Disassembly (GS 300 & GS 430)
- Remove hydraulic brake booster. See HYDRAULIC BRAKE BOOSTER under REMOVAL & INSTALLATION.
- Using special tool (09630-00014), 09631-00142), (09950-60010), (09951-00180) and (09951-00190), place brake booster in vise. See Fig 1.
- Remove reservoir cap. Remove 3 set screws, and pull out reservoir. Remove 3 grommets. Loosen lock nut, remove clevis and lock nut, and remove caliper boot.
- Using a 30 mm deep socket wrench, remove oil pressure sensor. See Fig 2.
- Press piston in with screwdriver and use a pin to push snap ring from hole in body, then remove.
- Remove piston, pulling STRAIGHT out. Disconnect actuator hose. Remove 2 bolts, hanger and clamp.
- Using special tool (09023-00100), remove brake actuator tube No. 1. See Fig 3.
- Remove screws and wire harness.
- Using 5 mm socket hexagon wrench, remove bolts, No. 1 and No. 2 accumulator brackets, booster pump and accumulator with No. 1 pump bracket. Remove bolt and No. 1 pump bracket. Remove washers, cushions, collars and sleeve. Remove bolts and No. 2 pump bracket and cushion.
- Place cloth around booster and place booster pump in vise. Using special tool (09318-12010), remove accumulator. Remove silencer tube. Remove spring and "O" ring. Ensure no foreign matter enters pump.
- To dispose of accumulator, drain high pressure gas from accumulator. Place accumulator in a vise. Cover accumulator and a saw with a cloth. Cut accumulator body slowly to release gas.
CAUTION:
Never cut at a stretch. When outer body of accumulator is cut, gas discharges. Be careful of flying debris.