Brake pad retaining pin removal

[Big Phil]

Hi,   
     I am starting the rebuild of my SRAD 750 front brakes which are Tokico 6 pot types. They are notorious for the brake pad retaining pins corroding and seizing and sure enough that's my latest problem. Try as I may I cannot budge them. I have cleaned the whole caliper assembly in an ultrasonic tank and doused and soaked them in penetrating lube but they won't budge. So far I have tried and failed to move them by twisting them with grips. My next method was to get a firm grip of them with mole grips and tap pretty hard with a hammer, but again not a sign of movement. I have 3 other ideas:

1) Using a Dremel cut the pin in half. Remove the pads and tap one side out and hopefully pull the other out.

2) Remove the caliper joining bolts and try and twist them apart. However, I'm very concerned this will only crack the caliper bodies at the pin locations.

3) Drill the back of the caliper directly through to the pin and tap it out as per a Del Boy video.

Any advice or further suggestions would be very much appreciated.

Thanks in advance
Phil

[Mick_J]

Are they the same type as fitted to the 1400?  You make no mention of using an Allen key so I'm trying to visualise what you are saying.

[Big Phil]

Hi Mate, Here are some pictures

[Big Phil]

To help clarify the last photo shows the pin that needs to be removed. The left side had a little R clip retaining the pin and with that removed you should be able to slide the pin out towards the left which has an open end (see first photo pin access central above middle pot). The right side has a closed end with no access to the pin (see second photo no access above middle pot).

[Mick_J]

From what I can see I would cut the pin off hard up against the out side edge of the brake pads and remove the pads.  With a bit of juggling around I would try to find a spacer to fill the gap between the inside faces of the calliper and punch out the inner pin with a drift (don't forget to support the bottom edge as well) then on the other side grip what's left with mole grips and give it a bit of a wiggle and twist.  Clean up the holes but don't ream out the holes bigger or they might rattle about too much, refit with SS pins and never seize.

[Big Phil]

Thanks Mate that sounds like my number 1 option but with adding a spacer for support which I hadn't thought of doing. Will definitely use SS pins once the old ones are out.🤗

[seth]

You could try heating with a Hot air paintstripper but be careful not to get anything to hot .

[Big Phil]

Thanks Seth that was in the back of my mind. I don't have a hot air paint stripper but I do have a precision hot air soldering station I use for my work when building electronic circuit boards. It will keep the heat very localised on the pins and can generate some pretty high temperatures.

[Del]

another way is to remove the half bolts and with the caliper in a vice, start to revolve the top of the caliper backwards and forwards to work the pin loose - once one side is off then take caliper out of the vice and place the pin in the vice and again start to move backwards and forwards till it works loose

when rebuilding run a drill though the holes to clear out any alloy corrosion on the sealed end don't go to deep or you will drill through the back of the caliper

[steve porter]

Bloody salt

[DP1400]

I`d go with Del - bolts out, copious quantities of WD40 and start twisting. Use Gunk to remove any WD40 residue afterwards.

[mlivkovich]

A couple days ago I tried to replace brake pads on friend's gsxr600 k6 and guess what? All 4 brake pad pins were loctited  and allen key holes were snapped. I had to take apart inner half of calipers, take out pistons and seals, heat the pins with torch and hammer in torx bit to take them out. Now waiting new pins and pads to arive

[Hooli]

Having had two retaining pins fall out of my 14, I loctite them too.

[mlivkovich]

Having had two retaining pins fall out of my 14, I loctite them too.

I never used loctite on these and they never fall out. Maybe I was lucky so far.

[gsxbarmy]

Having had two retaining pins fall out of my 14, I loctite them too.

Probolt do some stainless pins which you can wire once in - which would save on using loctite - if that would work better perhaps?

https://www.pro-bolt.com/stainless-steel-caliper-pad-pin-rear-race-spec-lsspinbp003rz2/