Old big-bored TVS Apache: Restoring and using it for daily commutes

The motorcycle was fitted with a bigger carb from a Bajaj Pulsar 200 and also had a K&N air filter installed. It was a perfect sleeper bike.

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The Apache belonged to a very good friend and I have been seeing it since it was new. Sometime in 2015, he received a surprise birthday gift from his wife - a RE Thunderbird 500. Since then, the Apache has taken a backseat.

Two years later in April 2017, we were discussing something when the matter of the Apache came up. He told me, why not take it? At that moment, I did not have a bike in Bangalore and gladly took him on that offer. So I went to his place later that week with a new battery in hand since the old one would have been toast. The bike of course did not start. The old fuel had gunked up the carb. We got it opened up by a mechanic and the pilot jet was just jammed and the head came off, making it impossible to take out with a screwdriver. Oh well, somehow we got it started and I rode it home.

Why is this Apache special? Apart from its history, the engine had been modified. It was bored out, new sleeve and a bigger piston put it, effectively making it 193cc instead of the standard 149cc. A bigger carb from a Pulsar 200 was also used along with a K&N Filter. This bike was the perfect sleeper. Looks like any other Apache on the road but goes like no other!

The day after it reached my house, after a good clean

Workhorse gets its first service! I got a great deal of Motul 300V from Amazon and ended up buying 8 or 9 liters of it. Ever since 300V has been the only oil it's running on. The damaged pilot jet was replaced with a new unit and the workhorse was ready to release all those horses!

New Rubbers. Zapper FY1 from the R15 doing duties in the front

The venerable Michelin M45 does duties in the rear

Workhorse experiencing the David and Goliath moment with an Africa Twin parked at home next to it

The instrument cluster came off

It was upgraded with all LEDs and a polished lens making it look better than new!

Workhorse even did light touring whenever it was needed

It was time for a serious brake upgrade

All done! Ironically the Apache had a bigger rotor and better feel than the RX despite the same pads and caliper.

May 2023. I come to Bangalore by bike for a couple of days and I meet up with a good friend at his house. Finally got to see his Duke 200 in the flesh. He did tell me he was looking to upgrade to a 390 Adventure at the end of the year. Hmm, this looked like a good contender for the next workhorse, especially after experiencing first-hand working on a Duke myself and the ease of getting parts for it.

Around June 2023, I was back working in Bangalore. I had a long 50KM commute every day and the workhorse took it on like a champ. However, the cracks soon began to appear. All this while for the past 5 years, I've only been changing the oil and basically not doing any other maintenance. Small things started to fail. The side stand would droop too much, one-way clutch would break down and have to resort to kick-starting.

One of the days, the bike refused to start after a routine grocery shop stop and I could hear loud puk puk noises when starting, as if there was a major exhaust leak. Spark plug intact, exhaust intact, still why? Turns out the carb just fell off the manifold, sigh. It worked itself loose and I never saw or felt the signs. In no way were these faults of the workhorse, but a testament of my negligence. All this while. the Duke 390 was getting superb treatment.

Fading into the sunset?

At this point, I was thinking about what next with the workhorse. Should I replace it with a newer bike? Or go all out and get it modified in other aspects to overcome its current shortcomings? I wished the suspension was better on the workhorse and I needed to do something about the foot-forward stance, I needed rear-set footpegs. Suspension from the Himalaya/Xpulse and rear set footpegs from the RTR? Or do I get a different bike? I was happy with the power it put out and the 35-36KMPL I would get from my daily commute.

While mulling over these, I was returning from work one day, late October 2023 and the clutch cable snapped. I somehow rode for another 10KMs, parked the bike when I couldn't ride anymore then took the metro and reached home. In my closet was a brand new clutch cable, still sealed and purchased 2 years ago and I was too lazy to change it despite the obvious signs since then. Enough was enough. The workhorse desperately needed a proper service and it was time.

Heading back to Mysore for its fixes

I rode back with my Duke 390. I have used the Duke in Bangalore for a couple of days at most, but never on a daily 50KM commute, 6 days a week. Riding the bike every day finally after putting so much effort into rebuilding it was great. However, filling up the bike every 3 days with 800 Rs of XP95 wasn't. The duke served me for 3 weeks in Bangalore while the workhorse was getting serviced.

List of fixes. Head rebuilt to fix slightly leaky valve stem oil seals. While in there, why not put fresh piston rings, timing chain, chain pads and tensioner? new valves, clutch plates, rear shock absorber rebuild and slight fork bend were also corrected. A new complete one-way clutch was sourced and I could use the self-starter again.

The next day, I rode back the workhorse slowly, varying speed between 40-60KMPH to seat in the rings. Power had definitely increased thanks to the new top end and rings! I was told to follow the running-in procedure for about 800KMs. At the end of 800KMs, I slowed down a lot and didn't feel like going fast. Maybe I've become older and an uncle now but hey, all for the better.

All this said, The ergonomics still irritated me. I couldn't shake off how much better the Duke felt in terms of suspension and ergonomics. The brakes? Workhorse was far ahead in a different league even with the Duke and its new master cylinder and EBC pads. I still love the brakes on my workhorse too much.

Another 2 weeks go and I hear my friend with the Duke 200 moving away from Bangalore. This probably meant he would sell his Duke for sure. I deliberated for two days and messaged him.

...but wait, what happened to the workhorse? It may be retired for now but it will get its moment of glory soon with a proper cosmetic restoration. The chassis has surface rust on many spots since it's over 17 years old now. More things will get fixed and it will do duties back in Mysore whenever I'm there. The workhorse for me is a permanent addition to my stable. The Dukes may go but the workhorse will never leave.

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