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Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

  1. #1
    Senior Member dhawks's Avatar
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    Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Hey, everyone. I had such success here the last time I posted a question about removing a stubborn bolt, so here goes Round 2:

    One of the bolts that holds the brake pads into the caliper (in the attached photo, the bolt that is directly across from the 'o' in 'Tokico') has become rounded-off. A hex/allen key simply spins inside the head of the bolt. As you can see, the bolt lies flush with the caliper surface. How do you remove such a bolt? A friend has suggested driving an appropriately sized Torx bit (or similar) into the head of the bolt and seeing if I could get the bit to impress into the sides and grip.

    Thanks for your suggestions.

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    /s/ Dustin
    LRRS #767
    '09 R6 / '11 848 Evo / '99 RS250

  2. #2
    Soul Rider Paul_E_D's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Try your friend's idea first, then you basically left with drilling for an easy out.

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    Paul_E_D


  3. #3
    Majer:Danjer™ ChicknStripEatr's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    You're gonna need a new bolt anyway, so you can try your friends idea or you can pick yourself up a screw extractor.


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    I get offended by people who cry they've been offended

  4. #4
    Changes come butcher bergs's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    If the Torx bit doesn't work, see about smashing a Standard hex key into the bolt. Throw a little heat on the caliper, concentrating on both ends of the pin, and twist. As an absolute last resort, drill but I feel a little heat is going to do the trick.
    The reason why it's stuck is because of galling and is very common with this type of retaining pin style.

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    Nooooooo! Don't heat the caliper!

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  6. #6
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?



    This I gotta hear....

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  7. #7
    Unsafe At Any Speeds Jim's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    dustin, when you do get the bolts out, put some anti-seize on them & use the proper hex socket to tighten them to the required torque. you're probably going to need a 4mm or 5mm metric socket, and tighten them to maybe 16.5 ft/lbs

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  8. #8
    Unsafe At Any Speeds Jim's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Quote Originally Posted by Degsy View Post
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    Nooooooo! Don't heat the caliper!
    Quote Originally Posted by bergs View Post


    This I gotta hear....
    my guess woul dbe because he could boil the brake fluid & contaminate it. not that replacing the fluid would be a horrible thing. but smashing in a standard sized hex socket might do the trick

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    Quote Originally Posted by bergs


    This I gotta hear....
    Rubber seals and piston o rings.

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  10. #10
    Changes come butcher bergs's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    EDIT: I re-read this post and apologise for its precieved tone, hence the complete edit. Not trying to sound dickish and I really don't care what method is used to extract that hardware but based on experience, a little heat will also work.

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    Last edited by butcher bergs; 08-23-10 at 07:47 PM.

  11. #11

    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    You can get bolt outs at sears for pretty cheap, or borrow mine. I had the same situation when Degsy tried to do my front sprocket. (not his fault, was already rounded out)

    Just tap it with a hammer and twist

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  12. #12
    Lifer Pittenger5's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Can you reach in back with a pair of needle nose and twist the shaft? (giggity)

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  13. #13
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Sorry Derek and Jim. Post edited. It didn't read quite right.

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  14. #14
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Quote Originally Posted by dhawks View Post
    Hey, everyone. I had such success here the last time I posted a question about removing a stubborn bolt, so here goes Round 2:

    One of the bolts that holds the brake pads into the caliper (in the attached photo, the bolt that is directly across from the 'o' in 'Tokico') has become rounded-off. A hex/allen key simply spins inside the head of the bolt. As you can see, the bolt lies flush with the caliper surface. How do you remove such a bolt? A friend has suggested driving an appropriately sized Torx bit (or similar) into the head of the bolt and seeing if I could get the bit to impress into the sides and grip.

    Thanks for your suggestions.
    I tried all that stuff myself on a lower fairing stay that was frozen bad. Stripped it then tried a torx bit and really screwed things up (no pun). Someone suggested a Alden Pro Grabbit kit from sears. Fits in your electric drill and as corny as it sounds it worked just like as seen on TV. Just be sure to get a set (3) thats got one bigger than the bolt thats stripped. It`s that easy. One side cleans things up and the other end gets it out.

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  15. #15
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Before you do anything spray some pb blaster on there and let it sit overnite. Do it again in the am. Don't forget to clean that stuff off all braking surfaces upon reassembly. I'd try the sae hex key trick first, myself.

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    Cliff's Cycles KTM
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    That's ok bergs. I learned by experience. Destroyed a master cylinder with heat once, right jim?

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    KB KB's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Get in between the pads with a pair of needle nose vice grips, some PB Blaster and a little luck. NO HEAT. Or I would find a size that is just a shade bigger, and slam it in with a hammer.

    KB

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  18. #18
    Unsafe at any speed GNTurbo6's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Hammer + Torx bit...

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  19. #19
    TRACK RAT!!!!! Pigman's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Those break rather easy......should be easy

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  20. #20
    Bike Junky FireboltEric_MA's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    I'd put a hex in there and give it a few good wacks, dont be shy, put some oomph into it, pb blaster next, maybe even another whack to try and get it to free up...

    then use the hex trick... It should turn right out. been there done that.


    Good luck.

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  21. #21
    Senior Member dhawks's Avatar
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    Many thanks for all the replies. I'll give it a go this weekend or early next week and see if I can gain the ability to change the brakepads.

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    /s/ Dustin
    LRRS #767
    '09 R6 / '11 848 Evo / '99 RS250

  22. #22
    Lifer Chippertheripper's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    If you aren't touching it for a while, start putting the penetrating oil on there now.

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  23. #23
    Senior Member dhawks's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Quote Originally Posted by Chippertheripper View Post
    If you aren't touching it for a while, start putting the penetrating oil on there now.
    Will do -- probably tonight, in fact.

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    /s/ Dustin
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    '09 R6 / '11 848 Evo / '99 RS250

  24. #24
    Member dudutzu's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    Quote Originally Posted by KB View Post
    Get in between the pads with a pair of needle nose vice grips, some PB Blaster and a little luck. NO HEAT. Or I would find a size that is just a shade bigger, and slam it in with a hammer.

    KB
    +1
    take the caliper out, push the pistons in so you get more room for the vice-grips, and if you think you gonna have enough room for vice-grips as far as the rotor goes, then put the caliper back on you don't have to hold it and use your both hands trying to get that sucker out

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  25. #25
    Unsafe At Any Speeds Jim's Avatar
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    Re: Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

    dustin, if you get one bolt out but the other is stuck, see if you can rotate/spin the pads in the caliper to loosen up the stuck bolt. it worked for me reciently

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