Brake Caliper Pins!!!!!

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

My suzuki SV650 brake pads are being changed - problem

The fecking pin retaining the pads won't come out! Evil or Very Mad

I have heated it, punch, cut in half and punch but its just not going anywhere!

I know a grinding cutting disc is good for cutting, but isn't there one like a grinding drill so i can grind the pins out completely!

My twist drills have all been knackered because of this

help!

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Is this on the rear caliper?

If so put some penetrating oil on the pins where they go into the caliper. Clamp the pins with some mole grips (very tightly) and try and rotate them in place. Might take a while.

All the best

Keith
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Darth · World Chat Champion Joined: 14 Mar 2008 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

They can be impossible. What you can also try is splitting the caliper, hopefully just leaving the pins stuck in one half. Hopefully both a bit less stuck and a bit easier to get at.

All the best

Keith
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chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I read the thread title assumed they where siezed and assumed the bike was a Suzuki before I opened the read. Laughing

Says something about the Suzuki reputation for metal quality
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Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

dodgydog · World Chat Champion Joined: 10 Sep 2009 Karma :

Took a day to get the pins out of the rear caliper on my Speed Triple, £12 for two new pins also Shocked

Snap on extractors and drills worked in the end Very Happy

drill very slowly, and use Rocol or similar lube.

Dog
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chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

The front of the 1200 Bandit are similar calipers to the Speed 4 I think. They are decent calipers. Work well and need little maintenance.

The Thunderbird has a twin pot sliding caliper Nissan on the front and on the back. They need a strip down at least every year (pins the calipers slide on stick, pistons stick and the allen key pin to hold the pads in place is a pig to get out even with copper slip on it).

All the best

Keith
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cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

Hi guys thanks for all replies -

Calipers are front, the pin goes into a blind hole and is retained in place using an R clip.

The pin is firmly wedged possibly because of bi-metallic corrosion so its pretty much welded itself in! Alloy and steel don't mix well! Evil or Very Mad

I'm left with:

One half of pin flushed in the blind hole, and one half of the pin flushed in the opening hole that lets it slide all the way in.

Conclusion no holes at either end!

So what tool could i use? Will a rotary cone grinder work?

Drilling is impossible, i get about 0.5mm then the drill goes blunt, i do use wd-40 as a cutting fluid

Still need answers and help, or i'm stuck to resorting to new a caliper job.

I haven't touched the left but thats probably fucked too Sad

Ta

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Just looked at an online fiche to see how the caliper goes together. And it does look like a pig to do.

If you still have bits to grip onto then try the mole grips.

Think I would be tempted to find a local engineers and see if they can drill out the pin for you accurately.

All the best

Keith
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nowhere.elysium · The Pork Lord Joined: 02 Mar 2009 Karma :

Having read all of this, would I be right in assuming that for future reference, it would be good to dip the ends of the retaining pin in copper slip before fitting it?
I'm not trying to sound like a smug tosser, I'm genuinely curious to see if there's a worthwhile preventative measure, other than by stripping the calipers regularly. Mainly because I've got one of these bikes coming my way in a week and a half...
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That_Hornet · World Chat Champion Joined: 23 Apr 2009 Karma :

When mine got stuck, i just brought a new caliper. Laughing

But the got it out after by easyouts.

Now stuck with a spare caliper Thumbs Up

As said, center punch it, then drill very slowly in, the easyouts.

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

SlimRick · World Chat Champion Joined: 29 Sep 2008 Karma :

Just had a similar problem with my ZZR, managed to get it out by removing the calliper, forcing the piston back into the calliper so there was room to get mole grips in between the pads and onto the pin. Twisted the pin round that way and worked it out.

TUG · World Chat Champion Joined: 12 May 2007 Karma :

Jesus christ, split the caliper in half or heat it up with a paint stripping gun aka heat gun.
Loads of wd-40 too, theres so many ways, even drilling a hole on the other side in extreme events.
I split the calipers as it saves me hassle i can also clean out the grooves with a drill bit.
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Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

The easiest way with Suzuki calipers when they are well and truly stuck is to drill into the blind hole from the back. Line the bit of pin sticking out from a couple of angles so you know you're in the right place and centre punch it. Use a 3mm drillbit (the pins are 4.6ishmm diameter so wont drop through afterwards) you'll get a puff of oxide when you break through to the pin then use a parallel punch or masonry nail to knock them out. Clean the hole out and use copper grease on the new pins, you won't have a problem in the future as you now have the hole to knock them out the next time.

Just realised it's the front caliper, early ones had the screw in brake pins later ones have the plain pins. The above works for the plain pins or stubs left in from the threaded ones. If it's the threaded part drill them out to 8.5mm then use an M10x1 tap to clean and remove what's left from the caliper thread.
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cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

Hi

Calipers can't be split in half, I can't seem to find myself a suitable drill bit that will attack the metal for a hole!

Even my black and decker bits have been ruined by trying.

Mole grips - can't use as nothing to grip on to - they are flushed /inline with the rest of the caliper body

Evil or Very Mad

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

The caliper on the curvy SV650 can definately be split, I had to on my old one when I changed the pads.

You could cut the pin with a small cutting disc on a dremel, but you'd probably still wreck the caliper trying to get it out. Splitting it takes no time at all.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

https://cgi.ebay.co.uk/SV650-front-brake-cylinder-calipers-braided-hoses_W0QQitemZ130378289532QQcmdZViewItemQQptZUK_Motorcycle_Parts?hash=item1e5b26d17c
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

The caliper body is alloy, any shitty quality 3mm drillbit will go straight through it no problem
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Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

lets say i got the pads out, but the pins were grinded down to body - both side!

Sad

I'll try and re drill the alloy side of the body.

But the real problem is that the pin is stuck on the open side and is stuck inside, no amount of punching with a centre punch has got it out

I have been at it 3 hours now!

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

I hope you have a drill press, a decent drill vice, some small, sharp drill bits, and patience.

TUG · World Chat Champion Joined: 12 May 2007 Karma :

This is why i hate slide type calipers, your going to have to file 2 flats into it and get a good grip with pliers or something of the like, heat it up with the heat gun (the caliper THE CALIPER!!!) not the pin, anf spray lots and lots of silkopen or wd-40 down it whilst turning slightly at a time with alot of patience.
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