Buggered: challenge with calipers and brake pads

[RockOn]

Decided today was the day to install new brake pads on the front calipers. I thought getting the cotter pin out would be the hardest part. Ha ha, wrong. The 5mm Allen head retaining pin will not budge and worse, it is rounded/stripped out to a point where my Allen head sockets and wrenches can't get a grip and slip too much.

So, I need ideas. Yes, I soaked the pin head with WD40 penetrating spray multiple times. I've considered grinding down a larger Allen head socket and pounding it in the pin head but suspect it will eventually spin and not grip. Should I try drilling it out? ???

 

[TURBO200R4]

No do not drill it
U can try rapping it with a small hammer to loosen it up. Also heat.
If u want to send it to me i have the know how and the tools to remove it.
Would expect to b paid for return postage no charge for the repair.

 

[Gerald]

Decided today was the day to install new brake pads on the front calipers. I thought getting the cotter pin out would be the hardest part. Ha ha, wrong. The 5mm Allen head retaining pin will not budge and worse, it is rounded/stripped out to a point where my Allen head sockets and wrenches can't get a grip and slip too much.

So, I need ideas. Yes, I soaked the pin head with WD40 penetrating spray multiple times. I've considered grinding down a larger Allen head socket and pounding it in the pin head but suspect it will eventually spin and not grip. Should I try drilling it out? ???

Think best way to try and drill would be to remove from bike and center under a drill press. Bolt is going to be hardened where they make the head. Start small drill, and lubricant, and keep increasing size until you can get a big enough ez-out to grab. Don't want to break ez-out in hole. If can't get to loosen keep increasing drill size to where you can pick threads out of housing. Before starting to drill, shock the bolt with a big hammer and biggest punch you can get into the hole. Good luck When you get it out, put some never-sieze on bolt thread before reassembling.

 

[RockOn]

No do not drill it
U can try rapping it with a small hammer to loosen it up. Also heat.
If u want to send it to me i have the know how and the tools to remove it.
Would expect to b paid for return postage no charge for the repair.

Okay, thanks, I will try the hammer and heat. If that doesn't work for me I will be in touch. Thanks.

 

[TURBO200R4]

I guess i should have mensioned that i repaired one for another guy and everything went ok.

 

[Gerald]

Think best way to try and drill would be to remove from bike and center under a drill press. Bolt is going to be hardened where they make the head. Start small drill, and lubricant, and keep increasing size until you can get a big enough ez-out to grab. Don't want to break ez-out in hole. If can't get to loosen keep increasing drill size to where you can pick threads out of housing. Before starting to drill, shock the bolt with a big hammer and biggest punch you can get into the hole. Good luck When you get it out, put some never-sieze on bolt thread before reassembling.

No do not drill it
U can try rapping it with a small hammer to loosen it up. Also heat.
If u want to send it to me i have the know how and the tools to remove it.
Would expect to b paid for return postage no charge for the repair.

That is an outstanding offer, hats off to you.

 

[sonny]

[expletive deleted] Another option: Drill the the thing out with a reverse drill bit and it will more than likely come out easily. Done it a few dozen times on many a bike including the rocket.

 

[TURBO200R4]

Sonny has a great idea and it will probably work and if it don't send it to sonny lol.

 

[sonny]

Look the pin is easy to remove with a reverse drill bit. It is not brain surgery.

 

[Gerald]

Look the pin is easy to remove with a reverse drill bit. It is not brain surgery.

Drill the the thing out with a reverse drill bit and it will more than likely come out easily. Done it a few dozen times on many a bike including the rocket.

Sometimes that works, sometimes it doesn't. Need to have another way if first plan doesn't work.