Apache 160 WWW.MOREFOTO.BLOGSPOT.COMa = - ame RT Ra) TVS -& GROUP INDEX | i el tee Lu Bo bts leel lea TNs /U lol tar ta fe) SERVICING OF ENGINE 8] Seanad a 9] PRE - DELIVERY INSPECTION ie | | | ola ar) eee | J wwnwamorefote blogspot.com1. GENERAL INFORMATION Electronic Fuel Injection (Fi) The first ever vehicle from the house of TVS with Electronic Fuel Injection (Fi) technology. ‘An Electronic Fuel injection system (Fi) isa self cantained custom built computer system which controls the operation of an engine by monitoring the engine speed, load and temperature, provides the spark atthe right time for the prevailing conditions and metering the fuel to the engine requirement accurately Insimplestterms, the purpose of electronic fuel injection sto deliver the following advantages: ADVANTAGE OF ELECTRONIC FUEL INJECTION (Fi) 1. Bottor control on air-fuel mixing ratio ‘A powerful on board computer (ECU - Electronic Control Unit) gives the signal to the Injector at an appropriate time before TDC thus ensuring delivery ofthe required fuel. Besides, the ECU monitors the atmospheric temperature through an Intake air temperature sensor (IAT Sensor) and the engine conditions through an Engine temperature sensor (ETS) and Manifold absolute pressure sensor (MAP. Sensor). and provides better control on air-fuel ratio resulting in ‘+ Improved cold startability and also improves hotfuethandling '* Improved pick up, faster throttle response and better altitude compensation thus ensuring good and comfortable onveabiity in various altitude conditions. © Lower emissions and improves mileage. 2 Lowermechanical complexity Unlike vehicles with carburettor. the Fi bike does not have a choke or any other mechanical levers. This. reduces mechanical comple» ity andis easy to service. 3. EasytoDiagnosis, The serviceability of the Fi becomes easy. By using its powerful diagnostic tool system, mal-functioning of its systemif any, can be easily detected. Special features of Apache RTR Fi Fi Technology ‘The first ever introduction from the house of TVS. Powerful Engine Management | Enhances Powerul ide feel (17.55 KW @8500rpm) and fastest (0-60 kph injust system (EMS) has an Electronic 4.6 secs) nits lass, control unit | Malfunetioning indicator Indicates defective or non functioning Fiparis Service Reminder Reminds Customer that his vehicle is due for servicing. Front roto petal Disc brake Forefficent and eflective braking mae j| |” Rear roto petal Disc brake 1 The first ever introduction from the house of TVS. Rear role pelal disc for efficient { % and effective braking i Digital speedormeterhasthe folowing Tealres {opSpeedresnde 2 Fasten acaeatio 0-60 Kin rood, Dig Speedometer ‘riinetorinaseoe 5 Low ater indetor 6. Seve Rerinde 7 Lon el waringlampin addon oFvelgauge & Dig lock Eiecirnie Fuel pump & injector | Lower mechanical conplesty ensures lw mainlancs and ease sco Adjustable split handle bar Two way adjustable handle bar for better ride comfort MIG Suspension ___[ Monotube inverted Gas rear shock absorber fr effective suspension ED Tail lamps ~~ [Forbetteriturination & Style ss Racing strips Racing strips on fuel tank for better stylingeubis 1a t aunssasd 1yBu ab gone Bnid weds, 193 oF Indu! soye>tpul ou poneG — — — 1464 uonouryen aisnipe poads mo ap1 ‘SepIYBR SANSByRp ay) BIGEUR O| Pas 2910n09 ansoubEia, (sour pylos) sindino Auew sianyep pue (Sou penop) sindur snouen sana ‘wayss 14 exqus uy yonuco 1h "wosks 14 91g jo ueay ALIN TOUINOD ANIDNA posn sj sosu0s & 1, GENERAL INFORMATION IMPORTANT INSTRUCTIONS - Customers _ FUELFILL: ‘Always use the good quality fuel & TVS Motor recommended fuel additives. Use of adulterated fuel may cause severe damage tothe Fi parts. ‘The electronic fuel pump is located inside the fuel tank and requites a minimum of 3 litres offuel to operate. So always maintain the fuel level above three litres. Low fuel level /no fuel in the fuel tank will cause the fuel pump to run dry and ‘may result in ue! pump fallure. As ne fuel pump runs at very high rpm, it may warm up the fuel and fuel tank, ifthe level islow. ‘SPEEDO SELF CHECK: Apache RTR Fisystem automatical y does the following self checks whenever the control keyis switched "ON" All LEDs of speedometer gets "ON" for 3 seconds after switching on the control key and then gets OFF, except the Mal- function indicator. This malfunction indicator also switches OFF, when the engine is cranked / started. If this indicator glows even after starting of engine, please bring the vehicle to TVS authorized service shop, the trained dealership ‘mechanic can check and enrrect the malfunctions by using the diagnostic equipment ‘As the Control key/is switched “ON” and the selfcheckisin progress, the tachometer needle moves til the extreme last point ofrpm dial and gets back othe original position. ‘The fuel pump set primes, once the control keys switched ON. This can be felt by a mild humming sound from the tank ‘or by a mild vibration atthe fuel tank area. Once the priming is done, the pump once again starts working when the engine cranked. (This soundis ncrmaliang the customer need not worry or feelas a problem) BATTERY CARE Re The battery cndtion and mntenonce are very npariand orluneionng of Fieystom. the battery wage becomes low. battery nccatoron Speedo panolgets ON. This means that the output voageis oo ow andthe batery needs immediate charging. Whenever the low batter incalor gots ON" please brig the veice to TVS motor authored sacs shop Donot use te electrical equipments such es parking lights, noms brake gis and pss by ight equenty when he eine isin OF conn it wilresultinquck cralingo bate Regularly bring your vehicle to dealership / authorized service centers as per service maintenance schedule so that batteries are inspecied and chargeditnecessary. MALFUNCTION LIGHT Whenever the engine is started, please check whether malfunction indicator is switching OFF afer starting. I the indicator is not getting OFF, please bring the vehicle to TVS authorised service shop, who will heck and correct the matfuntion by using the diagnostic equipment WATER WASH CARE Fi parts & Fi parts mounting areas of the vehicle are sensitive and hence do not wash the Fi parts and its mounting ‘areas with water. Care should be taken by customers not to apply water jets directly on these Fiparts mounting areas, ifthe vehicies are pressure washed at places other than TVS motor Authorised service centres, ‘SERVICE ONLY AT TVS-MOTOR AUTHORISED SERVICE CENTRES: ‘TVS Motor Company Authorised service centre mechanics have been spacially trained to handle Fi vehicle system and hence please ensure that your Fivehicleis attended and serviced at TVS Motor authorised service centres only. EXPLAIN ALL THESE POINTS TO OTHER USERS, BEFORE YOU HANDOVER YOURBIKE TOTHEMRT Rea TE) TVS 4 4. GENERAL INFORMATION IMPORTANT INSTRUCTIONS - Dealer Staffs A properly guided Installation process before vehicle delivery very important for customer to know the Fi ‘system adequately. During the vehicle delivery (Installation) emphasize /demonstrate (i required) al the points listed in annexure 1 ofthis Samachar. These points are also very important for mechanics to follow and check during servicing ofthe Fivehicles DON'T TOUCH / ADJUST / REMOVE THE Fi PARTS & COUPLERS UNNECESSARILY AS IT MAY ‘SEVERELY AFFECT THE VEHICLE PERFORMANCE Fi system comprises of mostly Electronic parts like Sensors, fuel pump and Electronic control unit. These parts and its connecting couplers should be carefully handled during servicing ofthe vehicles. Hence only identified {tained mechanics should service the Fl vehicles and replace these parts. ALWAYS DELIVER THE VEHICLE WITH FULLY CHARGED BATTERIES. Al Electronic parts ofthe Fi system works on DC power (battery) and hence maintenance of the Battery and its output voltages very important. During every service, the battery needs to be checked for its maintenance points and ensured for its for full state of charge during servicing of the vehicles. (12V and above). ENSURE THAT THE MAP SENSOR HOSE ROUTING IS CORRECT WITHOUT ANY KINKS / BENDS MAP sensor hose is very sensitive in Fivehicles. During every service, check the MAP hose for any blockage’! Puncture /cracks or hoseltt. Ifany punctures found on the hose, replace the hose with the new one, DO NOT CONNECT THE PC BASED DIAGNOSTIC TOOL UNNECESSORILY. USE ONLY WHEN MAL. FUNCTION LIGHT GLOWS AFTER STARTING THE ENGINE OR ANY ABNORMALITY IS NOTICED FOR WHICH IDLING RPMAND IDLE CO NEED TO BE CHECKED. DON'T TURN THE IDLING SCREW (LIKE A NORMAL CARBURETTOR IDLING SCREW) WITHOUT CONNECTING THE PC BASED DIAGNOSTIC TOOL. Use the special PC based Diagnostic kit only when the vehicles are reported with malfunctioning lamp Continuously glowing after starting ofthe engine. The Fisystem mostly does not require any adjustment of iling pm oF Idle CO. Incase of any abnormality noticed and malfunction lamp does not glow, The idling RPM / CO ‘adjustment should be adjusted only withthe diagnostic tool & software given by TVS Motor. WATER ENTRY OF Fi PARTS MAY CAUSE SEVERE DAMAGE SO BE CAREFUL WHILE WATER WASHING Don'tuse pressurized water jets directly on the areas where ever Fiparts are mounted (Refer Figure) while water | washing the vehicles. Wipe the dusty areas with cloth carefully _worw.morefoto.blogspot.com‘out Jo opis ‘mojaq) wun JosqUES OF WOR uM adi (21614 49)94) palUNoW a1e syed 14 1949 a1aym Seare oLn UO AyDaNp syal i9}em pazuNssax rad #6 0) my Aiquiosse duind jong + isu 14 9 SLuvd 14 | Joyem yum sease Bununow suediy ay) uea! ojjCU WALA esiApY'sease BuNUNOW Sed 14 puE AuaNISUas sued) Noge seWoIsMO aoe °—Z PYAR oty BUIYSEM BIEN SUM“ !STIOIN3A 3H NIRS YM USLVM STIHM BUY FLVNDIAV JAVA “BALLISNAS AYBA BUY SLNVd 3AISMOXA Ld (3uVvo HSM YSLVM YO4) LNO AVI SLuVd 14 Eas 1S ‘worw.morefoto blogspot.comRT aes TVS & ___4.,GENERAL INFORMATION TECHNICAL SPECIFICATIONS DIMENSIONS AND WEIGHT | Overalliength 2020 mm = a [Overal with 730 mm P = ‘Overall Height 11105 mm 2 Seat height 790 mm = Ground clearance 480 mm Wheelbase 7300 mm Kerb weight 139 kg with toolkit and 90% of fuel Payload _ 130k9 Gross vehicle weight 269 kg ENGINE z i = ae Type 4 stroke, ait cooled, SI Engine with Fi [Bore 62mm Stroke 52.9 mm Piston displacement 1597 ce No.of valves. 2 Ac iter Double polyurethane foam fiter element Z Oil Filter Wire mesh and micronic paper fiter Lubrication system Forced wet sump ‘Compression ratio 95£05:1 “4 ‘Maximum power in KW. 11.85 # 0.3 KW (15.7 bhp) @ 8500 + 200 rpm | Maximum torque in Nm 19.1 Nm @ 6500 + 200 rpm Maximum speed 120 Km J hr Engine idling rpm 1400 4 100 rpm Starting system Kickstarter / electric starter TRANSMISSION oes Clutch system ‘Wet - Mult plate type Gear shiftpattem 41. down and 4 up = Primary Transmission Helical gears | Secondary Transmission Chain and sprockets * ‘GEAR RATIO t First gear 2917 ° | Second gear 4.857 Third gear 1.383 Fourth gear 4.050 | “Fith gear (0.880 Primary reduction —_ 3.095 ‘Secondary reduction 3.385 CHASSIS ae = wi Frame type @ Doubie cradle Synchro STIFF : | Front suspension Telescopic oll dampea a S Rear suspension Monotube inverted gas filed 5 step adjustable shocks with rectangular swing arm ‘worw.mmorefoto blogspot.comReais TVS »& 1, GENERAL INFORMATION ‘Steering angle ar | Caster angle 25.5" Trail length [813mm Brakes T 3 Front Hand operated, 270 mm petal disc il Rear ei Foot operated, 200 mm petal disc ‘Tyre size a Front 907 90x17" Rear 100 780 x 18° Tyre pressure Solo Front | 4.75 kglom? (25 PSI) Gar 2.00 kglom® (28 PSI) pe Dual Front a 1.75 kglom? (25 PSI) Rear i 2.25 kg/om* (32 PSI) = ELECTRICAL t _Twe : [AG generator = “Tgnition system {DI ECU Contolied Mapped ignition = Sparkplug ig BOSCH URSDDC - twin electrode ~ Battery type 12V9AH Body eating Te Generator = Fly wheel magneto 12V 105W_ Head lamp | Halogen HS 12 35/35” Position lamp 12 4Wx2 Tail lamp / Brake lamp | LED indicators (0.5 / 3.5W) Turn signal lamp av TOW x4 ‘Number plate lamp [1av awit =e pacer ss LCD /LED ideation Tl Horn type. = 12V DC x2 Fuse = [hav t6ax2 | Voltage Regulator [Ful wave Regulator ECU Relay “NO’ type (12 V) CAPACITIES: hee i Fuel tank including reserve 16 lives (including reserve) Reserve. 25 litres | Front fork oll (rade) 1OC telashockab oil i} Front fork ol (ay) 141 £25 mi Engine cum transmission ol (grade) | 4T oll ee Engine cum transmission ofl (aty) c * [After draining +1000 mi = | After disassembly 1400 mi Note: 1. Specifications are subject to change as a part of continuous improvement in the product 2, For details on exclusive parts and part numbers, refer page No. 39 to 44 of this manual.Raa TVS >& A. GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBERS _ FRAME NUMBER 41. The frame serial numberis engraved on the frame at right side ofthe steering head pipe (Location same as ‘Apache RTR) 2. Variant identifier code changed from MD634KE to. mp6e34Le, FRAMENUMEER" (MD 3 ool E66 6 2 Al 0 0 0.0.7, Month Manufacturing Vehicle aos eee type Check Serial No, Won, Frame digit | | Plant manufacturer aie identifier Variant Engine ype identifier code ENGINE NUMBER 1. The Engine serial numberis engraved on the left side crankcase near cylinder block (Location same as ‘Apache RTR) 2, Engine number is changed from 04 to 0E5. ENGINE NUMBER Liisa Denaialia eneL pods Rind orl T gael race cueite Mont code] fle cael vero Note: For detailed procedures and instructions on the following, refer Apache Service Manual SER.MAN / APACHE 01 /Revision 0, August 2006. (Page No. 1-8 to 1-10) 4. Running in period 2. Fuel andl recommendations 3.Precautions and generalinstructions 4. List ofhandtools and special tools "LIST OF EXCLUSIVE TOOLS REQUIRED 9322410 PC Diagnostic kit (For details on using this tool, refer page no. 26 to 32 of this manual) 3 ‘wor.mmorefoto blogspot.comST eae TVS ~& 2. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE Periodic Maintenance For a trouble free performance of the vehicle and its longer if, the vehicle should be periodically inspected for wear of components. deposits, stretched cables, etc. The worn-out components have to be replaced or repaired and necessary adjustments to be made for certain items for consistent performance of the vehicle as indicated in the table, Note: More frequent maintenance checks may be performed on vehicies that are used in severe conditions like usty environment, dense traffic conditions, sustained fullthrottle operation and un-matalled roads. For detailed Periodic maintenance and tune-up procedure on the following, refer Apache service manual SER.MAN/ APACHE 01 - Revision 0, August 2006 (Page No. 2-4 to 2-35) and SIBs sont there after. 4. Cleaning oftircleanerassembly Engine cum transmission oillavel check Filter complete engine ollreplacement Compression pressure check, Decarbonising of Head complete cylinder, Piston, Piston rings, Valve, Valve guide and Valve seat, Setting of tappet clearance & Sparkpplug cleaning Battery assembly Headiamp beam adjustment Cable free play adjustment - Throttle cable, Clutch cable Front Brake - Inspection of brake pads and brake fluid level, air bleeding from brake system and brake fluid replacement, Inspection of hose complete brake. 40. Wheel assembly front & rear 11. Inspection and adjustment of chain 12. Inspection oftyres and tyre pressure 13. Inspection of bolts, nuts & Lubrication points For maintenance schedule and procedure for engine oil replacement, ‘O° ring chain assembly, steering adjustment and fork oil placement, refer Apache RTR Service information manuals SER INF. MAN | APACHE RTR - Revision 0, June 2007 (Page No: 4 to 7) and SER INF. MAN | APACHE RTR - Revision 1, March 2008 (Page No: 3) in addition to Apache Service manual SER MAN/APACHE 01 - Revision 0, August 2006 (Page FUEL FILTER The fue! fiter is very entical for better performance of the Fi system and hence need to be compulsorily replaced every 9000 Kms. Follow the procedure given below for replacing the fel. Before attempting any service on “uel system, always follow the cautions given below: Remove the Seat, Cover frame LH & RH as explained in the Apache Service manual SER.MANIAPACHE 01 - Revision 0, August 2006 (Page No: 2-11) Step 1: Loosen and remove the fuel tank mounting bolt 1 No- 12mm Spanner) along with bush fuel tank Step 2: Gently lift the fuel tank from rear and dislocate the tank from the front cushion. Hold the fuel tank in the lifted condition using suitable supportatrear end and disconnect the Fuel pump. ‘assembly coupler (White colour) _wwrw.morefoto. blogspot.comRT ete) TVS >». 2, PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE ‘Step 3: Disconnect the fuel sender unit coupler (Green colour) and carefully take out the fuel tank assembly. ‘Step 4: Unlock and pullout the hose clip. Dis- ‘connect the fuel hose from the injector and piug the hose end with suitable plug to avoid the fuel seepage /leakage ‘CAUTION: Dis-connect negative cable at battery Note : Before re-assembly, check all hoses for any cracks If any cracks or permanent set noticed replace the hoses. | While re-assembling the hoses, ensure the locking of hose | clip & tree from any sharp bends, ifrequired replace the hose |alips with a new one. Alter re-assembling the fuel hoses | ensure the folowing 1. Ensure availabilty of minimum 3 liters of fuel inthe fuel | tank |2. Tum ignition key to ON position for 3 seconds (to Do-not smoke, and place "No smoking” sign | | nahtatiia Wise daee | Step &: Locsen and remove the Philips head screw (1 No) fom the fuel fiter mounting ‘Step 6: Uniock and pull out all hose clips (3 nos.) and disconect the hoses from the fter by using thenose pier operate fuel pump) and then turn to OFF position, Repeat this for 3-4 times to apply fuel pressure in fuel lines. |3. Check to see that there are no fuel leakages from any part offuel system (Fuel tank, hoses, hose joints etc.) SPEEDOMETER - LED INDICATORS _ Fi sysiem has a digital speedometer with various indicators and warning lamp, These Indicators should be checked for its proper function, Once the control key is switched on, the digital speedometer will do the sel ‘check ofall ts functions. During the self-check, the speedometer verifies funetioning of LCD, glowing of al its Indicators and rpm meter. All indicators will glow and dis-appear (except Malsunction indicator) which will dis- ‘appear only after cranking or starting the engine. Ifthe indicators are not glowing during the self check, then the required connections! parts(Fuse,lgniton switch, speedometer)need tobe checked and replaceditrequired Pes LOW BATTERY INDICATOR LAMP _ a ‘Since the entice Fi system is based on DC, the battery outputvoltage is very critical for the functioning of ECU and fuel pump assembly. Replace the fiter with a new one and reverse the removal procedure forre-assembly. Low battery indicator The ECU requires sufficient voltage for effective functioning. Switch on the control key and wait til completion of the digital speedometer self-check. After the self-check of the digital speedometer, if the low battery indicator continues to glow, this indicates that the battery ‘outputis very low and requires charging MAL FUNCTION INDICATOR LAMP Mal function funetion indicator contin eaycarat'°” As mentioned earlier, the mal-funetion indicator continues {0 glow even after the completion of Speedo self check. | This indicator light goes off once the engine is cranked or started. Ifthe light continues to glow even afterstarting the | engine, this indicates that there is some error or detect in the functioning of the Fi system, Use the PC based diagnostic kit to findout the defect / error in the system Refer page number 26 to 32 of this manual for details on PC requirements, Installation of Diagnostic kit software, application and usage of diagnostic kit, 70 ‘wormmoretote blogspot.com