TVS Apache RTR 160 HYPER EDGE 2015, Owner'S Manual

Page 1: ...OWNER S MANUAL TVS Motor Company Limited HYPER EDGE ...

Page 2: ...Customer s Name and Address Frame Number Engine Number Key Number Colour Date of Sale Registration Number Selling Dustributor Dealers s Name Address Stamp I ...

Page 3: ...rt bike we have ever made It is the lightest fastest stopping quickest lapping TVS bike in history For the first time TVS Racing s Dirt and Road racing technology have been combined to create a racing bike that is Street Legal but just barely The results are stunning DESIGNED BY THE RACE TRACK The look and stance of the RTR 180 were designed by the combination of race track technology track derive...

Page 4: ...e 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 Note Acces...

Page 5: ...TS IV Safety information 01 Running in information 02 Safe riding tips 03 Know your Apache RTR 180 07 Riding your Apache RTR 180 26 Maintenance 31 Service Record Sheet 50 Technical specifications 52 CONTENTS ...

Page 6: ... V ...

Page 7: ...ssible to warn you about all 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 Warning Disregarding this message might result in injury to the rider Caution This message indicated special procedures or precautions to be followed to avoi...

Page 8: ... excessive stress Maximum recommended speed during the running in is Maximum 50 kmph speed upto 1000 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 pe...

Page 9: ...n 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 Wa...

Page 10: ...oportion with speed and the radius of the corner During cornering reduce speed so as to lessen the effects of centrifugal force By all means avoid abrupt application of brakes or sudden steering 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 ve...

Page 11: ...them sufficient friction does not develop and brakes do not work well SAFE RIDING TIPS 05 SAFE RIDING TIPS 2 Even when the brake works 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 3 Approximately 60 braking effect is from front brake Non usage of front brake causes poor braking Warning As the vehic...

Page 12: ... vehicle capacity of battery and magneto EMISSION CONTROL All the TVS vehicles are tested in the factory for optimum fuel efficiency and lowest possible CO levels Do not disturb the Carburettor 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 Dealer or Authorised Servi...

Page 13: ... to assist your Distributor Dealer for operating parts or referring to special information Please fill the above boxes now for future reference Frame number Engine number Control key number The frame serial number is stamped on the right side of the steering head tube The engine serial number is stamped on the left side crankcase assembly near cylinder block 0EGLA2058855 0E6E82034398 ...

Page 14: ...4 Clutch lever 5 Pass by switch 6 High low beam switch 7 Rear view mirror L 8 Digital speedometer 9 Ignition cum steering lock 10 Tachometer 11 Rear view mirror R 12 Master cylinder front 13 Engine cut off switch 14 Front brake lever 15 Throttle grip 16 Head lamp switch 17 Electric starter switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 15: ...KNOW YOUR APACHE RTR 180 1 Front wheel axle 2 Fuel cock 3 Choke lever 4 Gear shift lever 5 Centre stand 6 Side stand 7 Rider foot rest L 8 Pillion foot rest L 9 Rear shock absorber L 10 Rear wheel axle 11 Saree guard 12 Cover frame L screw 12 1 2 3 4 5 6 7 8 9 10 11 ...

Page 16: ... Disc plate front 2 Front wheel axle nut 3 Caliper assembly front 4 Spark plug 5 Gauge oil level 6 Kickstarter lever 7 Rear brake pedal 8 Rider foot rest R 9 Cover frame R lock 10 Pillion foot rest R 11 Rear shock absorber R 12 Disc plate rear 13 Muffler assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 17: ...L 2 Head lamp assembly 3 License plate front 4 Crash guard 5 Position lamps 6 Turn signal lamp front R REAR 1 Pillion handle R 2 Tail lamp assembly 3 Turn signal lamp rear R 4 Reflex reflector 5 License plate rear 6 Turn signal lamp rear L 7 Pillion handle L 6 5 1 2 3 4 1 2 3 4 5 6 7 Mandatory accessory will be charged extra ...

Page 18: ...moved in this position 3 LOCK position Apache RTR 180 steering can be locked in both left and right directions To lock the steering turn the handle bar all the way to the left or right Push the key in and turn it to the LOCK position and take out All the electrical circuits are turned OFF in this position Insert the key into the lock and turn it to OFF or ON position to unlock the steering KNOW YO...

Page 19: ...mp N Glows when the vehicle is in neutral and goes OFF if the gear is shifted from neutral 3 Turn signal indicator lamp Flashes when the left or right side turn signal indication is activated 4 Digital clock Displays the time in 12 or 24 hour time format Note If the battery is disconnected and reconnected during service the clock displays 12 00 by default You need to reset the time refer page no 1...

Page 20: ...ime taken so far to reach the 60 kmph speed You can reset and record new time if required Set the meter in St mode to know the time consumed by a rider to reach the specific speed from starting 8 Mode and Set switch buttons To change the mode between ODO TRIP A TRIP B HI Spd St and to set the clock timing the mode and set switches are provided Refer page no 15 for setting resetting the odometer tr...

Page 21: ...hicle is serviced and reset Get the vehicle serviced at TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers 12 Low battery indicator An icon with battery symbol glows when the battery charge is too low Get the battery checked at TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers KNOW YOUR APACHE RTR 180 15 Note Service reminder indicator lamp wo...

Page 22: ...e mode switch button A to increase the hours while hour digits are blinking 5 To access the minutes press the set switch button B again for few seconds 6 Press the mode switch button A to increase the minutes while minute digits are blinking 7 Press the set switch button B to exit the setting HANDLE BAR LEFT SIDE KNOW YOUR APACHE RTR 180 16 KNOW YOUR APACHE RTR 180 1 Horn switch Press the switch t...

Page 23: ...opriate turn signal lamps when you intend to change lanes or take turns Be sure to switch OFF the turn signal lamps after negotiating the turns or lanes Use appropriate head lamp beam high low as per the traffic and road conditions for your safety and to avoid inconvenience to other riders KNOW YOUR APACHE RTR 180 1 Electric starter switch Press the electric starter switch to start the engine elec...

Page 24: ...ngine speed and away from you or release it to decrease the engine speed 4 Front brake lever The front brake is applied by squeezing the front brake lever gently towards the throttle grip The brake lamp glows on application of front brake 5 Engine cut off switch To switch off the engine but to keep the battery activated press the switch to position To start the engine press the switch to position ...

Page 25: ... and close the protection lid KNOW YOUR APACHE RTR 180 19 The fuel tank is not a measuring instrument and the capacity of the fuel tank may slightly vary from the indicated capacity KNOW YOUR APACHE RTR 180 Warning Avoid spilling of fuel on the hot engine Never refill fuel near open flame Do not smoke while refueling Do not use cell phones while refueling Whenever refueling the bike fill upto the ...

Page 26: ...e is started and running in stable RPM push back the choke knob and ride the vehicle KNOW YOUR APACHE RTR 180 Leaving the fuel cock in ON or RESERVE position may cause the fuel tank to completely drain out incase any malfunctioning of carburettor float system Similarly if the fuel cock is positioned between ON and OFF may drain off entire fuel while riding the vehicle Note CHOKE KNOB Choke is prov...

Page 27: ... shift lever for first gear or lifting the gear shift lever for remaining gears up once for each gear KNOW YOUR APACHE RTR 180 21 KICK STARTER LEVER The kick starter lever is located on the right side of the vehicle To start the vehicle keep the ignition and engine cut off switch in ON condition With the transmission in neutral keep your foot on the lever extension and kick from top and stroke to ...

Page 28: ... the centre stand hold the handle bar left grip with left hand and pillion handle L with right hand KNOW YOUR APACHE RTR 180 ON Gear shift lever position can be set to your convenience Contact your TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers for setting the gear shift lever position Note ON Rear brake pedal position can be set to your convenience Contact your TVS ...

Page 29: ...lways release the side stand to its full up position before moving the vehicle Caution Never sit on the vehicle when it is supported by side stand Always park the vehicle on a flat firm surface 2 3 1 COVER FRAME R Apache RTR 180 is provided with lockable cover frame on the right side for accessing the battery rear disc brake master cylinder and the seat lock cable This cover can be opened in the f...

Page 30: ... holes 2 Gently press the cover frame lugs into the holes 3 Now lock the cover frame by turning the key in anti clockwise direction TOOL KIT To assist you in performing certain aspects of periodic maintenance and emergency repairs a tool kit is supplied along with the vehicle A tool kit is located below the seat assembly To access the tool kit open the cover frame R as explained earlier and pull t...

Page 31: ...tributor Dealer or Authorised Service Centers for removing or re fixing the rear fender flap KNOW YOUR APACHE RTR 180 25 KNOW YOUR APACHE RTR 180 With out fender flap With fender flap Note Rear fender without a fender flap may not protect the mud splashing since it is having the through holes in it It is strongly advised to fix the flap to protect from the splashing of mud during wet conditions ...

Page 32: ...mps neutral lamp pass by switch and electric starter Low battery indication page no 15 Electrolyte level page no 35 Speedometer Performing self check Lighting Proper working of head lamp high beam low beam high beam indicator speedo back illumination tail lamp and number plate lamp Steering Smooth movement No play or looseness Throttle Correct free play of cable Smooth operation Clutch Correct fre...

Page 33: ... no ventilation available Exhaust gas is extremely poisonous Caution Do not keep the engine in idling rpm for long and do not open excessive throttle when engine is idling and the vehicle is parked It leads to overheating of engine and damage to the internal components SETTING THE VEHICLE IN MOTION 1 Depress the clutch lever and engage first gear by pressing the gearshift lever down 2 Open the thr...

Page 34: ...icle stops 3 Turn the ignition OFF 4 Park the vehicle on a firm flat surface 5 Lock the steering and turn OFF the fuel cock FUEL RECOMMENDATION Use unleaded petrol only The petrol should be 85 to 95 octane by research method Use recommended fuel additives for longer life of engine components and lower maintenance Petrol mixed with ethanol will have impact on engine components Contact your TVS Moto...

Page 35: ...pect and clean the air cleaner element periodically Replace every 12000 kms Clutch Increase in engine rpm during acceleration without a increase in road speed indicates the clutch slip A slipping clutch will cause high fuel consumption and engine over heat If the condition persists even after adjusting the clutch lever play immediately have the clutch checked by TVS Motor Company Authorised Distri...

Page 36: ...refer page no 43 Never use tyres which are worn beyond the permissible limit Chain slackness Check and ensure drive chain slackness Excess slackness leads to higher fuel consumption refer page no 45 Wheel freeness Check and ensure the wheel freeness by rotating the wheel at least once in a week to avoid wastage of fuel Fast starting from rest wastes fuel A racing start from rest at full throttle c...

Page 37: ...nd wheel components etc are key items and require very special and careful servicing TVS Motor Company Limited strongly recommends that the jobs as per the maintenance schedule be performed by your TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers Periodic inspections may reveal one or more parts that may need replacement Whenever replacing parts on Apache RTR 180 it is...

Page 38: ...el I I I I I I Replace every three years 2 All control cables I A L I A L I A L I A L I A L I A L Throttle grip L L L Lubricate using grease Choke operation I I I I I I Steering smooth operation play I A I A I A I A C L A I A C L with fresh grease every 12000 km Front fork oil Replace every 18000 km Front and rear suspension I I I I I I Inspect for proper functioning All fasteners I TI I TI I TI I...

Page 39: ... I I I I I I Replace if necessary Brake fluid I T I T I T I T I T I T Replace every 21000 km Brake hose I I I I I I Replace every three years Master cylinder cups Replace every 21000 km Wheel freeness I I I I I I Tyre pressure at cold condition I S I S I S I S I S I S Engine idling RPM I S I S I S I S I S I S 4 Idling CO I S Ball joint gear shift lever L L L Lubricate using grease Centre side stan...

Page 40: ... 1100 ml after disassembly 4T oil Front fork oil 140 2 ml leg Gabriel make IOC Castrol Teleshockab oil 152 2 ml leg Top make Disk brake fluid TVS Girling DOT 3 DOT 4 Grease Bharath petroleum MP Grease no 3 IOC Servo Gem no 3 Bechem Bechem premium Chain lubricant TVS Motor Company TRU SPRAY Fuel additives As recommended IFTEX RECOMMENDED LUBRICANTS ...

Page 41: ...ll the filler caps and clean the battery thoroughly apply petroleum jelly to the battery terminals to protect it from corrosion Incase of any abnormality or for removal of battery from the vehicle contact TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers MAINTENANCE 35 MAINTENANCE Caution Once the battery is charged initially never add diluted sulphuric acid Use only di...

Page 42: ...and slide out blown fuse 5 Replace the fuse with a new extra fuse is provided inside the fuse case itself 6 Close the fuse case and re fix it into the battery band 7 Turn ON the ignition lock and check for proper functioning of electrical systems Incase the fuse fails again consult the nearest TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers MAINTENANCE MAINTENANCE 36 ...

Page 43: ...f spark plug electrodes No manual adjustments of gap is recommended If the gap found more than specified limit replace the spark plug After cleaning and inspecting the gap reinstall the spark plug and tighten by hand to avoid cross threading Finally tighten using the spanner Do not over tight or cross thread the spark plug MAINTENANCE 37 MAINTENANCE 0 6 0 8 mm Caution Always use only recommended m...

Page 44: ... Wipe off the surroundings of gauge oil level 2 Remove the gauge oil level and wipe it clean 3 Fix the gauge back to its mounting hole and thread in 4 Once again remove the gauge and check the oil level MAINTENANCE MAINTENANCE 38 Maximum Minimum Caution If the vehicle is driven with less engine cum transmission oil engine components will be severely damaged Check the oil level as per the schedule ...

Page 45: ...engine is cold 2 Loosen the lock nut 2 while holding the clutch cable adjuster 3 Adjust the clutch cable adjusting nut 1 in or out to give sufficient play in the clutch lever 3 After adjusting the play hold the adjuster nut in the same position tighten the lock nut MAINTENANCE 39 MAINTENANCE Caution Too much or too less clutch lever free play will damage the clutch plates thereby affecting the per...

Page 46: ...ble monotube inverted gas filled rear shock absorbers to meet different road and load There are 5 notches for adjusting spring load If the spring is adjusted to the minimum notch then the shock absorber will be softer which is good for light loads If the spring is adjusted to maximum notch then it willbestifferwhichisgoodforheavyloads SOFT HARD Warning Do not heat tamper the canister filled with G...

Page 47: ...hould be above the LOWER mark B provided on the master cylinder when the master cylinder is parallel to theground 3 If the brake fluid level is below the mark or while applying brake if you feel the brake is more spongy or ineffective due to air entry contact TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers for topping up the brake fluid air bleeding and other brake re...

Page 48: ...procedure 2 Check the brake fluid level in the reservoir It should be between maximum and minimum level MAINTENANCE MAINTENANCE 42 3 If the brake fluid level is below minimum or while applying brake if you feel the brake is more spongy or ineffective due to air entry contact TVS Motor Company Authorised Distributor Dealer or Authorised Service Centers for topping up the brake fluid air bleeding an...

Page 49: ...e wear but also seriously affects the stability of the vehicle Under inflated tyres make smooth cornering difficult and over inflated tyres decreases the tyre contact with the ground which can lead to skidding and loss of control Be sure that the tyre pressure is within the specified limits at all times Solo Pillion Front 1 75 kg cm 25 PSI 1 75 kg cm 25 PSI Rear 2 00 kg cm 28 PSI 2 25 kg cm 32 PSI...

Page 50: ...uld be taken not to damage the rim and tyre MAINTENANCE MAINTENANCE Tyre rotation direction While reassembling the tyre after removing from wheel rim ensure that the arrow mark A provided on the tyre facing the direction of wheel rotation A Warning The tyre inflation pressure in cold condition and the tyre tread condition are extremely important for the performance and safety of the rider Check th...

Page 51: ...il as frequently as every 1000 km for better chain life and smooth vehicle running Check clean lubricate and adjust the drive chain in the following manner 1 Place the vehicle on centre stand with the transmission in neutral 2 Inspect the drive chain slackness vertical movement using the finger as shown in the figure 3 The slackness of the drive chain should not exceed the limit 20 25 mm 4 If the ...

Page 52: ...ng and lift the vehicle up 4 Carefully dislocate the disc from the caliper assembly Dislocate the hub drive from the wheel and slide the wheel out 5 Reverse the procedure for reassembling Ensure proper seating of hub drive in the wheel assembly and front fork during reassembly R E A R W H E E L R E M O V A L A N D REASSEMBLY 1 Remove the axle nut 1 and along with the washer Warning Ensure proper s...

Page 53: ...provided in the swingarm assembly Always make sure that whenever the wheel is removed axle nut is properly retightened to the specified torque STORAGE PROCEDURES For storage of your motorcycle for longer periods of over a month and above we recommend to carry out the following steps 1 Clean the vehicle thoroughly Park the vehicle on centre stand 2 Warm up the engine and drain engine cum transmissi...

Page 54: ...r similar area to avoid damage due to dust and rain Make sure that the storage area is well ventilated and free from any source of flame or spark TAKING THE VEHICLE OUT OF STORAGE FOR REGULAR USE 1 Take the vehicle out of the garage and clean it thoroughly 2 Remount the battery after bench charging if required 3 Fill the engine cum transmission oil TVS TRU4 PREMIUM 4T oil and check the oil level u...

Page 55: ...s with correct torque value 2 Fitness of tyres tyre pressure tread depth 3 All bulbs indicators and horn function 4 Smooth functioning of all cables and their free plays 5 Smoothness of steering operation 6 Drive chain and sprocket condition Chain adjustment 7 Front rear brake functioning and rear brake lamp switch adjustment 8 Front fork for any abnormality 9 Fuel cock bowl filter cleanliness 10 ...

Page 56: ...se whichever of the two occurs earlier 3 3rd service between a 5000 6000 km or b 6 months from the date of purchase whichever of the two occurs earlier 4 4th service between a 8500 9000 km or b 9 months from the date of purchase whichever of the two occurs earlier 5 5th service between a 11500 12000 km or b 12 months from the date of purchase whichever of the two occurs earlier 6 6th service betwe...

Page 57: ...n a 20500 21000 km or b 21 months from the date of purchase whichever of the two occurs earlier 9 9th service between a 23500 24000 km or b 24 months from the date of purchase whichever of the two occurs earlier 10 10th service between a 26500 27000 km or b 27 months from the date of purchase whichever of the two occurs earlier 11 11th service between a 29500 30000 km or b 30 months from the date ...

Page 58: ... filter Wire mesh and micronic paper filter Lubrication system Forced wet sump Maximum power in kW 12 52 17 bhp 8500 rpm Maximum torque in Nm 15 5 6500 rpm Maximum speed 124 km hr Engine idling rpm 1400 100 rpm Starting system Electric starter kick starter TRANSMISSION Clutch Wet Multi plate type Gear shift pattern 1 down and 4 up Primary transmission Helical gears Secondary transmission Chain and...

Page 59: ... arm Trail length 84 3 mm Turning radius 2400 mm TYRE Tyre size Front 90 90 x 17 Tubeless Rear 110 80 x 17 Tubeless Tyre pressure 2 Front 1 75 kg cm 25 PSI 2 Rear solo 2 00 kg cm 28 PSI 2 Rear dual 2 25 kg cm 32 PSI BRAKES Front Hand operated 270 mm petal disc Rear Foot operated 200 mm petal disc ELECTRICAL Type AC generator Ignition system IDI Dual mode digital ignition Spark plug BOSCH UR5DDC T ...

Page 60: ...er disassembly Front fork oil grade IOC teleshockab oil Front fork oil capacity 140 2 ml per leg Gabriel make 152 2 ml per leg Top make Brake fluid TVS Girling DOT 3 DOT 4 The fuel tank is not a measuring instrument and the capacity of fuel tank may slightly vary from the indicated capacity TECHNICAL SPECIFICATIONS 54 Caution Using the bulb other than the specified rating can result in overloading...