Apache RTR 160 Manual

PRODUCT TRAINING CENTRENexGe

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PRODUCT TRAINING CENTRE

Exclusive features of Apache RTR 160All New Racing Graphics

Racing Throttle Response Engine (RTR)

Digital Speedowith Service indicator system

Split Type sporty Handle bar

Bull horn pillion Handle

Adjustable Link type gear shift mechanism

270mm Front Disc brake

16 LED Tail Lamp

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RTR

Feature:

RTR : Racing Throttle Response

15.2 bhp engine

Benefit:

Quick Response to the throttle.

Feel of a race bike.

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IDI System

Feature:

TCI : Transistor controlled ignition

Benefit:

Long and high intensity Spark for better combustion of Fuel mixture.

Help in cold start & Cold Recovery

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CDI Vs IDI

CAPACITOR

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Gas Filled Shock Absorber

Feature

Gas filled 5 step adjustable shock absorber with Bottle designed Canister

Benefit

Comfortable ride even on bad roads

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Sporty SilencerFeature

Stainless steel, sporty silencer with catalytic converter and exhaust resonator.

Narrow snout designed muffler.

Benefit

Sporty looks

Resonator helps to achieve good power & Torque

Rust Free

Catalytic converter reduces pollution

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Stylish Contoured Fuel Tank

Feature

Sporty and Stylish

16 liters (including Reserve 2.5 ltr) capacity with flushed petrol tank cap

Benefit

Higher capacity Petrol Tank for long distance ride.

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Halogen HL Bulb with Twin City Lamps

Feature

Halogen HL bulb with Twin city lamps

Benefit

Brighter light

Safer to ride in city traffic condition

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RCF Technology

Feature

Roller Cam Follower

Auto De-Compression Valve

Benefit

Friction free engine

Low maintenance

Longer engine life

Smoother engine

No back kick during kick starting

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Racing Response Engine

Feature

Powerful Engine -

Power 15.2 BHP@8500 rpm

Torque13.1 Nm@6000 rpm

Engine with Charcoal Grey colour is added look.

Benefit

Excellent Initial pickup

Better top speed

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270mm Disc Brakes

Feature

Disc brakes with Sprocket design disc

Benefit

Sporty looks

Effective braking

Better stability

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Any Gear Electric Start

Feature

Any Gear Self Starting

Constant mesh self starter

SM-6 Motor

Benefit

Positive engagement

Effortless Starting

Soft button start

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Digital Speedo

Feature

Vehicle speed, clock, odometer, Trip meter on LCD screen.

Benefit

Guides the customer in time

More accurate

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IE SURGEFeature

IE SURGE - Intake Exhaust Resonator Surge

Induction resonator on air filter

Exhaust Resonator on Silencer

Benefit

Intake Resonator accelerates the air fuel mixture flow during sudden throttling and helps in quicker power response to zoom the bike.

Exhaust Resonator helps in clearing exhaust gas quickly out of the silencer during sudden throttling which results in high torque.

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5 Speed Transmission

Feature

5 Speed gear box

Link type Adjustable shifting system

Carbo-nitrating Gears

Benefit

High speed

Racing bike gear shifting system.

Improved life of gears

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SPECIFICATIONS TVS Apache RTR 160 TVS Apache

Dimensions

Overall Length 2020 mm 1976 mm

Overall Width 730 mm 743 mm

Overall Height 1050 mm 1100 mm

Ground Clearance 180 mm 165 mm

Wheel Base 1300 mm 1260 mm

Kerb Weight 136 kg 136 kg

Pay Load 130 kg 130 kg

Gross Vehicle Weight 266 kg 266 kg

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Engine

Type

Bore 62 mm 57 mm

Stroke 52.9 mm 57.8 mm

Piston Displacement 159.7cc 147.5 cc

Carburettor Type Ucal mikuni BS - 26 Ucal mikuni BS - 26

Air Filter

Starting System

Lubrication System

Compression Ratio

Compression Pressure

Maximum Horse Power 11.19 KW (15.2 bhp) @ 8500 rpm 9.95 Kw(13.5 BHP)@8500 rpm

Maximum Torque 13.1 Nm @ 6000 rpm 12.3 Nm@6000 rpm

Valve Clearance (Cold) Inlet 0.08 / Exhaust 0.11 mm Inlet 0.07 / Exhaust 0.12 mm

Maximum Speed 118 kmph 108 kmph

Engine Idling Speed

4 stroke ,air cooled, single cylinder OHC

Double polyurethene foam filter element

Kick start / Electric start

Forced wet pump

9.5:1

10 - 13 kg/cm2

1400100


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Clutch

Transmission

Gear Shift Pattern

Primary Reduction

Final Reduction

First Gear

Second Gear

Third Gear

Fourth Gear

Fifth Gear

Wet Multiplate type

Constant mesh 5 speed gearbox

65/21

44/13

35/12

All down heel - toe shift

26/14

24/18

21/20

22/25

Transmission


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Frame Double Cradle SynchroSTIFF Double cradle tubular type

Front Suspension and Travel lescopic Forks, 105mm Stroke

Telescope oil damped 105mm

Rear Suspension Monotube Inverted Gas filled shox (MIG) with spring aidGas filled 5 step adjustable with

canester

Steering Angle 41'

Caster Angle 25.5 25.5'

Trail Length 81.3 mm 90mm

Brakes: Front 270 mm Petal Disc 130/240 mm dia Drum/Disc

Brakes: Rear 130 mm Drum 130 mm foot operated

Tyre Size Front 90/90 x 17 90/90 x 17 - 6 ply

Tyre Size Rear 100/80 x 18 100/80x 18

Chassis


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Ignition SystemSparkplug

Sparkplug GapBattery TypeBody Earthing

Generator

Head Light 35/35W Halogen HS1, Clear lens with MFR

12V, 35/35 W HS 1 halogen

Tail Light/Brake Light 0.5 W. LED-Twin triangle with prism on lens

12 V, 5W / 21W

Turn Signal LightHigh Beam Indicator Light

Neutral Indicator LightSpeedometer Light

Economy & power mode lamp

Turn Signal Indicator Light

IDI -dual mode digital ignition - DCBosch Super UR 5 DDC

0.6 mm12V 9 Ah

12V,3.4W12V,2W12V,2W

Negative terminal

12V,10W12V,2W

12V,3.4W

12V, 100W

ElectricalSPECIFICATIONS TVS Apache RTR 160 TVS Apache

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Fuel Tank Including Reserve

Reserve

Front Fork Oil

Transmission cum Engine Oil (Grade)

Transmission cum Engine Oil (Qty)

1000ml(Overhauling)

16 Lts

2.5 lts

125 2.5 ml each

4T Oil

Capacity


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Discription TVS APACHE RTR 160 TVS APACHE

Carburettor Type BS26 CV Ucal Mikuni BS26 - X21 CV Ucal Mikuni

Main Jet 105 102.5

Needle Jet

Jet Needle

E - ring position

Pilot Jet 15 12.5

Pilot air jet (1) 1.45 1.45

Pilot air jet (2)

Piston valve CA - 3.9(2 vacuum sensing holes)CA - 3.9(1 vacuum sensing

hole)Throttle ValveMCS screw - No of turns

Idling RPM

Idling CO%(with SAI) 0.8 ~ 1.2% 0.6 0.4%Idling CO%(without SAI) 3.5 ~ 4.5%

NA

21(1 ~ 3 turns out)

140050

120

Carburettor Specifications

P2

QK

2 nd from top

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Cylinder Head

Combustion Chamber diameter increased.

bigger Inlet & Exhaust valve seats provided.

Painted with Charcoal grey colour.

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Cylinder Block

Bore Dia. increased to 62 mm

Auto Chain Tensioner mounting design is changed.

159.7 cm3 embossed for identification.


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Piston Assy.

Piston Dia. increased to 62 mm

Piston Rings dia increased to match the new piston.

Piston Pin and locks also modified

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Crankshaft Assy.

Crankshaft web weight increased.

Connecting rod modified.

Chamfer on Crank web are bigger.

150cc

160cc

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Clutch Cover

New Part

Rod comp. Clutch release is modified.

Charcoal grey painting is provided

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Auto Chain Tensioner

New Part

Strip coil type tensioner

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Crankcase RH

New Part

Guide bush provided for Cam gear shift shaft.

Painted with charcoal grey colour.

Guide bush

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Crankcase LH

New Part


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New Part

Clutch plate Drive and plate driven are modified.

Clutch spring are changed.

Clutch plate serrations reduced to 45( Apache 150 48 serrations).

Plain surface provided for pressure plates (Apache 150 dotted surface)

Clutch Assy.

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Cover Magneto

New Part

Charcoal grey colour.

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Stator coil assy.

New Part

Charging and lighting coils increased to 8(Apache 150 7 coils)

Since Source coil is not available here, that location is used for one additional lighting /charging coil.

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CV CarburetorNew Part

Fuel Jets and Tuning specifications changed

Main Jet 105

Pilot Jet 15

Piston Valve CA-3.9(1 vacuum hole)

CO (with SAI) 0.8 ~ 1.2%

Since change in By pass pitch , RTR 160 have new carburetor body

Can not interchange with Apache 150cc Ne

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Inlet & Exhaust Valve

New Parts

Valve face diameter increased

Inlet tappet clearance 0.07 mm

Exhaust tappet clearance 0.11 mm

ExhaustInlet

RTR 150cc

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Silencer Assy.

New Part.

Narrow snout Muffler Assy. design is to suit the new styling.

Mounting bracket point is changed.

Exhaust resonator position shifted to bottom side vehicle.

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Lever Kick Starter

New Part.

Design is changed to suit the new styling.

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Suppresser Cap

New part.

Suppressor cap design is changed to avoid the water entry.

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Lever Gear Shifting

New Part.

Link type design provided to give racing bike feel during gear shift.

Cam gear shift design changed to match the changes in Crankcase RH for smoother gear shifting.

Transmission gears are same as Apache 150cc.

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Rear Brake Pedal

New part.

To suit the new styling.

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Wiring Harness

New Part.

New couplers to connect the LED tail lamp.

Water proof coupler provided for avoiding the water entry.

Special coupler provided to connect the digital speedometer.

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Relay pass by

New part

Relay unit provided for Pass by operation.

Pass by will work in both DC and AC.

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TCI Unit

New part.

Ignition timing curves are changed in TCI of RTR.

For identification IDI in grey colour.

150cc

160cc

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Handle Bar

New part.

Split type handle bar to suit the new styling.

Handle bars can be adjusted to two positions as per the requirement.

Upper bracket cover added for styling.

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Bracket Pillion Foot Rest

New part.

diecasted pillion foot rest holder.

Charcoal Grey colour to match the look of the bike.

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Bracket Side Stand

New Part.

To improve the Part lift.

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Chain Case

New part

both Chain case upper and Lower are modified to match the new swing arm fitments.

Dimple profile provided at inner side of case to avoid wheel fouling during the ride.

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Rear Fender

New part.

Rear fender design is changed to suit the new styling.

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Number Plate Lamp

Design is changed.

Rear Reflector is fitted to lamp body.

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Digital Speedo Hub Drive

New Part.

Connected to digital Speedo meter through the wires.

Speedo cable is not provided.

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Front Fork RH

New Part.

Outer Tube design is changed

Disk Mounting point is changed.

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Vibration Dampers & Handle Grip

New Part.

Handle grip is modified

Vibration damper is modified.

Chrome plating is provided for Clutch lever and Front Brake lever.

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Engine Guard

New Part.

To provide a sporty look to the bike.

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Gas filled Rear shock Absorbers

New Part.

Canister Design modified.

Filled with Nitrogen Gas.

Lower mounting bracket length increased.

150cc 160ccNexGe

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Front Wheel Assy.

New Part.

Disc mounting positions changed to mount the 270 mm disc.

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APACHE - IGNITION CIRCUIT

Spark Plug

HT COIL

Charging Coil

RR Unit

WR

RW BW

Battery

RBW

Ignition Switch

R

Or

10A Fuse

DC TCI

PULSER COIL

W

Br

B

BW B

BBDC CIRCUIT

ENGINE KILL SWITCH

BWOr

HT Cord

Or BlBW

TCS

THROTTLE CONTROL SWITCH

BlWGW

BlRDigital

SPEEDOMETER

SELF STARTER SWITCH

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APACHE IDI CIRCUIT

SELF STARTER

RELAY UNIT

Spark Plug

HT COIL

Battery

RBW

Ignition Switch

R

Or

10A Fuse

DC IDI

PULSER COIL

W

Br

BWB

BBDC CIRCUIT

ENGINE KILL SWITCH

BWOr

HT Cord

Or BlBW

TCS

THROTTLE CONTROL SWITCH

BlWGW

BlRDigital

SPEEDOMETER

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APACHE - CHARGING CIRCUITCharging Coil

RR Unit

WR

RW BW

Battery

RBW

Ignition Switch

R

Or

10A Fuse

B

BW

DC TCI

SELF STARTERSWITCHB

B

ENGINE KILL SWITCH

BW

Fr.Br Switch Rr.Br. Switch

Brake Light

WW

BW

OrOr

BW

Horn(2)

Horn Switch

Or

G

TSL Switch

Fr. TSL

lbl

Rr. TSL

TSL Indy

VlG

Fr. TSL

Rr. TSL

TSL Indy

L RFlasher

Unit

DC TCI

RELAY PASS BY

HEAD.LAMP PASS BY SWITCH

High/Low Beam switch

GBY OrY

Or Or

YBl

Lighting SwitchNexGe

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APACHE SELF START CIRCUIT

R

Ignition Switch

R

10A Fuse

BW

BB

ENGINE KILL SWITCH

BW

DC TCI

Battery

Starter Relay

Gr

BW

B

Starter Button

STARTER MOTOR

Neutral Lamp

Neutral Switch

Bl

Or

Bl

BlW

BlW

Clutch Switch

TO DC Circuit

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APACHE - LIGHTING CIRCUIT

Lighting CoilBW

Y

Gr

BWH

LWR BW

Headlamp Switch

HeadlampGr

RELAY PASS BYYW

Tail Lamp

Yor

YB

RR Unit

Lighting Switch

YR

BW

City lamp

BW

Gr Gr

City lamp

Number plate lamp

Gr

BW BW

Gr

Y

PASS BY SWITCH

GBOR

SPEEDOMETER

BW

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Oh ms+-

AP ACH E - COI L TE S T I NG

2 0 0 0Ohm s

Pulser coil

+-

Resistance: 125 - 150 OhmsPulser Coil

2 0 0Ohm s

Lighting coil

+-

Resistance:0.25 - 1.0 ohmLighting Coil

IGNITION COIL TESTING

2 0 K

Resistance: 11.0 - 13.0 KOhms

Secondary Coil

2 0 0Oh ms

Ignition coil

+-

Resistance: 2.0 - 4.0 Ohm

Primary Coil

2 0 0Ohm s

Charging coil

+-

Resistance: 0.4 - 1.0 OhmsCharging Coil

Br

Y

To Spar k Plug

Ignition coil

From CDI Unit

WRB

BWRB

RB

WRBW

Or Bl HT CORDHT CORD

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08.ROAD TRIAL09.POST TRIAL (ON STAND)

05.FASTENER TIGHTNESS CHECKS06.GENERAL CHECKS (AFTER STARTING THE ENGINE)07.ELECTRICAL FUNCTION CHECKS

01.CHECK FOR PAINT SCRATCHES/DAMAGES02.MISSING ITEMS03.ALIGNMENTS/GAP04.STANDARD CHECKS

PDI

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Customer InstallationBasic Check points before starting the VehicleAll controls operations(clutch,brake,throttle,gear shifting)Explain all settings on Digital Speedometer Tank capacity : 16lit Res: 2.5litTyre pressure Battery condition Proper functioning of horn,brake lights,turn signal

indicators,electrolyte levelTool kitFirst aid kitEngine oil levelLighting

Service scheduleExplain Service schedule of Apache RTR 160 as per owners manual

Warranty Warranty period, Parts not covered under warranty, Limitations of warranty.

Tips for achieving best performance from vehicleProper tyre pressureBattery condition checkingUsage of IFTEX for petrol(2ml/ltr)Running in periodRiding tips

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Warranty Period: 30000kms/24 months

Service Kms Month Free/Pay

I 500 - 750 1 month

II 2500 - 3000 3 Months

III 5500 - 6000 6 Months

IV 8500 - 9000 9 Months

V 11500 - 12000 12 Months

VI 14500 - 15000 15 Months

VII 17500 - 18000 18 Months

VIII 20500 - 21000 21 Months

IX 23500 - 24000 24 Months

X 26500 - 27000 27 Months

XI 29500 - 30000 30 Months

Free

Pay

Service Schedule

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Periodic Maintenance

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Documents

Apache RTR 160 Manual