Brake pad removal (another stupid question)

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by ZenMoto, Mar 7, 2006.

  1. ZenMoto

    ZenMoto Bikeslut

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    How do you remove the pin to get the front brake pads out? I want to replace the stock squealers with some Galfer green pads. I had no problem getting the rear done (Galfer black), but after pulling the clip from the guide pin on the front calipers I can't seem to get that pin to go anywhere. :huh

    It seems to me that if they made the rear so you didn't have to pull the caliper to do the pads, they would design the front the same way ...I'm sure I'm just missing something obvious. Of course, it's the one thing that isn't in any of the manuals. :baldy

    Anyone? I'm all ears! :ear

    Thanks
    #1
  2. RAGrote

    RAGrote Long timer

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    If I remember correctly you don't remove the pin. The pads just "hang" in the caliper.
    #2
  3. ZenMoto

    ZenMoto Bikeslut

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    Well, the pin goes through the pads, so the pin must get removed to remove the pads (the other end fits into the guide-slip, same as any other caliper); I just can't figure out how to remove the bloody pin! :baldy

    ...apparently nobody else has either! :lol3
    #3
  4. ktmMike

    ktmMike Long timer

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    When I change brake pads on an unfamiliar caliper, I unbolt it from the front end (not the brake line) so I can turn it over and and get a better look at it.
    Have you unbolted one of the calipers from the front end yet? So you can look at them properly?:D(as Blue suggests) They bolt right back on ... really.
    #4
  5. BLUE(UK)

    BLUE(UK) Long timer

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    NOOOOOOOOOOOOOOO!!!!!

    Simple really.......you gotta 'drive' em out with a nail punch.Unfortunately you have to drive them from the wheel side(awkward)AFTER you have removed the clips.Quite simple really but ya gotta look properly at them.

    *Edit*

    After going outside to check i have to backtrack and say you drive them TOWARDS the wheel......re installing is a b'stard trying to get you punch through the spokes and hit it with an hammer.
    #5
  6. RAGrote

    RAGrote Long timer

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    Just I was going to come back and answer correctly... yes.
    This is true.

    sorry for my inaccurate description. I've had my pads out 3 times for different reasons. I couldn't remember between bikes how they came out.
    Thanks Blue.:clap
    #6
  7. ZenMoto

    ZenMoto Bikeslut

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    That's what it looked like, but I couldn't tell for sure that they would come out that way (the "head" of the pin looks like it's part of the caliper body in my crappy parking-garage light) and I didn't want to apply any serious force without being sure.

    I didn't have the right tools to pull the caliper (larger sockets) last night, so I didn't. I live in an apartment and all my real tools live in a friend's garage near LAX, which can be quite a long drive on a rainy SoCal day (native Californians FREAK OUT when it rains, and drive into eachother with startling consistancy). :eek1

    If I can't get the pin out tonight, I'll go get my real tools and pull the calipers. It just seemed that it was, most likely, not necessary.

    ...I still don't understand why they exclude the brakes from the service & owner's manuals. :huh
    #7
  8. ktmMike

    ktmMike Long timer

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    Me either! KTM is so sloppy that way!
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  9. jsrider

    jsrider Long timer

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    On the other hand, they give you a picture and a part number for every frickin' bolt, washer, and otherwise on the bike. :D
    #9
  10. BLUE(UK)

    BLUE(UK) Long timer

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    I have even made the mistake of trying to drive the pins out from the wrong end......this would normally be forgiven BUT at that stage i'd had them out before but just couldn't see(nor think about)what i was doing!!:huh :huh

    Please dont thank me for any info guys.....sometimes i get loadsa info off here so it's a fair trade!!:D :D
    #10
  11. ZenMoto

    ZenMoto Bikeslut

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    Ok, I must be an idiot, because I can't get the pin out. :huh

    I looked at it the way you mentioned Blue, and there is no way the pin is getting pushed from the wheel-side out, the hole in the caliper body is smaller than the head of the pin (I tried anyway of course). I tried knocking the pin out from the outside in, towards the wheel, and it simply won't budge. :baldy

    Here are some pics, maybe someone can explain it to me using small words and short sentances! :lol3

    This is the right caliper, looking through the wheel, at the retaining pin (yes, I removed the clip before trying to remove the retaining pin).
    [​IMG]

    It's fairly obvious in this shot that the pin must come out toward the wheel as the hole on the outside of the caliper body has a smaller ID than the pin itself:
    [​IMG]

    After removing the clip, I tried using a punch through the caliper to push the pin out, and it won't budge. I can spin it in the caliper with my fingers, so it's not tight ...it just won't come out! :umph

    Anyone? ...should I use a bigger hammer? :evil
    #11
  12. Tim McKittrick

    Tim McKittrick Long timer

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    The pin slides toward the center line of the bike as you suspected- a small punch and a sharp rap should remove it. There is a spring clip around the pin that locates the pin inside of the caliper- if yours is stuck a little shot of lps1 or similar may help to dislodge it.
    Good luck- it really should be about a 15 minute job to change the pads.
    #12
  13. ZenMoto

    ZenMoto Bikeslut

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    Thanks Tim. I can't believe I've had such a hard time with these bloody brakes; I've probably dismantled 3 dozen calipers and never had a problem getting them apart before! lol I just wanted to make sure I wasn't doing something wrong, but couldn't see any other way than knocking the pins inward, toward the wheel.

    Thanks again,
    D
    #13
  14. Nillbymouth

    Nillbymouth Been here awhile

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    Thanks everyone for all the info in this thread. ZenMoto, you are not alone. I too wanted to remove my front pads to give the brakes a good clean (I just LOVE winters in the UK) but couldn't remove the pin. Didn't want to hit the centre punch too hard! Bike was getting close to needing a service anyway so in the end I got the dealer to do it. Useful info for next time though.
    #14
  15. ktmMike

    ktmMike Long timer

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    If that were enough, then why do they print a shop manual for MOST of the bike, but not all of it?:D I have shop manuals for Hondas, Yamahas, Suzukis, Kawasakis, Moto Guzzis, BMWs, Triumphs: They all include the brakes. AND all the info for each bike is ONE BOOK! I've had 4 KTMs, each came with a handful of incomplete manuals, plus the LC4 and LC8 shop manuals I aquired in addition: I've got piles of KTM manuals on a shelf I have to sort through every time I want to look at something, AND THE SHOP MANUALS DONT EVEN INCLUDE THE WHOLE BIKE. I'm sorry, that's sloppy!
    #15
  16. BLUE(UK)

    BLUE(UK) Long timer

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    OOOOOOOOPS!!
    Just been out to look at the pins.Crack it hard with the hammer from the OUTSIDE(not the inside as i previously stated) and it will pop out.

    I think i made the mistake before because i remembered struggling to get the pin through the spokes and hit it with the hammer......that was when i must have been re installing the pins.Sorry for the confusion guys.
    #16
  17. johnnyotis

    johnnyotis Loungemaster

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    Hey Zen,
    Punch the pin out the big hole with a punch that fits the small hole, it's a fairly tight fit. The easist way is with the wheel on so that the caliper stays striaght. then pull the wheel and all the shit falls out.
    mark
    #17