Seized retaining pins & splitting calipers

[Ripp3rCrust]

Finally got around to attempting to remove the seized retaining pins in my bandit calipers, the pins to which the pads attach have seized in their holes in one of the front calipers and both pins in the rear.

Previously I had tried to drill a hole to the rear of the pin and tap them out with a drift, however this was unsuccessful.
As a result, I decided to split the calipers and get them out that way, the plus side of this being that I can also rebuild the pistons whilst I am at it.

However, as is tradition I seem to have encountered problems at every stage.

- Front brake caliper: Am I correct in thinking that these are unable to be split? As I cannot see any means to split them, and I cannot remove the pin so how can I remove the pin and pads and allow me to rebuild?

- Rear brake caliper: Here both pins are seized, I intended to crack open the bolts holding the caliper together slightly and then remove the caliper and subsequently open it up. The problem here however is that one of the bolts (highlighted red in the image) has rounded off. What are my options here in regards to removing this bolt?

Many thanks.
____________________
Current: '05 CBR600F - Previous: '01 GSF600S Bandit, '06 XR125

[orac]

you maybe able to use a bolt extractor, drill the the head and use a stud extractor, drill it right out and retap the thread with a helicoil.

or if you are having that much troubles (which it sounds like you are) get another caliper thats in better nick.

as for the front calipers, if they are the floating twin pot type, then no they can not be split
____________________
Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

[Ripp3rCrust]

Thanks for the reply.

Yeah, the front ones are the floating type, any suggestions on how to remove the pin here?

New/salvaged calipers aren't an option for me, unfortunately, due to cost. Do you reckon an impact driver may work? Would prefer not to tap and helicoil if at all possible.
____________________
Current: '05 CBR600F - Previous: '01 GSF600S Bandit, '06 XR125

[Pete.]

I have a pair of Mk2 front calipers. You can have them for the cost of postage, I was going to sling them in the bin. I'll make sure the bolts and pins are all free before I send them.

This is where you drill the holes to knock the pins out.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[orac]

if its rounded then no the impact wrench will have the same effected as hand tools.

second hand rear caliper is ony about £40. as for the front pins if it the same as the GS5 one then there should be an r-clip that needs to be removd first. the r-clip is on the inside behind the flang on the wheel side of the caliper. the oins should then be withdrawn towards the wheel side of the caliper.

if you have the r-clip out and it doesnt want to move try using a good quality set of mole or vice grips to rotate the pins an wiggle them out slowly - the most important thing is not to rush - thats when things get broken
____________________
Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

[Vincent]

If you havn't already, get yerself a decent vice....then find a good sturdy bench to put it on. They're like an extra set of hands.............very strong hands. I picked my last vice up for £3 at a car boot but you sometimes see them for "collection only" on eBay too. I've got them everywhere at home - even got one in the bedroom
____________________
Space Is Deep

[Ripp3rCrust]