Help!!! ST1100 Front brake pad pin head stripped

ak85lp

ak85lp

(Paul)
Joined
Jul 12, 2009
Messages
232
Location
Franktown Ontario Canada
Bike
2018 VStrom 1000XA
Got some new front pads for my bike tonight, easy job right..just 20 minutes and I'll be done. The right side cap over the pin came out kind of hard but nothing that a larger flat screwdriver took care of. Put the metric allen key inside the retainer pin and it stripped right around. I tried the slightly larger non metric version and it was too big.

Got my ezy-out and of course broke the head of it right off in the pin :mad:. I only had another smaller extractor and it was no good. I also tried everything in my tool box as well, torx bits, phillips bits, flat screwdrivers and nothing seems to catch the corners. I can't get enough purchase on the smooth part of the pin back by the spring clip either.

I don't have a dremel tool or a tap and die set. I'm supposed to leave on a big trip in a week and now I'm stuck with brake pads that "may" make the trip but I will be worried the whole time.

Life sucks.

45215ML7922_large.jpg
 
I have had this happen and simply drilled the head off to remove it. It was pretty easy to do as the internal socket hole acts as a guide for the drill bit. Find a drill that is just the same or very slightly larger than the pin itself. When you drill through the head you can simply push the pin out. When the the head is drilled through it usually will come right out with an easy out.

Dan
 
bdalameda said:
I have had this happen and simply drilled the head off to remove it. It was pretty easy to do as the internal socket hole acts as a guide for the drill bit. Find a drill that is just the same or very slightly larger than the pin itself. When you drill through the head you can simply push the pin out. When the the head is drilled through it usually will come right out with an easy out.

Dan
Click to expand...

I think the broken EZ-out was removed as he mentioned trying a bunch of different tools which did not work, so drilling is probably still an option. Shoot some PB Blaster in there to loosen it up and try drilling. If the threaded piece still won't come out with the EZ-out after drilling, if your hole is centered you can keep expanding the hole one drill size at a time, and then chase the threads with a tap when the remaining metal gets thin. Before doing any of this make sure you have a replacement part, you don't want to have to wait to order one after removing the old one.
 
Drilling out sounds like the way to go.

I would go ahead and get on ebay, order a used caliper and have it shipped quickly to have on hand, just in case.
 
BTDT, got the T-shirt. Penetrant didn't help (and I always use anti-seize in the pins' threads), so...

I ended up removing the caliper completely, put it in a vice, cut the pin to remove the brake pads, and broke it free with a vice-grips on the pin shaft. FYI FWIW

Good Luck, John
 
When you finaly get the pin out, try to remember how hard it was to get the plastic piece out. Screw the pin in using anti-seize or moly grease. Snug it down. Do not over tighten. Install the plastic screw.
 
If you can get access you might have enough room to get vise-grips on the shaft of the pin between the brake pads. It will ruin the pin, but at this point its already ruined. Or do as John suggested and cut the shaft to remove the pads. Remember to cut it as far away from the head as possible, so you have enough shaft to grab onto.
 
Thanks for the ideas..all good plans. Going to order the part soon and work on it again. I'll try not to take the caliper off as I don't want to get into brake bleeding but I will use that as an option if I need to.
 
You can always remove the caliper but leave the hose attached. That will gain you some working room without having to bleed them. And besides, on an 1100 bleeding is a 5 minute process.
 
This shows how stuck mine were:
Even after heating the lot, the Allen wrench turned in the pin head.
My solution was the use of a star bit, which has more teeth than a Torx.
brake2.jpg

Had to use the 1/2" wrench with maximum force on it to get it loose. It was really a matter of either breaking the calliper or that stupid pin coming loose.
I got lucky in the end.
brake1.jpg

If there is lack of time, you better order a spare calliper just to make sure you have it in case things go wrong.

Regards, Rob
 
Hi. I had a similar problem, and no matter the amount of coppergrease I have used the UK climate causes havoc with these pins and caps. They must be treated as a service item and re greased on a regular basis. I found a replacement aftermarket part that extends out past the caliper and has a regular hex head. This eliminates the end cap and allows the pin to be removed with a regular socket. I can not find a link to the supplier at this time but will continue to look and can post pics of mine fitted if required. Cheers
 
I think, I have an extra caliper and pin. Used but in fair condition if this helps. I can check in like 10-15 min and I could express mail or overnight it to you tomorrow. You say its the right one?

Mark
 
I got both, right and left. Just need to be cleaned up a little and I believe that I've put new piston seals in them. In any case you can install your pistons in it, it's an easy procedure and bleed them. PM me if you're interested.

Mark
 
Thanks for the offer Mark for the caliper but things turned out better tonight. I had to take the hacksaw blade out and just use it on the pin as it was in such a tight spot. After about 15 minutes of sawing it came apart and I was able to get the brake pads out. A new pair of vise grips on the remainder of the pin and I was able to start turning the bolt. Once I ran out of room with the grips I was able to lodge a torx bit in there and ratchet the rest out. I took the pin out of the other side and put this brake set together..done
Now just to wait for the new part tomorrow and I should be back in business.

That's what I like so much about this forum. Everyone is so helpful and they would do anything to help you through things..a classy bunch :)
 
Hey Paul. Let me know if you have any issues with getting your new part. I have a pin and cap from a rear caliper that you are welcome too, I believe they are the same. Stuart
 
Basic

I am having this same problem. What size star bit is that? looks like 6mm. Looks like I'll be ordering two replacement pins. Thanks for the tutorial.
 
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