondary winding

2 - 3 ohm
12 - 14 K ohms

Lighting coil resistance

0.01 - 1.0 ohm

Charging coil resistance

0.01 - 1.5 ohms

Suppressor cap resistance

5 K ohms

Battery (Type / Amp.)

12V - 9Ah

Generator

12V - 100W

Spark plug

BOSCH UR5DDC - Twin electrode

10

Head lamp - high / low beam

11

Tail lamp

12

Brake lamp

13

Turn signal lamp

14

Instrument panel lamp

LCD/LED indicator

15

Turn signal indicator lamp

LCD/LED indicator

16

Fuel level sensor resistance

Full
Empty

12.5 0.3 ohms

76 5 ohms

12V - 35/35W x 1
12V - 0.5 (LED)
12V - 3.5W (LED)
12V - 10W x 4

17

Horn

12V DC x 2

18

Fuse

12V 10 A

Service information 7-6

SERVICE INFORMATION
BRAKE AND WHEEL ASSEMBLY

[Link].

Unit : mm

DESCRIPTION

STANDARD

SERVICE LIMIT

15 - 20

Front brake free play

Rear brake pedal free play (Drum brake)

Hub complete (brake drum) ID

Front
Rear

130

130.7

Shoe complete brake (brake shoe) thickness

Front
Rear

1.5

Disc plate face out (Disc brake Fr & Rr)

0.05

0.1

Disc plate thicknesst (Disc brake Fr & Rr)

3.5

Alloy wheel runout (Fr & Rr)

1 mm

Axial
Radial

Axle runout

Tyre size

RTR 160 & 180

RTR 160
RTR 180

Front
Rear

0.25/100 mm

Front
Rear
Rear

90/90 x17
100/80x18
100/80x17

11

Tyre tread depth

Front
Rear

1.5 or TWI

12

Tyre pressure- Front

Solo
Dual

1.75 kg/cm (25 PSI

2.00 kg/cm (28PSI

13

Tyre pressure - Rear

Solo
Dual

1.75 kg/cm (25 PSI)

2.25 kg/cm (32 PSI)

Note:
Any part in use is subject to wear and tear. The maximum amount of acceptable wear is called Service Limit.
Any part which is within the service limit is expected to provide a satisfactory period of service life.

7
Service information 7-7

SERVICE INFORMATION
TIGHTENING TORQUE
ENGINE

[Link].

DESCRIPTION

QUANTITY

TORQUE IN Nm

Hexagonal flange bolt, cover cylinder head mounting

10

8 - 12

Cap inspection hole (cover tappet)

22 -25

Domed nut, cylinder head mounting

22 - 27

Hexagonal flange nut, cylinder head mounting

10

Hexagonal flange nut,cylinder mounting

10

Hexagonal screw, cam sprocket mounting

10-12

Hexagonal screw, adjuster assembly tensioner mounting

8 - 10

Bolt, adjuster assembly tensioner

5-7

Hexagonal screw, tensioner cam chain mounting

8 - 10

10

Union bolt, oil pipe

12 - 16

11

Hexagonal flange nut, crankcase mounting

13

8 - 12

12

Hexagonal nut, gear primary mounting

60 - 80

13

Nut, clutch shaft

35 - 45

14

Hexagonal flange bolt, cover clutch mounting

10

8 -12

15

Hexagonal flange bolt, cap oil filter mounting

8 -12

16

Hexagonal flange nut, magneto rotor mounting

75 - 85

17

Hexagonal screw, sprocket engine mounting

10 - 12

18

Hexagonal flange bolt, cover magneto mounting

8 -12

19

Plug oil drain

20 - 25

20

Hexagonal bolt, lever kick starter mounting

22 - 25

21

U nut, engine mounting

30 - 35

22

Hexagonal flange bolt, muffler comp front mounting

12 -20

23

Hexagonal flange bolt, engine front bracket mounting

37 - 45

24

Spark plug

10 - 12

Service information 7-8

SERVICE INFORMATION
TIGHTENING TORQUE
CHASSIS

[Link].

DESCRIPTION

QUANTITY

TORQUE IN Nm

U nut, axle front

50 - 70

Hexagonal nut, lever front brake cam

6.7 - 8.3

Hexagonal screw, front fender mounting

16 -20

Hexagonal socket head cap screw, front fork upper mounting

70 -110

Bolt, front fork lower mounting (under bracket complete)

18 - 24

Lock nut, steering

60 -100

Bolt, handle bar comp holder

9 - 13

Bolt, rider footrest assembly mounting

16 - 20

Nut, stand complete centre mounting

36- 40

10

Nut, swingarm assembly mounting

44 - 54

11

Nut, footrest assembly pillion

16 - 20

12

Nut, shockabsorber mounting

22 - 34

13

Bolt, shockabsorber mounting

32 - 40

14

Nut, torque link complete mounting

10 - 16

15

Nut, panel assembly rear mounting

11 - 16

16

Nut, sprocket (rear sprocket)

20 - 30

17

Nut, shaft rear sprocket mounting (drum mounting)

55 - 70

18

Bolt, lever rear brake cam (rear brake lever)

6.7 - 8.3

19

Nut, axle complete rear

50 - 70

20

Bolt, handle holder comp

16 - 20

21

Bolt, chain case complete mounting

16 - 20

22

Nut, side stand mounting

32 - 40

23

Bolt, rear fender mounting

16 - 20

24

Nut, muffler assembly mounting (at rear)

16 - 20

7
Service information 7-9

SERVICE INFORMATION
SPECIAL MATERIAL REQUIRED FOR MAINTENANCE
The following recommended materials are required for maintenance work on TVS Apache and should be kept in hand for
ready use.

[Link].

APPLICATION

MATERIAL

LUBRICATION
1

Oil seal lip, swing arm assembly pivot, centre

stand pivot, pedal complete brake pivot, steering
races, steering cup and steering cone.

Engine cum transmission oil

4T oil

ADHESIVES
1

Fastening nuts adhesion

Anabond thread locker

Fastening rubber, plastics and ceramic

Anabond (Eng) Cyanoacrylate adhesive 202 and

201 Dendrite adhesive

Bearing fitment adhesive

Specfit

CLEANING SOLVENTS
1

Crankcase, shafts, gears and filter air cleaner

Inflammable solvent like kerosene.

Piston and rings

Carbon tetra chloride and Acetone carbon chloride.

Carburettor

Carbon tetra chloride

USE OF GENUINE TVS MOTOR COMPANY PARTS

When replacing any part of the machine, always use TVS-M genuine parts only. Non genuine parts reduce the performance
and cause failures.

FUEL
ITEM

SPECIFICATION

Fuel type

Unleaded Benzine

Fuel tank capacity including reserve

16 litres

Reserve

2.5 litres

Service information 7-10

SERVICE INFORMATION
TROUBLE SHOOTING

A. STARTING TROUBLE
STEP
1

REASON

POSSIBLE CAUSE

COUNTER MEASURE

No fuel flow to carburettor

No fuel in fuel tank

Fill petrol

Clogged fuel filter / fuel cock

Clean

Blockage of vent hole in cap assy. fuel tank

Clear vent hole

Incorrect spark plug gap

Correct gap

Dirty / excess gap spark plug

Clean and adjust gap

Bridging of electrodes

Clean and adjust gap

Loose suppressor cap

Correct / fix properly

Defective ignition coil

Replace

Defective ignition switch

Replace

Defective digital CDI unit (combined CDI)

Replace

Defective pulsar coil

Replace

Defective source coil

Replace

Oily sparkplug

Check oil leakages through

Rings, valves into combustion
chamber and correct.

Valve timing marks not matching

Correct valve timing

Improper valve tappet clearance

Adjust tappets

Loose carburettor mounting

Tighten

Damaged intake pipe and gasket

Replace

Sticky / worn out float needle

Clean / replace

Loose main jet / pilot jet

Tighten

Blocked passages

Clean the passages

Incorrect air screw adjustment

Tune up correctly

Excessive CO

Tune up correctly

Incorrect jet size

Replace with specified size

Incorrect float height

Correct

No spark / weak spark /

intermittent spark

Incorrect valve timing

Induction leakage

Improper carburation

7
Service information 7-11

SERVICE INFORMATION
TROUBLE SHOOTING

A. STARTING TROUBLE (Contd.)

STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Poor compression

Leakage through gasket cylinder head

Tighten bolts / replace gasket

Incorrect valve clearances

Adjust to specification

Worn out piston rings

Replace

Worn out cylinder and piston

Replace

Leakage through valve

Do lapping and correct

B. POOR PICK-UP
STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

No free movement of vehicle

Brake binding

Adjust both brakes

Low tyre pressure

Inflate to specification

Jammed wheel bearings

Replace / lubricate

Tight chain

Adjust free play

Improper ignition

Refer complaint No. A.2

Refer complaint No. A.3

Improper carburation

Refer complaint No. A.5

Clutch slippage

Incorrect free play

Adjust as per specification

Burnt drive, driven plates

Check and replace

C.

Poor compression

Refer complaint No. A.6

SMOKY EXHAUST (WHITE SMOKE)

STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Burning of oil in
combustion chamber

Oil mixed in fuel

Replace fuel in tank and clean

Adulterated fuel

Replace fuel in tank and clean

Improper routing / clogged breather pipe

Correct routing / clean

Damaged seal valve stem oil / valve stem

Replace

Incorrect fitment of 2nd and Oil rings

Fit properly

Worn out piston rings

Replace Rings

Worn out cylinder and piston

Replace cylinder and piston

Engine oil level exceeded maximum limit

Fill to the specified level

Service information 7-12

SERVICE INFORMATION
TROUBLE SHOOTING

D. SMOKY EXHAUST (BLACK SMOKE)

STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Very rich mixture

Sticky / worn out float needle

Correct / replace

Worn out jets

Replace

Clogged air filter

Clean / replace

Punctured float

Replace

Choke plunger stuck

Correct

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Poor cooling

Cooling fins covered with mud

Clean

No free movement of vehicle

Refer cause No.1 of complaint B

Incorrect ignition

Refer cause No.2 of complaint A

Poor lubrication

Incorrect type of oil

Use recommended oil

Low quantity / poor quality

Top up / replace as specified

Oil filter clogged

Clean / replace

Defective oil pump

Replace

Blocked oil passages

Clean / Correct

E. ENGINE OVER HEATING

STEP

Clutch slippage

Refer cause No.4 of complaint B

High compression pressure

Excessive carbon deposition

Decarbonise engine & muffler

Incorrect valve timing

Maladjusted valve clearance

Check and adjust

Incorrect sparkplug

Wrong heat range of sparkplug

Replace

F. HEAD LAMP NOT WORKING

STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Bulb fused

Defective bulb

Replace

High voltage flow to bulb

Check regulator voltage output

Loose contact in bulb holder/switch

Correct contacts

No power supply from lighting coil

Check lighting coil resistence

No power supply to bulb

Service information 7-13

SERVICE INFORMATION
TROUBLE SHOOTING

G. HORN NOT WORKING

STEP

REASON

POSSIBLE CAUSE

COUNTER MEASURE

No sound

Blown fuse

Replace

No / discharged battery

Fix / recharge

Defective horn

Replace

Defective horn button

Correct / replace

Wiring cut / disconnected terminal

Replace / connect

Loose connection

Correct

Discharged battery

Recharge

Incorrect tuning of horn

Tune properly

Defective horn

Replace / tune

Loose clamp

Correct

POSSIBLE CAUSE

COUNTER MEASURE

Weak / irregular sound

Rippling noise

H. HIGH FUEL CONSUMPTION

STEP

REASON

1
2

Refer causes B.1,2,3,4 & 5.

Fuel leakages

Leakage through fuel tank, fuel hose,

fuel cock and carburettor

Correct leakages

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Improper carburation

Refer causes A.5

Malfunctioning of
exhaust gas analyser

Wrongly selected settings / accessories

Rich mixture

Refer causes D.1

I . EXCESSIVE CO
STEP

Correct

J. JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM

STEP
1

REASON

POSSIBLE CAUSE

COUNTER MEASURE

Excessive CO

Improper idling rpm

Adjust idling

Service information 7-14

BROWN

BLUE WHITE

BLUE RED

BLUE GREEN

BLUE BLACK

BLUE

BLACK WHITE

BLACK

WIRE COLOUR CODE

TURN SIGNAL LAMP FRONT - R

(12V 4W) (2 NOS)

POSITION LAMP
(12V 4W) (2 NOS)

HEAD LAMP BULB

(35/35W)

FROM
TO

LIGHT SWITCH

BATTERY ASSEMBLY
STARTER RELAY
RELAY TURN SIGNAL

GREY

DIGITAL SPEEDOMETER

DIGITAL SPEEDOMETER

TCI UNIT

TCI UNIT

HUB DRIVE SPEEDO

TCI UNIT

THROTTLE SWITCH

PULSAR COIL
LIGHT BLUE

DIGITAL SPEEDOMETER

FUEL SENDER ASSEMBLY

GREEN YELLOW

CLUTCH SWITCH AND

STARTER RELAY

STARTER SWITCH

TURN SIGNAL SWITCH

DIGITAL SPEEDOMETER,
POSITION LAMPS,
TAIL LAMP AND
NUMBER PLATE LAMP
STARTER RELAY
STARTER MOTOR ASSY

THROTTLE SWITCH

STARTER RELAY

TCI UNIT

GREEN WHITE

CLUTCH SWITCH

TO

PASS BY SWITCH

HORNS

RELAY
PASS BY

GREEN RED

RELAY PASS BY

RELAY
TURN SIGNAL

NOTE A

DIGITAL SPEEDOMETER

DIGITAL SPEEDOMETER AND

STARTER RELAY

HORN SWITCH

GREEN BLACK

FROM

GREEN

WIRE COLOUR CODE

12
7

FUEL SENDER UNIT

IGNITION SWITCH

NEUTRAL SWITCH

STATOR ASSY Jn.

IGNITION SWITCH AND
ENGINE KILL SWITCH

SWITCH
ASSEMBLY - L

HORN 12V (2 NOS)

EARTH

STATOR ASSY
TCI UNIT

CLUTCH SWITCH

SWITCH ASSEMBLY
STOP LAMP FRONT

SWITCH ASSEMBLY - R

WHITE

VIOLET

RED WHITE

RED

ORANGE

LIGHT GREEN

WIRE COLOUR CODE

SWITCH
STOP LAMP Rr

THROTTLE SWITCH

PULSAR COIL
STOP LAMP SWITCH Fr & Rr

TURN SIGNAL SWITCH

STATOR ASSEMBLY Jn.

REGULATOR

IGNITION SWITCH

TURN SIGNAL SWITCH

FROM

SPEED SENSOR

REGULATOR

TO

FUSE 10A

TCI UNIT AND

BRAKE LAMP

TURN SIGNAL LAMPS L (Fr & Rr)

DIGITAL SPEEDOMETER

REGULATOR

IGNITION SWITCH, BATTERY

AND DIGITAL SPEEDOMETER

TCI UNIT, IGNITION COIL,

STARTER SWITCH,
Fr & Rr BRAKE SWITCH,
HORNS, PASS BY RELAY AND
RELAY TURN SIGNAL

STATOR ASSEMBLY

YELLOW WHITE

YELLOW RED

REGULATOR

STATOR ASSEMBLY Jn.

PASS BY SWITCH

LIGHT SWITCH

REGULATOR

PASS BY RELAY

BEAM CONTROL SWITCH

YELLOW ORANGE

DIGITAL SPEEDOMETER
LIGHT SWITCH
YELLOW BLUE

DIGITAL SPEEDOMETER AND

HEAD LAMP HIGH BEAM
HUB DRIVE SPEEDO

PASS BY RELAY
YELLOW BLACK

YELLOW

TO
STATOR ASSEMBLY Jn.,
HEAD LAMP LOW BEAM

STATOR ASSEMBLY,
BEAM CONTROL SWITCH

FROM

NOTE A:COLOUR MARK ON THE THROTTLE

SWITCH SLIDER SHOULD MATCH WITH
THE BODY AS SHOWN IN THE FIGURE
WHEN THE THROTTLE IS IN FULLY
OPEN CONDITION.

WHITE RED

WIRE COLOUR CODE

STARTER RELAY

TCI UNIT

NEUTRAL SWITCH

TURN SIGNAL LAMP REAR - R

(12V 10W)

MOTOR ASSEMBLY STARTER

SPARK PLUG

BATTERY 12V 9Ah

IGNITION COIL

TURN SIGNAL LAMPS R (Fr & Rr)

DIGITAL SPEEDOMETER

PULSAR COIL

GAP BETWEEN MAGNETO PIP

AND PULSAR COIL SHOULD BE
BETWEEN 0.6 - 0.8mm

TVS APACHE RTR 160 & 180 - WIRING DIAGRAM

11
10
9
8

rpm
x1

TURN SIGNAL LAMP FRONT - R

(12V 10W)

SERVICE INFORMATION

Service information 7-15