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

Manufacturing serial no.

0 0 3 9

000 8

Month code

F 2 P

F 2 0

Year code

Plant code

A R 1 6

0R1 P

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

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