About Apache RTR 160 Motor Bike with Circuit Diagram

Apache RTR 160 is an excellent sport bike for city area. It has 160cc (cubic centimeter) engine which is enough for city area. The Apache RTR 160 is widely famous for having exceptional pickup. In fact, the "RTR" in its name stands for Racing Throttle Response. TVS(Thirukkurungudi Vengaram Sundram) specifically tuned this engine for immediate acceleration. It's engine is designed such that the revolution is very quick, allowing it to jump from a standstill to 60 km/h in just under 5 seconds. This rapid power delivery gives it a distinctly "punchy" feel. Its maximum torque ($13.85\text{ Nm}$ on the 2-valve version and up to $14.73\text{ Nm}$ on the 4-valve model) kicks in heavily in the low-to-mid RPM ranges. This makes slicing through aggressive city traffic incredibly easy without needing to constantly downshift.
apache bike

I have been riding this bike since 2012. I had to open the engine twice, the last time was just one month ago. According to bike mechanic the gear box was damaged, and the engine had to be opened. After I repaired, the engine sound and the quick pick-up feature was still there. So, I called the mechanic again and told him that even after fully battery charge it was not working. I left the bike at the workshop and later on he said the problem was with rectifier. Afterwards, I checked the bike and there has no problem since then.

From this experience I wanted to know how the Apache electrical system works. As an engineer you want to collect information and there are vast of knowledge one can acquire studying such proven technology. So below is the electrical diagram of the Apache RTR 160 motorbike.

Apache RTR 160 Motor Bike Circuit Diagram

The system can be naturally divided into three main functional loops: Power Generation & Regulation, Engine Control & Ignition, and the Chassis Output Loads.

1. Power Generation & Regulation Loop

This section acts as the primary energy plant of the motorcycle, converting mechanical rotation from the engine crankshaft into stable electrical power.

  • Magneto Stator (U4): Spun by the engine, it outputs three high-power AC voltage phases from terminals A, B, and C. It also features a separate P and PG terminal set that provides an isolated trigger signal to the pickup coil sensor.

  • Rectifier Regulator (U6): The three chaotic AC phase lines enter pins 1, 2, and 3. Inside this block, the AC is rectified into DC and regulated down to a safe charging voltage (typically around $14.4\text{V}$), exiting through +V and -V (Ground).

  • 12V Battery (BAT2): Connected directly across the regulated +V and -V DC bus bar. When the engine is off or idling low, the battery supplies current to the system; when the engine spins fast, the Rectifier Regulator recharges the battery.

2. Engine Control & Ignition Loop

This loop manages the critical microsecond timing required to keep the internal combustion engine running smoothly.

  • Pickup Coil: Reads the magnetic pulse from the stator flywheel and sends a clean, low-power AC timing wave (Pout) straight into the ECU.

  • Electronic Control Unit (ECU): The computer brain of the circuit.

    • It takes direct power from the main DC bus via its V+ and GND pins to turn on.

    • It processes the engine speed from the RPM input pin.

    • It sends timed execution signals out of its Inj (Injector) pin and HT (Ignition) pin.

  • Injector / Purge Valves: Receives the low-voltage command from the ECU to open and close its internal solenoid, controlling raw fuel delivery into the engine cylinder.

  • High Tension (HT) Coil: Receives the low-voltage pulse from the ECU into HTIN. It functions as a step-up transformer, converting that low-voltage pulse into an ultra-high voltage blast ($20,000\text{V}+$) which fires out of HTOUT.

  • Spark Plug: Connected in series after the HT Coil, it receives the high-voltage spike to jump its air gap, creating a hot spark to ignite the compressed fuel-air mixture.

3. Chassis Bus & Auxiliary Loads

This section represents everything else on the bike that relies on a steady diet of $12\text{V}$ DC power to operate.

  • Digital Dashboard / Display Unit: Connected directly across the positive and negative rails, representing the electronic instrument console that displays speed, fuel level, and diagnostics to the rider.

  • Switch Matrix: The momentary push buttons represent your handlebar switches (such as turn signal, horn, pass light, or starter switches) that complete the circuit path when pressed.

  • Lighting Network (L1 to L5): These lamps model the actual physical illumination loads on the chassis, including the headlamp, tail/brake light, and turn indicators, drawing current directly from the regulated DC bus.









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