HYPER EDGE

OWNER’S MANUAL

TVS Motor Company Limited

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-
 FOREWORD

Dear Customer

FOREWORD
Congratulations on the taking home the new Apache RTR 180. Rest assured you can look forward to exciting times ahead. And
you will know what we are hinting at every time you gun that throttle that is meant to live up to its name - Racing Throttle
Response 180.
The priority in every step of the RTR 180 development has been Performance first. Every system, every detail and every
component has been studied and pared down to its essence and performance increased to the maximum. If it didn't make the
RTR 180 lighter, faster or deliver quicker lap times on our Racetrack, it wasn't considered.
The result: the RTR 180 is the fastest motorcycle with the highest power-to-weight ratio of any sport 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-derived components at
our Apache Racing Group. The bike's striking aerodynamic shape naturally embraces its Racing Ergonomics. The all new Tank
Scoops and new Data logging facilities which display Top speed and 0 - 60 lap time are the seen for the first time.
Also this Owner‘s Manual has all details to ensure your bike is in top notch race ready condition.
So get astride and burn rubber on every road you hit. Every road will now seem a race track.
Enjoy Riding!

TVS MOTOR COMPANY LIMITED

-II-
 NOTICE

This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle
NOTICE

when resold or transferred to a new owner.

All information, illustrations, photographs and specifications contained in this owner’s manual are based on the
latest product information available at the time 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
Accessories shown in the picture may not be part of the standard equipment.

Part Number :- N9216950 Revision 1, October 2015

-III-
CONTENTS

CONTENTS
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

-IV-
-V-
 SAFETY INFORMATION

Operating this vehicle safely is an important responsibility of the rider. To help you make decisions about safety,

SAFETY INFORMATION
we have provided operating procedure and other information in this manual. This information alerts you on
potential hazards that could hurt you or others. Since it is not possible 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 avoid damage to the vehicle.

Note
This message provides further clarification for clearer understanding of any particular information.

-01-
 RUNNING-IN INFORMATION
RUNNING-IN INFORMATION

The first 1000 km is a crucial part of your motorcycle. Proper running-in operation during this period helps in
ensuring a maximum life and smooth performance of your motorcycle.
The reliability and performance of your motorcycle depends on the special care and restrain exercised during the
running-in period. It is especially important that you avoid operating the engine in high speed (RPM), which could
expose the engine parts to 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 performance of the first service will ensure optimum service life and performance from the
engine.

Caution
Replacing the engine cum transmission oil during first service is most important for better life of engine. Always use
TVS TRU4 PREMIUM , 4T oil for better performance and life.

-02-
 SAFE RIDING TIPS

SAFE RIDING RECOMMENDATIONS

SAFE RIDING TIPS

Any two wheeler riding requires some precautions to be taken to ensure the safety of the rider, pillion rider and
other road users. These precautions are:
Familiarise yourself with new Apache RTR 180
Riding skill and your mechanical knowledge form the foundation of safe riding practices. We suggest you to
practice riding Apache RTR 180 in a low-traffic condition 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.

Warning
Two wheeler safety equipment starts with a safety helmet of good quality. One of the most serious injuries that can
happen is a head injury. Always wear good quality helmet. You should also have good suitable eye protection.

-03-
 SAFE RIDING TIPS

Posture Warning
SAFE RIDING TIPS

Proper vehicle riding starts with proper posture. One-hand riding is dangerous. Keep both hands
1. Keep your elbows inside close to the body and firmly on the handle bar and both feet securely on
flexible. the foot rest. Under no circumstances should both
2. Hold your arms at an angle of about 120°. the hands be removed from the handle bar, as it is
3. Hips should be in a position so that arms and very dangerous.
shoulders are relaxed.
Avoid use of mobile phones while riding as it could
4. Look widely instead of gazing at one point.
lead to fatal accident.
5. Relax to guard against a sudden impact.
6. Hold the tank tightly with knees. Do not downshift the gears in the midst of cornering.
7. Point the toes straight ahead. Slow down to a safe speed before negotiating a
corner. If this is the first time that you are riding a
Cornering vehicle of this type, we suggest that you practice on a
When cornering, centrifugal force works in a safe, open area to become thoroughly familiar with
direction perpendicular to the direction in which the operation of the vehicle.
the vehicle is moving. Centrifugal force increases
in proportion 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.

-04-
 SAFE RIDING TIPS

Braking 2. Even when the brake works normally, if the

SAFE RIDING TIPS

road surface is wet or the tyre surface is
For safe riding, it is very important to master the
worn-out, tyres do not take a firm hold on the
braking techniques.
surface, increasing the stopping distance.
1. Close / release the throttle.
3. Approximately 60% braking effect is from
2. Hold the vehicle upright as you apply the brake. front brake. Non-usage of front brake causes
3. Progressive application of brakes is safer. poor braking.
4. Never depress the clutch lever while braking at
higher speeds. Warning
5. Apply both the brakes.
6. Riding down hills, while cornering and wet As the vehicle speed increases, the stopping distance
roads close throttle and down shift the gear to also increases progressively. Be sure that, you have
take advantage of gearbox and engine which sufficient distance between you and the vehicle or
acts as an additional brake. This will avoid the obstruction ahead of you.
loss of control over the vehicle due to over
speed. Using only the front or rear brake is dangerous and
can cause skidding and loss of control. Apply both
Causes for poor braking the brakes together and with great care on a wet
1. If the brake shoes / pads or drum / disc are worn road or other slippery surfaces. Any abrupt braking
out or if there is water or oil on them, sufficient on slippery or irregular roads can cause loss of rider
friction does not develop and brakes do not control.
work well.

-05-
 SAFE RIDING TIPS

ACCESSORY INSTALLATION AND Do not disturb the Carburettor settings as this

SAFE RIDING TIPS

may lead to higher fuel consumption and also

SAFETY TIPS
higher CO levels.
Use extreme caution while selecting and installing
If the vehicle needs any adjustments, please
the accessories for your motorcycle.
consult nearest TVS Motor Company Authorised
The addition of unsuitable accessories can lead Distributor / Dealer or Authorised Service Centers.
to unsafe operating conditions. Your friendly
While adequate care is exercised at the factory to
Distributor / Dealer will assist you in selecting
ensure that the emissions are within the limits, it is
quality accessories and installing them correctly.
essential for the owner to always maintain the
While selecting the accessories, make sure the motorcycle in good condition by getting it
accessories should not obstruct lighting, periodically checked and serviced by TVS Motor
steerability, suspension level and ground Company Authorised Distributor / Dealer or
clearance. Please ensure that, if the tank cover is Authorised Service Centers so that the emission
used, it not getting en-trapped between fuel tank and fuel consumption levels are maintained as per
and fuel tank cap. norms.
Additional electrical equipments and controls
should not exceed the specified electrical
Note
system load of the vehicle (capacity of battery
and magneto). Have your vehicle certified by the Government
EMISSION CONTROL authorised emission testing stations at specified
intervals.
All the TVS vehicles are tested in the factory for
optimum fuel efficiency and lowest possible CO
levels.
-06-
 KNOW YOUR APACHE RTR 180

VEHICLE IDENTIFICATION NUMBER

KNOW YOUR APACHE RTR 180

Serial numbers of both frame and engine are required for vehicle identification. They are also required to assist
your Distributor / Dealer for operating parts or referring to special information.

8
3439
E820058855
0E6G 2
0E LA

The frame serial number is stamped on the right The engine serial number is stamped on the left
side of the steering head tube. side crankcase assembly near cylinder block.

Frame number

Engine number

Control key number

Please fill the above boxes now for future reference
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 KNOW YOUR APACHE RTR 180

LOCATION OF PARTS - HANDLE BAR

KNOW YOUR APACHE RTR 180

7 8 9 10 11 1. Fuel tank cap

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

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 KNOW YOUR APACHE RTR 180

LOCATION OF PARTS - VEHICLE LEFT SIDE

KNOW YOUR APACHE RTR 180

1. Front wheel axle
12 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

1 2 3 4 5 6 7 8 9 10 11

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 KNOW YOUR APACHE RTR 180

LOCATION OF PARTS - VEHICLE RIGHT SIDE

KNOW YOUR APACHE RTR 180

1. 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

13 12 11 10 9 8 7 6 5 4 3 2 1

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 KNOW YOUR APACHE RTR 180

LOCATION OF PARTS - VEHICLE FRONT AND REAR

KNOW YOUR APACHE RTR 180

FRONT
1. Turn signal lamp front L
2. Head lamp assembly
6 7 1 3. License plate front*
1
4. Crash guard
5 2
2 5. Position lamps
6 3 6. Turn signal lamp front R
3
5
REAR
4
4
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

* Mandatory accessory will be charged extra

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 KNOW YOUR APACHE RTR 180

CONTROL KEY 2. ‘ON’ position

KNOW YOUR APACHE RTR 180

Apache RTR 180 comes with a pair of identical In this position, all the electrical circuits are turned
control keys. These keys are to operate ignition ‘ON’ and the engine can be started now. Key
cum steering lock, fuel tank cap and cover frame R. cannot be removed in this position.
IGNITION CUM STEERING LOCK 3. ‘LOCK’ position
There are three positions in the ignition cum Apache RTR 180 steering can be locked in both
steering lock. They are: ‘left’ and ‘right’ directions.
1. ‘OFF’ position To lock the steering, turn the handle bar all the way
All the electrical circuits are turned ‘OFF‘ in this to the ‘left’ or ‘right’. Push the key in and turn it to
position. Engine will not start. Key can be taken the ‘LOCK’ position and take out. All the electrical
out. 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.

Note
Position lamps glows automatically once the ignition
key is turned ‘ON’ without switching on any lamps.
When the ignition switch is turned ‘ON’ the
speedometer performs self test (count down starts).
Wait till the message ‘GO’ appears on the speedo
dial.

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 KNOW YOUR APACHE RTR 180

Warning

KNOW YOUR APACHE RTR 180

9

Never attempt to move the vehicle when the steering 6 7 8

is locked, you may lose balance.
5 10
Caution 11
4
Leaving the ignition cum steering lock in ‘ON’ 12
position will drain the battery when vehicle is not in
use . So “Switch off” and take the key out when the 3 2 1
vehicle is unused.

DIGITAL SPEEDOMETER 5. Fuel gauge

1. High beam indicator lamp ( ) Fuel gauge indicates the approximate quantity of
Glows when the head lamp high beam is activated. fuel available in the fuel tank.
2. Neutral indicator lamp (N) 6. Speedometer
Glows when the vehicle is in neutral and goes Indicates the vehicle speed in kilometers per hour.
‘OFF’ if the gear is shifted from neutral.
3. Turn signal indicator lamp ( )
Flashes when the ‘left’ or ‘right’ side turn signal Note
indication is activated. If the battery is disconnected and reconnected
4. Digital clock during service, the clock displays 12:00 by default.
Displays the time in 12 or 24 hour time format. You need to reset the time (refer page no. 16).
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 KNOW YOUR APACHE RTR 180

7. Odometer / Trip meter A & B / High 8. Mode and Set switch buttons
KNOW YOUR APACHE RTR 180

speed indicator / Shortest time indicator To change the mode between ‘ODO’, ‘TRIP A’,
Odometer registers and displays the total distance ‘TRIP B’, ‘HI Spd’, ‘St’ and to set the clock timing,
covered by the vehicle in kilometers. The digit after the mode and set switches are provided.
the dot mark denotes one tenth of a kilometer. Set Refer page no. 15 for setting / resetting the
the display in ‘ODO’ mode to know reading. odometer, trip meter, high speed indicator and
Trip meter registers and displays the partial shortest time indicator.
distance covered in kilometers. The digit after the
dot mark denotes one tenth of a kilometer. Option Note
is provided to measure two different distances Maximum speed recorded so far will be displayed
(‘TRIP A’ and ‘TRIP B’). You can reset it whenever whenever the ignition switch is turned ‘ON’ and the
required. Set the display in ‘TRIP A’ or ‘TRIP B’ meter is in ‘HI Spd’ mode. If the high speed is reset,
mode to know the trip distance. the speed value will be shown as ‘0’.
High speed indicator records the maximum speed
(top speed) achieved by the rider so far. You can Similarly, minimum time taken recorded so far to
reset and record new speed if required. reach 60 kmph speed will be displayed when the
Set the meter in ‘HI Spd’ mode to know the ignition is turned ‘ON’ and the meter is in ‘St’ mode.
maximum speed achieved by any user so far. The value will be displayed as 9.9 seconds if the ‘St’
Shortest time indicator records the minimum time mode is reset.
taken so far to reach the 60 kmph speed. You can
reset and record new time if required. Set the In ‘St’ mode, fuel level indication bars of fuel gauge
meter in ‘St’ mode to know the time consumed by disappears. These bars appears only after changing
a rider to reach the specific speed from starting. the mode from ‘St’ to another.
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 KNOW YOUR APACHE RTR 180

9. Tachometer Note

KNOW YOUR APACHE RTR 180

Tachometer indicates the engine speed in
Service reminder indicator lamp works only based on
multiples of 1000 rpm (revolutions per minute).
the distance (km) covered by the vehicle. This is only
10. Fuel warning indicator ( ) a reminder indicator. Customers are advised to keep
Fuel warning lamp glows continuously for a few track and follow the service schedule.
km if the fuel in tank comes to minimum safe level.
This gives warning to the rider that the vehicle is ODOMETER / TRIP METER / HIGH
running with less fuel and it needs to be filled SPEED / SHORTEST TIME INDICATOR
immediately.
SETTING
11. Service reminder To change the mode between ‘ODO’, ‘TRIP A’,
If the service is due, whenever the ignition switch ‘TRIP B’, ‘HI Spd’ and ‘St’ just press the mode
is turned ‘ON’, an icon with spanner symbol switch button ‘A’.
‘ ’ blinks for 10 seconds after the self test cycle
of speedometer, and continues to glow till the
vehicle is serviced and reset. Get the vehicle
serviced at TVS Motor Company Authorised
Distributor / Dealer or Authorised Service Centers. B
12. Low battery indicator A
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.

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 KNOW YOUR APACHE RTR 180

To reset the trip meter / high speed indicator / HANDLE BAR LEFT SIDE
KNOW YOUR APACHE RTR 180

shortest time indicator, set the meter in respective

mode. Press and hold the set switch ‘B’ for a few
seconds. 4 5

DIGITAL CLOCK SETTING 3

Digital clock can be set in ‘ODO’ mode only. Set

the digital clock time in the following manner:
1. Change the meter to ‘ODO’ mode by pressing
mode switch button.
2. Press and hold the mode switch button (A) for
a few seconds to change clock timing to 12 or 2 1
24 hour format.
3. Press and hold the set switch button (B) for a 1. Horn switch
few seconds to enter the clock setting mode. Press the switch ‘ ‘ to operate the horn.
4. Press the mode switch button (A) to increase
2. Turn signal lamp switch
the hours (while hour digits are blinking).
Slide the turn signal lamp switch to left ‘ ’ or
5. To access the minutes press the set switch
right side ‘ ’ to operate respective turn signal
button (B) again for few seconds.
lamps (LH / RH). Press the knob to turn ‘OFF’.
6. Press the mode switch button (A) to increase
the minutes (while minute digits are blinking). 3. Clutch lever
7. Press the set switch button (B) to exit the Use the clutch lever to disengage the drive to the
setting. rear wheel while shifting the gears. Squeezing the
lever towards grip disengages the drive.
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 KNOW YOUR APACHE RTR 180

4. Pass by switch HANDLE BAR RIGHT SIDE

KNOW YOUR APACHE RTR 180

When the pass by switch is pressed intermittently,
the head lamp flashes and signals the approaching 5
vehicle. This pass by signal can be used while over 4
taking other vehicle during day time.
5. Head lamp high / low beam switch
With the head lamp switch in ‘ON’ condition, press
the beam control switch towards ‘ ’ to turn-on
the head lamp high beam. Press the switch
towards ‘ ’ to turn-on the head lamp low beam.
1 2 3

Warning 1. Electric starter switch

Press the electric starter switch ‘ ’ to start the
Always use the appropriate turn signal lamps when
engine electrically with the transmission is in
you intend to change lanes or take turns. Be sure to
neutral or by depressing the clutch lever when the
switch ‘OFF’ the turn signal lamps after negotiating
transmission is in gear.
the turns or lanes.
Note
Use appropriate head lamp beam ‘high / low’ as per
the traffic and road conditions for your safety and to For cold starts, avoid using electric starter. Use
avoid inconvenience to other riders. kickstarter. A typical example is early morning
start. This would reduce load on the battery and
prevents quick drain.

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 KNOW YOUR APACHE RTR 180

2. Head lamp switch 5. Engine cut off switch

KNOW YOUR APACHE RTR 180

Head lamp switch has three positions. working of To switch off the engine but to keep the battery
head lamp at various positions are as follows: activated, press the switch to ‘ ‘ position.
OFF: All the lamps are turned ‘OFF’ except To start the engine, press the switch to ‘ ‘
position lamp when the switch is positioned position.
at ‘ ’ even though the engine is running.
PO : Speedometer back illumination, tail lamp Note
and number plate lamp glows when the
switch is positioned at ‘ ’ and engine is Before starting, ensure to turn ‘ON’ the engine cut off
running. switch.
ON: Head lamp also glows along with the above
said lamps when the switch is positioned at Apache RTR 180 is provided with adjustable LH and
‘ ‘ and engine is running. RH handle bar. Contact your TVS Motor Company
3. Throttle grip Authorised Distributor / Dealer or Authorised Service
Centers for any such adjustment.
Engine speed is controlled by the rotation of the
throttle grip. Twist it towards you to increase the
engine speed and away from you or release it to Warning
decrease the engine speed.
Please do not adjust the handle bar your self or by
4. Front brake lever any unauthorised persons. Improper adjustment
The front brake is applied by squeezing the front may affect the maneuverability of the vehicle.
brake lever gently towards the throttle grip. The
brake lamp glows on application of front brake.

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 KNOW YOUR APACHE RTR 180

FUEL TANK* CAP Warning

KNOW YOUR APACHE RTR 180

Flush type fuel tank cap (1) is provided in Apache
Avoid spilling of fuel on the hot engine. Never refill
RTR 180. To open the fuel tank cap, lift the
fuel near open flame. Do not smoke while refueling.
protection lid (2), insert the control key into the lock
Do not use cell phones while refueling.
and turn it in clockwise. Take out the tank cap along
with the key. Note
To close, press the cap gently in its position by
keeping the front end ( ) towards the handle bar. Whenever refueling the bike, fill upto the bottom of
Take out the key and close the protection lid. neck portion of the fuel tank. Filling above the neck
may result in improper breathing of fuel tank and
seepage of fuel.
2 1
FUEL COCK

RES

OFF

* The fuel tank is not a measuring instrument and the

capacity of the fuel tank may slightly vary from the ON
indicated capacity.

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 KNOW YOUR APACHE RTR 180

Fuel cock has the following three positions: During cold start, apply the choke and start the
KNOW YOUR APACHE RTR 180

ON: Fuel flows in this position when the fuel is vehicle using electric starter or kick lever
above the reserve level in the tank. without opening / with less opening of throttle.
RES: Switch over the fuel cock lever to this Once the engine is started and running in stable
position when the fuel stops flowing in ‘ON’ RPM, push back the choke knob and ride the
position. vehicle.
OFF: Fuel flow cuts off from the tank to
carburettor.

Note
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.
Caution
CHOKE KNOB
Always use choke for starting the cold engine. Never
Choke ‘ ’ is provided in the carburettor assembly open the throttle fully when the choke is applied. It
itself. Gently pull out choke knob to operate the may lead to flooding of engine and difficulty in
choke. starting.

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 KNOW YOUR APACHE RTR 180

KICK STARTER LEVER GEAR SHIFT LEVER

KNOW YOUR APACHE RTR 180

The kick starter lever is located on the right side of Apache RTR 180 is equipped with a 5 speed
the vehicle. To start the vehicle, keep the ignition constant mesh transmission. Press the gear shift
and engine cut off switch in ‘ON’ condition. With lever down or lift up with the left foot toe to engage
the transmission in neutral, keep your foot on the the gears. After selecting a gear, the gear shift
lever extension and kick from top and stroke to lever will return to its normal position, ready to
bottom with rapid motion. select the next gear.
Each time shifting into the higher gears one by one
from neutral position is accomplished by
depressing the clutch lever and pressing the gear
shift lever (for first gear) or lifting the gear shift
lever (for remaining gears) up once for each gear.

4 5
3
2
N
1

5
4
3
2
Note N
It is recommended to start the vehicle always in
1
ON
neutral gear. However, the vehicle can be started in
any gear after depressing the clutch lever.

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 KNOW YOUR APACHE RTR 180

Note Note
KNOW YOUR APACHE RTR 180

RES
Gear shift lever position can be set to your Rear brake pedal position can be set to your
ON ON
convenience. Contact your TVS Motor Company convenience. Contact your TVS Motor Company
OFF
Authorised Distributor / Dealer or Authorised Service Authorised Distributor / Dealer or Authorised Service
Centers for setting the gear shift lever position. Centers for setting the brake pedal position.

REAR BRAKE PEDAL STANDS

Rear brake pedal is located on the right side of the Apache RTR 180 is equipped with a centre (1) and
vehicle. Press the rear brake pedal with your right side stand (2). To place the vehicle on the centre
foot to apply the rear brake. The brake lamp glows stand, hold the handle bar left grip with left hand
on application of brake. and pillion handle L with right hand.

1
1a

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 KNOW YOUR APACHE RTR 180

Place your foot firmly on the centre stand COVER FRAME R

KNOW YOUR APACHE RTR 180

extension (1a) and press with adequate effort.
Ensure both the legs of centre stand are touching
the ground before placing the vehicle on the stand. 2
Side stand can be operated by sitting on the vehicle
with your left foot by pushing it away from the 3
vehicle till it stops.

Warning
1
Always release the side stand to its full up position
before moving the vehicle.

Caution Apache RTR 180 is provided with lockable cover

frame on the right side for accessing the battery,
Never sit on the vehicle when it is supported by side
rear disc brake master cylinder and the seat lock
stand. Always park the vehicle on a flat, firm surface.
cable. This cover can be opened in the following
manner:
1. Insert the control key in the cover frame lock (1)
and rotate it in clock wise direction.
2. Take out the cover frame by gently pulling out
at front (2) and rear (3).

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 KNOW YOUR APACHE RTR 180

Assembling the cover frame back 4. 14 x 17 open end spanner

KNOW YOUR APACHE RTR 180

1. Locate the lugs of the cover frame at (2) & (3) to 5. 10 x 12 open end spanner
the hole provided in the fuel tank and frame 6. Tool bag
while ensuring the availability of cushions in the
holes
2. Gently press the cover frame lugs into the
Caution
holes. It is recommended to use the tool kit in case of any
3. Now, lock the cover frame by turning the key in emergency only. It is always advisable to take your
anti-clockwise direction. vehicle to TVS Motor Company Authorised
TOOL KIT Distributor / Dealer or Authorised Service Centers.
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 the seat lock cable.
Carefully take out the seat assembly from its
mountings.
Tool kit consists of one number each of the
following.
1. Box spanner 16
2. Grip driver
3. Bit (+) (–)

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 KNOW YOUR APACHE RTR 180

REAR FENDER FLAP

KNOW YOUR APACHE RTR 180

Your Apache RTR 180 comes with a removable
rear fender flap. Which can be removed or re-fixed
for a better look to suit your taste.
Contact nearest TVS Motor Company Authorised
Distributor / Dealer or Authorised Service Centers
for removing or re-fixing the rear fender flap.

Note
Rear fender, without a fender flap may not protect With fender flap
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.

With out fender flap

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 RIDING YOUR APACHE RTR 180
RIDING YOUR APACHE RTR 180

INSPECTION BEFORE RIDING

Check the following items before riding.
ITEM WHAT TO CHECK FOR
Engine cum transmission oil Availability of oil upto the level (page no. 38)
Fuel Enough fuel for the planned distance of running
Tyres Correct pressure (page no. 43)
Adequate tread depth / No cracks or cuts.
Battery Proper working of position lamps, horn, brake lamp, turn signal lamps, 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 free play of cable (page no. 38) / Smooth and progressive action.
Brakes Availability of brake fluid and proper working of brake (refer page no.41)
Wheels Free rotation.
-26-
 RIDING YOUR APACHE RTR 180

Caution

RIDING YOUR APACHE RTR 180

STARTING THE ENGINE
Turn the fuel cock lever to ‘ON’ or ‘RESERVE’ Do not keep the engine in idling rpm for long and do
position based on the availability of fuel in the tank. not open excessive throttle when engine is idling and
Insert the control key into the ignition cum steering the vehicle is parked. It leads to overheating of
lock and turn it to the ‘ON’ position. Wait till the self engine and damage to the internal components.
test cycle of speedometer gets over.
Keep the transmission in neutral and press the SETTING THE VEHICLE IN MOTION
electric starter switch to start the engine 1. Depress the clutch lever and engage first gear
electrically or kick start. by pressing the gearshift lever down.
When the engine is cold 2. Open the throttle slowly and simultaneously
q Pull the choke knob and start the engine using release the clutch lever gently and gradually.
kick starter with no opening / very less opening The vehicle starts moving forward.
of throttle. 3. As the vehicle picks up speed, shift to the next
higher gear by closing the throttle, applying the
q Once the engine is started and running stable,
clutch and lifting the gear shift lever up.
push back the choke knob and ride the vehicle
4. Release the clutch lever and open the throttle
(when the engine is worm / hot do not use
smoothly. Select the required gears in similar
choke).
manner.
Warning Using the transmission
The transmission is provided to keep the engine to
Do not run the engine indoors where little or no run smoothly in its normal operating speed range.
ventilation available. Exhaust gas is extremely The gear ratios have been carefully chosen to meet
poisonous. the characteristics of the engine.

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 RIDING YOUR APACHE RTR 180

The rider should always select the most suitable 3. Turn the ignition ‘OFF’.
RIDING YOUR APACHE RTR 180

gear to achieve the necessary speed and pulling 4. Park the vehicle on a firm, flat surface.
power smoothly. 5. Lock the steering and turn ‘OFF’ the fuel cock.
Riding on hills / gradients FUEL RECOMMENDATION
When climbing steep hills, the motorcycle may
Use unleaded petrol only.
begin to slow down and show lack of power. At this
The petrol should be 85 to 95 octane by research
point you should shift to a lower gear so that the
method. Use recommended fuel additives for
engine will again be operating in its normal power
longer life of engine components and lower
range. Shift gears rapidly to prevent the motorcycle
maintenance. Petrol mixed with ethanol will have
from losing momentum.
impact on engine components. Contact your TVS
When riding down a hill, the engine may be used as
Motor Company Authorised Distributor / Dealer or
braking by shifting to a lower gear.
Authorised Service Centers for usage.
STOPPING AND PARKING
1. Close the throttle completely and apply both
the brakes simultaneously.
Caution
2. Down shift the gears as the road speed Never mix oil in petrol in the fuel tank. Always fill fuel
decreases. Bring the engine to neutral position from the reputed and reliable fuel stations.
just before the vehicle stops.

Warning Note
Reduce speed to a safe limit before turning / Use fuel additives in petrol as recommended by the
cornering. Do not apply brake while turning / respective manufacturer for low carbon deposition.
cornering. Do not disengage clutch before braking.
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 RIDING YOUR APACHE RTR 180

RIDING YOUR APACHE RTR 180

CHECKS AND TIPS FOR IMPROVING Clutch
FUEL ECONOMY Increase in engine rpm during acceleration,
Regular checks without a increase in road speed indicates the
clutch slip. A slipping clutch will cause high fuel
Carry out the periodic maintenance checks as
consumption and engine over heat.
specified in this manual (refer page no. 32 and 33).
If the condition persists even after adjusting the
Regular maintenance checks will save fuel and
clutch lever play, immediately have the clutch
ensure trouble-free, enjoyable and safe riding
checked by TVS Motor Company Authorised
besides keeping environment clean.
Distributor / Dealer or Authorised Service Centers.
Spark plug
A dirty or defective spark plug leads to wastage of
Engine cum transmission oil
Dirty or less engine cum transmission oil increases
fuel due to incomplete combustion. Inspect and
the friction between various parts of engine and
clean the plug if necessary. Visually inspect the
reduces the engine life, thereby increases the fuel
spark plug gap and replace if the gap is found more.
consumption.
Replace the spark plug every 12000 kms
Regularly inspect the engine cum transmission
(1 year). Always use recommended spark plug
oil for correct level and top-up if necessary. Get
only. Since twin electrode plug is used in the
it replaced at regular intervals as per the
vehicle, do not try to adjust the gap of the
maintenance schedule.
electrodes as it may damage the plug.
Air cleaner element Caution
A dirty air cleaner element restricts airflow and
increases fuel consumption. Inspect and clean Never drive the vehicle with half clutch. This will
the air cleaner element periodically. Replace reduce the life of clutch and affects the performance
every 12000 kms. of the vehicle and fuel economy.

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 RIDING YOUR APACHE RTR 180
RIDING YOUR APACHE RTR 180

Fuel leak Chain slackness

Check and arrest fuel leak if any, from tank, Check and ensure drive chain slackness. Excess
carburettor and fuel lines. Loss of fuel due to leak slackness leads to higher fuel consumption (refer
may drain the fuel tank completely. page no. 45).
Evaporation Wheel freeness
Check and ensure the wheel freeness by rotating
Vehicle parked in the hot sun leads to wastage of
the wheel at least once in a week to avoid wastage
fuel through evaporation. Also lower fuel levels in
of fuel.
the tank will have increased evaporation and
condensation of moisture inside, which may result Fast starting from rest wastes fuel
in rusting of the tank. A racing start from rest at full throttle can waste
fuel and damage the engine. It also creates a
Ensure to close fuel tank cap after every filling. If
potentially dangerous traffic situation.
the fuel tank cap kept open for long time, it leads to
safety and fuel loss. Fast acceleration wastes fuel
Fuel is wasted whenever you suddenly accelerate
Tyres or apply brake.
Low tyre pressure has adverse effects on the Avoid unnecessary idling
vehicle. The drag on the vehicle increases While waiting for someone or stopping in signals
resulting decreased fuel economy. Further more, for long time, if the engine is kept running at idle
handling may be adversely affected. speed, it causes unnecessary wastage of fuel.
Check the tyre pressure regularly (weekly) and Avoid frequent braking
inflate it to the recommended pressure (refer page Anticipate corners and slopes as well as the traffic
no. 43). Never use tyres which are worn beyond conditions. Unnecessary frequent braking will
the permissible limit. reduce the fuel economy.

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 MAINTENANCE

MAINTENANCE SCHEDULE

MAINTENANCE
The maintenance schedule indicates the intervals between periodic services. At the end of each interval, be sure
to inspect, check, replace, adjust, lubricate and service as instructed. If the maintenance is not done periodically, it
will result in rapid wear and severe damage to the vehicle. If the vehicle is used under high stress conditions such
as continuous full throttle operation or is operated in dusty climate, certain jobs should be performed more often
to ensure reliability of the vehicle. Cylinder head, steering components, suspension, chain and 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 recommended that you use only the TVS Motor Company Genuine parts.

Caution
Proper running-in and maintenance are mandatory for making certain that your vehicle is reliable and gives optimum
performance at all times. Be sure that the periodic maintenance is performed thoroughly in accordance with the
instructions given in this owner’s manual.

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 MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE (months or km whichever occurs earlier)

MAINTENANCE

Item service
Service 1st 2nd 3rd 4th 5th Remarks
Every Every
km 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000 km
Period from the date of sale 1 month 3 months 6 months 9 months 12 months
Engine cum transmission oil R R R R R R –
Oil filter (strainer) C – C – C – C
Oil filter (paper filter) R – R – R – R
Spark plug I&C – – – R – – Replace every 12000 km
Air cleaner element1 I&C I&C I&C I&C R I&C – Replace every 12000 km
Carburettor assembly C&A – – – C&A – – C & A every 12000 km
Tappet clearance I&A – I&A – I&A – I&A
Fuel cock sediment bowl C C C C C C –
Hose fuel I I I I I I – Replace every three years
All control cables2 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 & TI I & TI I & TI –
Drive chain* C, L & A C, L & A C, L & A C, L & A C, L & A C, L & A – Adjust if necessary
All bulbs, horn and switches I I I I I I – Inspect for proper functioning
Head lamp beam I&A I&A I&A I&A I&A I&A –
Battery electrolyte level I&T I&T I&T I&T I&T I&T –

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 MAINTENANCE

Item service

MAINTENANCE
Service 1st 2nd 3rd 4th 5th Every Every Remarks
km 500-750 2500-3000 5000-6000 8500-9000 11500-12000 3000 km 6000 km
Period from the date of sale 1 month 3 months 6 months 9 months 12 months
Specific gravity and voltage3 I I I I I I –
Brake effectiveness I I I I I I –
Brake pedal shaft L L L L L L – Lubricate using TRU4 oil
Brake pad wear 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 –
Idling CO%4 I&S – – – – – –
Ball joint gear shift lever – – L – L – L Lubricate using grease
Centre / side stand pivot L L L L L L – Lubricate using TRU4 oil
Kick starter pedal pivot L L L L L L – Lubricate using TRU4 oil
Swing arm bearings – – – – – – – Lubricate using grease
every two years
R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set
1
Inspect for any damage 2 Inspect for proper operation and adjust play. Lubricate ends using grease. 3
Recharge if necessary
4
Idling CO% should be set with the help of exhaust gas analyser and tachometer only

* Clean the drive chain with dry cloth and apply TRU SPRAY / TRU4 oil as frequently as every 1000 km for better chain life and smooth vehicle
running.

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 MAINTENANCE

RECOMMENDED LUBRICANTS
MAINTENANCE

Application Qty Manufacturer Brand

Engine cum transmission oil 1000 ml (after draining) TVS Motor Company TVS TRU4 PREMIUM,
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

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 MAINTENANCE

SELF - MAINTENANCE PROCEDURES 3. If the electrolyte level is below the lower level,

MAINTENANCE
add only distilled water upto the upper level by
BATTERY removing the filler caps.
Battery is located below the cover frame R. The
4. Reinstall the filler caps and clean the battery
electrolyte level of the battery must be maintained
thoroughly, apply petroleum jelly to the battery
to avoid damages to the battery. To check the
terminals to protect it from corrosion.
electrolyte level, follow the procedure:
Incase of any abnormality or for removal of battery
1. Place the vehicle on centre stand on a flat
from the vehicle, contact TVS Motor Company
surface and open the cover frame R as
Authorised Distributor / Dealer or Authorised
explained in page no. 23.
Service Centers.
2. Inspect the battery electrolyte level. It should
be between the upper and lower level. Caution
Once the battery is charged initially, never add
diluted sulphuric acid. Use only distilled water for
topping up. Never add tap water.
Never check the battery charge by shorting the
terminals. Always connect the positive terminal first
and then negative to avoid sparking.
Do not obstruct, bend or change the routing of
battery air vent tube. Make sure that the vent tube is
firmly attached to the battery and the other end is
open and clear.
-35-
 MAINTENANCE

FUSE REPLACEMENT
MAINTENANCE

Non-working of electrical systems may be due to

safety fuse failure. Short circuit or overload in the Failed fuse
electrical system are the main causes for fuse
failure. Follow the procedure given below for 4. Open the fuse case and slide out blown fuse.
inspecting and replacing the fuse. 5. Replace the fuse with a new (extra fuse is
1. Open the cover frame R as explained earlier provided inside the fuse case itself).
(refer page no. 23). 6. Close the fuse case and re-fix it into the battery
2. The fuse case fitted on the battery band band.
contains a 10 A fuse. 7. Turn ‘ON’ the ignition lock and check for proper
3. Pull out the fuse case from battery band. functioning of electrical systems. Incase the
fuse fails again, consult the nearest TVS Motor
Company Authorised Distributor / Dealer or
Authorised Service Centers.

Caution
Do not use vehicle by shorting the wires without a
fuse. This may result in overheating of electrical /
wiring and may result in fire.

Do not use fuse of higher amperage than specified

for the safety of electrical system.

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 MAINTENANCE

SPARK PLUG Inspect the spark plug electrodes (A) and (B) for any

MAINTENANCE
corrosion. If found any replace the spark plug with a
1. Clean the dust and mud around the spark plug
new.
mounting to avoid falling inside the cylinder.
Visually inspect the gap of spark plug electrodes.
2. Pullout the suppressor cap from spark plug.
No manual adjustments of gap is recommended. If
Using spark plug spanner, remove the spark
the gap found more than specified limit, replace
plug.
the spark plug.
A spark plug with heavy carbon deposits will not
After cleaning and inspecting the gap, reinstall the
produce strong sparks. Hence, only if necessary,
spark plug and tighten by hand to avoid cross
remove the carbon deposits from the spark plug
threading. Finally tighten using the spanner. Do not
with a small wire brush or using spark plug cleaning
over tight or cross thread the spark plug .
tool.
Caution
Always use only recommended make and type of
spark plug. Replace spark plug every 12000 km.

Cover the spark plug hole with cloth when the plug is
removed to prevent dust / water entry.

A A It is advisable to tight the new spark plug by hand till

the end and then loose and again re-tight the spark
B plug by 1/8 of rotation after sealing by using only the
0.6 ~ 0.8 mm hand tool.
-37-
 MAINTENANCE

ENGINE CUM TRANSMISSION OIL 5. The oil level should be between the minimum
MAINTENANCE

LEVEL and maximum level marks of the gauge as

shown in the figure.
Check the engine cum transmission oil level
6. If the oil level is less than the minimum level,
periodically.
add ‘TVS TRU4 PREMIUM’ 4T oil upto the
1. Place the vehicle on centre stand on a flat maximum level mark.
surface. Wipe-off the surroundings of gauge oil 7. Wipe out the oil traces with a clean cloth to
level. prevent dust accumulation and assemble back
2. Remove the gauge oil level and wipe it clean. the gauge oil level.
3. Fix the gauge back to its mounting hole and
thread in. Caution
4. Once again remove the gauge and check the oil
level. 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 to
avoid costly damage. Do not fill excess oil may cause
Maximum oil leak. Always use ‘TVS TRU4 PREMIUM’ 4T oil only.

CLUTCH ADJUSTMENT
Clutch lever free play is one of the most important
Minimum
adjustment which you may need to check
in-between services for better life of the clutch
plates.
-38-
 MAINTENANCE

The free play of the clutch lever should be

MAINTENANCE
5 ~ 15 mm as measured at the clutch lever end
before the clutch begins to disengage. 1
Adjust the clutch lever free play periodically by
means of clutch cable adjuster at arm clutch
release if the free play is not within the specified
2 3
limit.
1. Ensure that the 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.

Caution
Too much or too less clutch lever free play will
damage the clutch plates, thereby affecting the
performance of the vehicle.

Clutch lever free play should be adjusted only

when the engine is cold.

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 MAINTENANCE

REAR SHOCK ABSORBERS

MAINTENANCE

Apache RTR 180 is provided with triple rated,

5 step adjustable, 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
will be stiffer which is good for heavy loads.
Adjust the spring pre-load by shifting the adjuster to
the required notch according to the different load
conditions. The more you compress the spring, the
suspension becomes more stiff.

Warning
SOFT HARD Do not heat / tamper the canister filled with GAS.

Caution
Keep both left and right shock absorbers spring
adjusters in the same position.

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 MAINTENANCE

BRAKES

MAINTENANCE
Front brake
You can observe a master cylinder (1) on the right
side of the handle bar, a caliper assembly (2) fitted LOWER

to the fork leg R, a disc (3) to the front wheel and a A

B
high pressure hose (4) connecting the master
cylinder and the caliper assembly.
1. Check the master cylinder brake fluid level
through the view piece glass (A).
2. Brake fluid level always should be above the
‘LOWER’ mark (B) provided on the master
cylinder when the master cylinder is parallel to 3. If the brake fluid level is below the mark or
the ground. while applying brake if you feel the brake is
more spongy or ineffective due to air entry,
1 contact TVS Motor Company Authorised
4
Distributor / Dealer or Authorised Service
Centers for topping-up the brake fluid, air
bleeding and other brake related inspections.

2 Note
3 Check the brake fluid level only when the master
cylinder is parallel to the ground.
-41-
 MAINTENANCE

Rear brake
MAINTENANCE

2 3 Maximum
1
5
Minimum

3. If the brake fluid level is below minimum or

You can observe a master cylinder (1) mounted on while applying brake if you feel the brake is
the right side pillion foot rest, a reservoir (2) below more spongy or ineffective due to air entry,
the cover frame R, a caliper assembly (3) fitted on contact TVS Motor Company Authorised
the rear wheel axle, a disc (4) to the rear wheel and Distributor / Dealer or Authorised Service
a high pressure hose (5) connecting the master Centers for topping-up the brake fluid, air
cylinder and the caliper assembly. bleeding and other brake related inspections.
1. Remove the cover frame R (refer page no. 23
for removal procedure). Note
2. Check the brake fluid level in the reservoir. It
should be between maximum and minimum Check the brake fluid level only when the master
level. cylinder is parallel to the ground.
-42-
 MAINTENANCE

Brake pad wear indicator TYRES

MAINTENANCE
Visually check the brake pads wear. If the wear is
Tyre pressure:
found beyond the wear indicator groove as shown
Check the tyre pressure atleast once in a week if
in the figure then, replace the brake pads as a set
not more frequently. Insufficient air pressure in the
with a new one.
tyres not only hasten tyre 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
Wear limit
within the specified limits at all times.
Solo Pillion
Front 1.75 kg/cm² (25 PSI) 1.75 kg/cm² (25 PSI)
Rear 2.00 kg/cm² (28 PSI) 2.25 kg/cm² (32 PSI)
Tyre tread condition
Caution Operating the vehicle with excessively worn tyres
will decrease riding stability and can lead to loss of
Replace the brake pads, if the wear indicator shows control.
beyond the wear limit. It is recommended to replace the tyre when the
tyre wears off to the tyre wear indicator level
(indicated by TWI on the tyre).
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 MAINTENANCE

Tyre puncture
MAINTENANCE

Apache RTR 180 is fitted with a tubeless tyre on

both front and rear wheel. Incase of any puncture /
tyre damage it is advised to visit nearest tyre
manufacturer Dealer / Sercive Centers or the tyre
A repair shops who know the repairing methods of
tubeless tyre.
It is not necessary to remove the tyre from wheel
rim always to attend the puncture. Even though, if
there is a need of tyre removal, it is strongly
recommended to use a tyre removal / fitment
Tyre rotation direction machine. If at all, tyre levers need to be used, the
While reassembling the tyre, after removing from levers should be free from sharp edges and care
wheel rim, ensure that the arrow mark (A) provided should be taken not to damage the rim and tyre.
on the tyre facing the direction of wheel rotation.
Caution
Warning
Side walls of the tubeless tyres which in contact with
The tyre inflation pressure in cold condition and the the wheel rim are only seals the air inside the wheel
tyre tread condition are extremely important for the assembly. Hence care should be taken not to
performance and safety of the rider. Check the tyres damage the side walls of the tyres during removal /
frequently for inflation pressure as well as the wear reassembly.
pattern on it. Use of a tyre other than the standard
may cause instability.
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 MAINTENANCE

DRIVE CHAIN Check, clean, lubricate and adjust the drive chain in

MAINTENANCE
Proper lubrication and adjustment of drive chain the following manner:
gives long service life of chain. Poor maintenance 1. Place the vehicle on centre stand with the
of chain causes premature wear or damage to the transmission in neutral.
drive chain and sprockets. The drive chain must be 2. Inspect the drive chain slackness (vertical
cleaned, checked, lubricated and adjusted at movement) using the finger as shown in the
specified intervals mentioned in the maintenance figure.
schedule. Even though the chain is cleaned,
3. The slackness of the drive chain should not
lubricated and adjusted during regular service
exceed the limit (20 ~ 25 mm).
by the Dealers, the user must clean the chain
with dry cloth and apply TRU SPRAY / TRU4 oil 4. If the slackness is found more, contact TVS
as frequently as every 1000 km for better chain Motor Company Authorised Distributor / Dealer
life and smooth vehicle running. or Authorised Service Centers for adjustment.
5. If the slackness is found within the limit, clean
the chain with a dry cloth and lubricate using
TRU SPRAY / TRU4 oil.

20 ~ 25 mm

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 MAINTENANCE

FRONT WHEEL REMOVAL AND 3. Place a support below the frame to prevent
MAINTENANCE

REASSEMBLY vehicle from falling and lift the vehicle up.

4. Carefully dislocate the disc from the caliper
1. Remove the axle nut (1) along with a washer.
assembly. Dislocate the hub drive from the
2. Pull out the axle (2) along with a washer and wheel and slide the wheel out.
remove a spacer from the right side of the 5. Reverse the procedure for reassembling.
wheel. Ensure proper seating of hub drive in the wheel
assembly and front fork during reassembly.
REAR WHEEL REMOVAL AND
REASSEMBLY
1. Remove the axle nut (1) and along with the
washer.

1 2

Warning 1
2
Ensure proper seating of disc in the caliper assembly
while reassembling.

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 MAINTENANCE

2. Partially pull out the axle (2). STORAGE PROCEDURES

MAINTENANCE
3. Take out the caliper assembly by dislocating it For storage of your motorcycle for longer periods
from the disc and the swing arm lug. of over a month and above, we recommend to
4. Carefully hang the caliper assembly in the carry out the following steps:
swing arm itself. Take out the spacer and pull 1. Clean the vehicle thoroughly. Park the vehicle
out the axle fully. on centre stand.
5. Remove the wheel assembly by gently tapping 2. Warm up the engine and drain engine cum
it along with the disc. transmission oil. Store the oil, if new, in a dust
6. For locating and reassembling the rear wheel free container.
easily, engage gear. This will arrest the free
movement of the drum sprocket. Reverse the Warning
procedure for reassembly.
The exhaust system becomes hot after a run. Park the
vehicle in a place where pedestrians or children are
Warning not likely to touch the vehicle.
While assembling the caliper assembly ensure that
the slot provided in the caliper is properly located to Caution
the lug provided in the swingarm assembly.
Do not park the vehicle on a slope or soft ground or
Always make sure that whenever the wheel is else it may fall.
removed, axle nut is properly retightened to the
specified torque. During storage, the battery must be recharged on a
constant current battery charger at recommended
amperage atleast once in a month.
-47-
 MAINTENANCE

3. Empty the fuel tank. Turn the fuel cock lever to TAKING THE VEHICLE OUT OF
MAINTENANCE

‘OFF’ position. STORAGE FOR REGULAR USE

4. Drain the petrol from carburettor.
1. Take the vehicle out of the garage and clean it
5. Remove the spark plug and feed in several thoroughly.
drops of engine cum transmission oil through
2. Remount the battery after bench charging if
spark plug hole. Crank the engine few times
required.
and reinstall the spark plug.
3. Fill the engine cum transmission oil (TVS TRU4
6. Remove the battery, store it away from direct
PREMIUM, 4T oil) and check the oil level using
sunlight and freezing temperatures.
the gauge oil level.
7. Place a suitable support at the bottom of the
4. Lubricate the parts as instructed in the
frame so that both the tyres are off the ground.
maintenance schedule.
This will ensure better tyre life.
5. Fill up fresh petrol in the fuel tank.
8. Cover up the vehicle completely with a clean
tarpaulin or any other suitable cover. Store the 6. Check and inflate the tyres to the specified tyre
vehicle inside a garage or similar area to avoid pressure.
damage due to dust and rain. Make sure that 7. Check and correct the points mentioned in
the storage area is well ventilated and free from page no. 26.
any source of flame or spark.
Caution
Avoid using alkaline solution like detergent soaps for
washing. This may damage head lamp and other
lamp assemblies.

-48-
 MAINTENANCE

8. Turn the ignition switch to ‘ON’ position. Start 4. Smooth functioning of all cables and their

MAINTENANCE
the engine with choke ‘ON’ for a few minutes free plays.
and ride out. 5. Smoothness of steering operation.
RECOMMENDED TIPS WHEN TAKING A 6. Drive chain and sprocket condition. Chain
LONG TRIP OF MORE THAN 500 KM: adjustment.
A) Please keep the following items for use in case 7. Front / rear brake functioning and rear brake
of emergency: lamp switch adjustment.
1. Tool kit complete. 8. Front fork for any abnormality.
2. Recommended spark plug one number. 9. Fuel cock bowl filter cleanliness.
3. Head lamp and turn signal lamp bulb one 10. Spark plug gap and condition of spark plug.
each. 11. Air filter element cleanliness.
4. Throttle and clutch cable each one each. 12. Correct idling speed.
5. Drive chain lock - one number. 13. Lubrication of all items mentioned in the
B) Precautions to be taken for the journey: periodic maintenance schedule.
1. Ensure engine cum transmission oil and 14. Any other job as necessary.
brake oil level are up to the level. 15. Have your vehicle checked at any TVS
2. Adequate fuel in fuel tank. Motor Company Authorised Distributor /
C) Check your motorcycle for the following: Dealer or Authorised Service Centers.
1. Tightness of all bolts and nuts with correct
torque value.
2. Fitness of tyres / tyre pressure / tread
Caution
depth. Long journey are to be taken only after the running-
3. All bulbs, indicators and horn function. in period of 1000 km.
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 SERVICE RECORD SHEET
SERVICE RECORD SHEET

SERVICE RECORD SHEET

Sl.No. Description Odometer Job card no. / Date Servicing Dealer’s

reading stamp and sign.
1 1st service
between (a) 500 - 750 km or (b) 1 month from the date
of purchase, whichever of the two occurs earlier.
2 2nd service
between (a) 2500 - 3000 km or (b) 3 months from the
date of purchase, 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
between (a) 14500 - 15000 km or (b) 15 months from
the date of purchase, whichever of the two occurs earlier.

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 SERVICE RECORD SHEET

SERVICE RECORD SHEET

SERVICE RECORD SHEET

Sl.No. Description Odometer Job card no. / Date Servicing Dealer’s

reading stamp and sign.
7 7th service
between (a) 17500 - 18000 km or (b) 18 months from
the date of purchase, whichever of the two occurs earlier.
8 8th service
between (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 of purchase, whichever of the two occurs earlier.

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 TECHNICAL SPECIFICATIONS

MANUFACTURER : TVS MOTOR COMPANY LIMITED

TECHNICAL SPECIFICATIONS

P.B. No1, Bythahalli, Kadakola post, Mysore - 571 311, India.

ENGINE TRANSMISSION
Type : 4 stroke, air cooled, single Clutch : Wet - Multi plate type
cylinder OHC Gear shift pattern : 1 down and 4 up
Cylinder bore : 62.5 mm Primary transmission : Helical gears
Stroke : 57.8 mm Secondary transmission : Chain and sprockets
Piston displacement : 177.4 cc
Compression ratio : 9.5 : 1 GEAR RATIOS
Carburettor : Ucal BS-29 I gear : 2.917
Air filter : Double polyurethane foam II gear : 1.857
filter element III gear : 1.333
Oil filter : Wire mesh and micronic IV gear : 1.050
paper filter
V gear : 0.880
Lubrication system : Forced wet sump
Primary reduction : 3.095
Maximum power in kW : 12.52 (17 bhp) @ 8500 rpm
Maximum torque in Nm : 15.5 @ 6500 rpm Final reduction : 3.286
Maximum speed : 124 km / hr
Engine idling rpm* : 1400 ± 100 rpm
Starting system : Electric starter / kick starter
* Under warm condition

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 TECHNICAL SPECIFICATIONS

CHASSIS TYRE

TECHNICAL SPECIFICATIONS
Overall length : 2085 mm Tyre size
Overall width : 730 mm Front : 90/90 x 17 (Tubeless)
Rear : 110/80 x 17 (Tubeless)
Overall height : 1105 mm
Tyre pressure
Seat height : 790 mm
Front : 1.75 kg/cm2(25 PSI)
Ground clearance : 165 mm Rear - solo : 2.00 kg/cm2(28 PSI)
Wheel base : 1326 mm Rear - dual : 2.25 kg/cm2 (32 PSI)
Kerb weight (with toolkit : 137 kg
and 90% of fuel) BRAKES
Pay load : 130 kg Front : Hand operated, 270 mm petal
Maximum laden weight : 267 kg disc
Rear : Foot operated, 200 mm petal
Steering angle : 36°
disc
Caster angle : 25.5°
Frame : Double cradle Synchro ELECTRICAL
STIFF Type : AC generator
Front suspension : Telescopic oil damped Ignition system : IDI - Dual mode digital ignition
Rear suspension : Monotube inverted gas filled Spark plug : BOSCH UR5DDC - TWIN
ELECTRODE
5 step adjustable shocks
with rectangular swing arm. Battery type : 12V, 9.0 Ah
Generator : Fly wheel magneto, 12V, 100W
Trail length : 84.3 mm
Head lamp : Halogen HS 12V, 35/35W x 1
Turning radius : 2400 mm
Position lamp : LED 12V, 3W
Tail / brake lamp : LED indicators (0.5W / 3.5W)

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 TECHNICAL SPECIFICATIONS

Turn signal lamp : 12V, 10W x 4 Caution

TECHNICAL SPECIFICATIONS

Number plate lamp : 12V, 4W x 1

Instrument panel : LCD / LED indicators Using the bulb other than the specified rating can
Horn : 12V DC x 2 result in overloading of the electrical system or
Fuse : 12V 10A x 1
premature failure of the bulb.

CAPACITIES
Note
Fuel tank capacity : 16.0 litres (including reserve)**
Reserve : 2.5 litres Specifications are subject to change without notice.
Engine cum transmission : TVS TRU4 PREMIUM, 4T oil
oil grade
Engine cum transmission : 1000 ml (after draining)
oil and capacity 1100 ml (after 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.

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