Reassembly - TVS Apache RTR 200 4V Service Manual

CHASSIS
Holding the master cylinder by hand slightly
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press the piston with thumb finger and remove
the circlip from the master cylinder using a
circlip plier without damaging the piston and
cylinder. (Fig. 6.41)
Circlip plier
Note:
Ensure that the circlip is seated properly in
its position after installation.
Slowly pull out the piston along with the
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P - cup, S - cup and spring. (Fig. 6.42) Clean the
system thoroughly using fresh brake fluid.
Caution:
Never use kerosene, petrol or other
solvents for cleaning the brake system.
Otherwise rubber parts will get damaged.
Do not wash the brake pads. Ensure that
the brake fluid is not in contact with the
pads surface.
Inspection of master cylinder
Inspect the following parts:
- Master cylinder for any scratches or any
other damages.
- Piston and cup surface for scratches or
other damages.
- Piston boot and other components for wear
and damages.
- Master cylinder recuperation and feed port
for any blockage, if so clear the block using
compressed air.
After the above inspection, if any defect found
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replace the respective parts.

REASSEMBLY

Reassemble the master cylinder in the reverse
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order of dismantling.
assembly details.
Caution:
Apply the brake fluid to the cylinder bore
and all internal parts before inserting
piston assembly into the bore.
Refer Fig. 6.43 for
TVS APACHE RTR 200
Fig. 6.41
Fig. 6.42
SERVICE MANUAL
6-15