04 950 front brake pad replacement w/single retainer clip?

Discussion in 'Dakar champion (950/990)' started by jmvance1, May 16, 2015.

  1. jmvance1

    jmvance1 Mountain cruiser

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    I have an early 2004 950 adventure. While installing a new set of wheels and tires today I decided to change the front brake pads while I was at it since there about half worn-out . The pad pins (bolts) are kept in place by a single retaining clip. Not two as shown in the shop manual and in the how section of orange crush.

    With the retaining clips removed both pins spin freely but will not come out of the caliper. I even tried using a punch and dead blow hammer tapping gently to see if I could get them to move out without any luck. I have owned several KTM's and other motorcycles and always do my own service work. This should be a super simple task but I'm at a bit of a loss about why the pins won't come out. Figure I'm missing some easy step.....

    I checked carefully to make sure that there wasn't a set of retaining clips missing, there is not as there's only one hole drilled in each pin. Also my pins are flush with the outside of the caliper and don't extend beyond the outside surface of the caliper as shown in the service manual. So I'm thinking I have some early or different version of pins installed on my bike. The end of the pin is round so there's no way to get a socket or other tool on it for unscrewing it. I spun it around several times and it did not want to come out or unscrew.
    O
    Any insight would be greatly appreciated! Thanks in advance for any information you can send my way.
    #1
  2. Sumi

    Sumi Long timer

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    They do have one pin and clip on the front calippers (two clips and one pin on the rear brake calipper).

    You have to tap it out with a hammer + screwdriver* or similiar that fits in the little hole on the "Brembo" side. (puting it back is also done this way, but from the other side ofcourse)

    * I use a little allen wrench and tap on it with the hammer
    #2
  3. Sumi

    Sumi Long timer

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    I've took some pictures for you, this is how it looks like normally (well probably not this messy:D):

    The pin is flush on this side.

    [​IMG]

    And you tap the pin out from this side after pulling the clip (might take some effort).

    [​IMG]
    #3
  4. jmvance1

    jmvance1 Mountain cruiser

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    Thanks Sumi,

    That is exactly what I have. It's interesting the photo in the manual is of a rear brake caliper in the front caliper section. I did try tapping the pins through the small hole very lightly and either pin didn't move at all so I decided to stop and ask the question rather than break something.

    I had the wheel off while I was trying to remove the pins now that it's all back together I'll try tapping again. I guess if that doesn't work I can always remove the calipers and do it on the bench.

    Thanks for your quick response and the photos I really appreciate it!
    #4
  5. Sumi

    Sumi Long timer

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    Actually it's easier to do with the wheel in place, as the fork legs can't rotate that way - okay, doing it on the bench is probably the easiest:).. It takes some big hits to get the pin out, don't be afraid (also has a metalic sound when tapping, but that's normal) Don't forget to use copper paste on the pin on reassembly, so the pads can slide easily on the pin
    #5
  6. jmvance1

    jmvance1 Mountain cruiser

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    #6
  7. Sumi

    Sumi Long timer

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    Yep, that looks incorrect.
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  8. Sumi

    Sumi Long timer

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    This is how it is done (after pulling the clip ;)):

    [​IMG]

    [​IMG]
    #8
  9. Peanuts

    Peanuts Long timer

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    #9
  10. Sumi

    Sumi Long timer

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    +1.

    Also the rear calipper on the ADV is the same as the front on the EXC.
    #10
  11. ICERIDER

    ICERIDER Adventure Rider

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    Yes rub the pin down and lube. It's takes the little details like this to give this brake it's full potential. Then it works fine with OEM parts but great with HH pads.
    #11
  12. jmvance1

    jmvance1 Mountain cruiser

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    Got it, thanks everyone. I'm just not in the habit of whacking on the old girl too hard, usually just a few taps and whatever I need to come loose does. These front pins are about as hard to get off as the steering head bearing races were. I'll soak them a bit with penetrating oil and then whack on them. The rear slid right out with finger pressure....:clap
    #12
  13. wheelriding

    wheelriding Adventurer

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    I'd just like to say thanks for this thread, I was beginning to wonder if I was mad this afternoon. The thread gave me confidence to whack the pin and get the pads out. It's not too daunting with the brake on the wheel.
    #13
  14. jmvance1

    jmvance1 Mountain cruiser

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    Big thanks go to Sumi since he is the one that shared the secret for pin removal and took the time to post pics of the process. It's nice to see my dumb question helping somebody else.

    Happy trails!
    #14
  15. Sumi

    Sumi Long timer

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    Glad it helped you guys out:)
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  16. Mikamadu

    Mikamadu n00b

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    Wow, this was really helpful. I was sitting in my garage trying to figure out what I was doing wrong for a good hour. Even got my wife to take a look make sure I wasn't missing something glaringly obvious.

    On a side note, what's the deal with the "Photobucket" picture that replaces the pictures in the thread? I couldn't see any of the pics.
    #16
  17. Goss

    Goss LC8 Adventurer

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    Note the posting dates. Likely the persons photo link is long gone.
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  18. hondacb500

    hondacb500 n00b

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    sorry to revive an old thread but how do i push the pin back in? it wont go in far enough so the r clip hole doesnt show
    #18
  19. AdvRonski

    AdvRonski They call me......Ronski

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    Install the pin with the same hammer and punch you used to remove it. The pins have a floating bushing on the end that is a press fit into the caliper body.
    #19
  20. hondacb500

    hondacb500 n00b

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    i didnt use a punch to take it iut but a nail instead. so i i ju really hit it strongly with a hammer? i did all this without taking the caliper off
    #20