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SERVICE DATA
VALVE AND VALVE GUIDE
Unit : mm
S.No.
DESCRIPTION
STANDARD
SERVICE LIMIT
Valve diameter
Inlet
Exhaust
27.220
24.220
Valve clearance
Inlet
Exhaust
0.06
0.08
Inlet
Exhaust
4.990 - 4.975
4.970 - 4.955
Inlet
Exhaust
5.000 - 5.012
0.035
Inlet
Exhaust
Inlet
Exhaust
0.01
0.05
Inlet
Exhaust
0.75
0.70
0.5
Inlet
Exhaust
0.03
0.075
Inner
Outer
30.00
33.80
0.50
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
Inlet
Exhaust
12.000 - 12.018
Inlet
Exhaust
11.996 - 11.984
0.05
0.05
7
Service information 7-1
SERVICE INFORMATION
CYLINDER, PISTON AND RINGS PISTON
S.No.
Unit : mm
DESCRIPTION
STANDARD
SERVICE LIMIT
Compression pressure
10-13 kg/cm2
8 kg/cm2
0.025 - 0.035
0.120
62.000 - 62.015
62.500 - 62.515
62.110
62.610
61.970 - 61.985
62.475 - 62.490
61.875
62.380 - 62.395
0.05
Top
2nd
approx 7.0
approx. 5.5
5.5
4.4
Top
2 nd
0.20 - 0.350
0.350 - 0.50
0.70
0.70
Top
2 nd
0.015 - 0.045
0.015 - 0.045
0.15
0.15
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
11
15.002 - 15.008
15.030
12
14.996 - 14.998
14.980
CRANKSHAFT COMPLETE
S.No.
Unit : mm
DESCRIPTION
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
S.No.
DESCRIPTION
STANDARD
SERVICE LIMIT
5 - 15
2.920 - 3.080
2.60
Lever assembly gear shift play (to adjust clutch play at cover)
15.750 - 15.850
15.20
0.10
29.5
28.7
TRANSMISSION SPECIFICATION
S.No.
DESCRIPTION
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
S.No.
1
Unit : mm
DESCRIPTION
STANDARD
SERVICE LIMIT
0.050 - 0.200
0.3
254
259.4
20 - 30
SUSPENSION
S.No.
Unit : mm
DESCRIPTION
(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
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)
AXLE REAR
6205/RS1/C3 (25x52x15)
(ON DRUM REAR SPROCKET)
6001/C3 (12x28x8)
(ON CLUTCH RELEASE PLATE)
6201 (12x32x10)
ON CRANKCASE R)
6302/Z/C3 (15x42x13)
(ON WHEEL HUB R)
SERVICE INFORMATION
CARBURETTOR ASSEMBLY
S.No.
DESCRIPTION
SPECIFICATION
RTR 160
RTR 180
BS26-X39
BS29
Carburettor type
Z1
-----
Main Jet
105
125
Needle Jet
P-2
P-0
Jet Needle
4DHZ56
4DHL42
E - Ring position
Pilot Jet
15
20
145
145
Piston valve
120
120
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
S.No.
1
DESCRIPTION
SPECIFICATION
Ignition timing
At coinciding mark
Full advance
2 - 3 ohm
12 - 14 K ohms
5 K ohms
12V - 9Ah
Generator
12V - 100W
Spark plug
10
11
Tail lamp
12
Brake lamp
13
14
LCD/LED indicator
15
LCD/LED indicator
16
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
BRAKE AND WHEEL ASSEMBLY
S.No.
Unit : mm
DESCRIPTION
STANDARD
SERVICE LIMIT
15 - 20
Front
Rear
130
130.7
Front
Rear
1.5
0.05
0.1
3.5
1 mm
Axial
Radial
Axle runout
Tyre size
Front
Rear
0.25/100 mm
Front
Rear
Rear
90/90 x17
100/80x18
100/80x17
11
Front
Rear
1.5 or TWI
12
Solo
Dual
13
Solo
Dual
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
S.No.
DESCRIPTION
QUANTITY
TORQUE IN Nm
10
8 - 12
22 -25
22 - 27
10
10
10-12
8 - 10
5-7
8 - 10
10
12 - 16
11
13
8 - 12
12
60 - 80
13
35 - 45
14
10
8 -12
15
8 -12
16
75 - 85
17
10 - 12
18
8 -12
19
20 - 25
20
22 - 25
21
30 - 35
22
12 -20
23
37 - 45
24
Spark plug
10 - 12
SERVICE INFORMATION
TIGHTENING TORQUE
CHASSIS
S.No.
DESCRIPTION
QUANTITY
TORQUE IN Nm
50 - 70
6.7 - 8.3
16 -20
70 -110
18 - 24
60 -100
9 - 13
16 - 20
36- 40
10
44 - 54
11
16 - 20
12
22 - 34
13
32 - 40
14
10 - 16
15
11 - 16
16
20 - 30
17
55 - 70
18
6.7 - 8.3
19
50 - 70
20
16 - 20
21
16 - 20
22
32 - 40
23
16 - 20
24
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.
S.No.
APPLICATION
MATERIAL
LUBRICATION
1
4T oil
ADHESIVES
1
Specfit
CLEANING SOLVENTS
1
Carburettor
FUEL
ITEM
SPECIFICATION
Fuel type
Unleaded Benzine
16 litres
Reserve
2.5 litres
SERVICE INFORMATION
TROUBLE SHOOTING
A. STARTING TROUBLE
STEP
1
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Fill petrol
Clean
Correct gap
Bridging of electrodes
Replace
Replace
Replace
Replace
Replace
Oily sparkplug
Adjust tappets
Tighten
Replace
Clean / replace
Tighten
Blocked passages
Tune up correctly
Excessive CO
Tune up correctly
Correct
Induction leakage
Improper carburation
7
Service information 7-11
SERVICE INFORMATION
TROUBLE SHOOTING
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Poor compression
Adjust to specification
Replace
Replace
B. POOR PICK-UP
STEP
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Brake binding
Inflate to specification
Replace / lubricate
Tight chain
Improper ignition
Improper carburation
Clutch slippage
C.
Poor compression
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Burning of oil in
combustion chamber
Adulterated fuel
Replace
Fit properly
Replace Rings
SERVICE INFORMATION
TROUBLE SHOOTING
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Correct / replace
Replace
Clean / replace
Punctured float
Replace
Correct
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Poor cooling
Clean
Incorrect ignition
Poor lubrication
Clean / replace
Replace
Clean / Correct
Clutch slippage
Incorrect sparkplug
Replace
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Bulb fused
Defective bulb
Replace
Correct contacts
SERVICE INFORMATION
TROUBLE SHOOTING
REASON
POSSIBLE CAUSE
COUNTER MEASURE
No sound
Blown fuse
Replace
No / discharged battery
Fix / recharge
Defective horn
Replace
Correct / replace
Replace / connect
Loose connection
Correct
Discharged battery
Recharge
Tune properly
Defective horn
Replace / tune
Loose clamp
Correct
POSSIBLE CAUSE
COUNTER MEASURE
Rippling noise
REASON
1
2
Correct leakages
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Improper carburation
Malfunctioning of
exhaust gas analyser
Rich mixture
I . EXCESSIVE CO
STEP
Correct
REASON
POSSIBLE CAUSE
COUNTER MEASURE
Excessive CO
Adjust idling
BROWN
BLUE WHITE
BLUE RED
BLUE GREEN
BLUE BLACK
BLUE
BLACK WHITE
BLACK
POSITION LAMP
(12V 4W) (2 NOS)
FROM
TO
LIGHT SWITCH
BATTERY ASSEMBLY
STARTER RELAY
RELAY TURN SIGNAL
GREY
DIGITAL SPEEDOMETER
DIGITAL SPEEDOMETER
TCI UNIT
TCI UNIT
TCI UNIT
THROTTLE SWITCH
PULSAR COIL
LIGHT BLUE
DIGITAL SPEEDOMETER
GREEN YELLOW
STARTER 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
HORN SWITCH
GREEN BLACK
FROM
GREEN
12
7
IGNITION SWITCH
NEUTRAL SWITCH
SWITCH
ASSEMBLY - L
EARTH
STATOR ASSY
TCI UNIT
CLUTCH SWITCH
SWITCH ASSEMBLY
STOP LAMP FRONT
SWITCH ASSEMBLY - R
WHITE
VIOLET
RED WHITE
RED
ORANGE
LIGHT GREEN
SWITCH
STOP LAMP Rr
THROTTLE SWITCH
PULSAR COIL
STOP LAMP SWITCH Fr & Rr
REGULATOR
IGNITION SWITCH
FROM
SPEED SENSOR
REGULATOR
TO
FUSE 10A
REGULATOR
STATOR ASSEMBLY
YELLOW WHITE
YELLOW RED
REGULATOR
PASS BY SWITCH
LIGHT SWITCH
REGULATOR
PASS BY RELAY
DIGITAL SPEEDOMETER
LIGHT SWITCH
YELLOW BLUE
PASS BY RELAY
YELLOW BLACK
YELLOW
TO
STATOR ASSEMBLY Jn.,
HEAD LAMP LOW BEAM
STATOR ASSEMBLY,
BEAM CONTROL SWITCH
FROM
WHITE RED
STARTER RELAY
TCI UNIT
NEUTRAL SWITCH
SPARK PLUG
IGNITION COIL
PULSAR COIL
11
10
9
8
rpm
x1
SERVICE INFORMATION