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Allen key size for front brake pad pin?

4K views 8 replies 5 participants last post by  bobl 
#1 ·
2002 GSXR-750. I'm trying to change brake pads. One of the pad pin's head is a bit stripped out, but even for the one that's fine, I can't find the right size allen key.

I have tried:
  • 5mm (too small)
  • 5.5mm (too big)
  • 3/16" (too small)
  • 7/32"(too big)

I have searched quite a lot and I can find the replacement OEM part, and other people posting problems with this pin, but I haven't seen anyone post the size. It's also not listed in the Haynes manual I have.

I hope someone can help, because I have a track day coming up Sunday and these have to be changed. Thanks in advance for any help!
 
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#3 ·
^ What he said.

Cheap tools sometimes have low tolerances and just cause damage.

I don't know the size, but I'll guess it's the 5mm and hole is enlarged.

I would take one of the wrenches that is just too big and grind it down till you could tap it in with a hammer. Heat the caliper first then spin that sucker out.

#4 in the link, and they are pretty fond of those things, but you can get them.

2002 Suzuki GSX-R750 FRONT CALIPERS | CyclePartsNation
 
#4 · (Edited)
I have used torx bits on some stripped allen bolts in the past, sometimes it works, sometimes it doesn't :0001136745-huh:

Find the size that "fits" and try that first, if nothing go 1 size up and lightly tap it into the stripped allen key hole and try again. sometimes the splines on the torx bit are enough to grip and allow you to back the bolt out. Might lose a torx bit in the meantime but hey that bolt is out:grin
 
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#5 · (Edited)
What brand of wrenches? It's metric. Sometimes cheap tools will put you in that exact scenario.
Seems harder and harder to find tools that aren't cheap these days. The metrics I've been using are the Capri Tools CP30002 S2 sockets. The standard size keys I have are just an old set from who knows where.

I don't know the size, but I'll guess it's the 5mm and hole is enlarged.
I'm asking the size because the pin on the right caliper appears to be perfectly fine, and I don't want to screw it up. I'm guessing the reason the left one is wallered out is that it's an odd size and one of the previous owners used something not-quite-right. It definitely is not a match for my 5mm, which I use all the time with no problems until now.

I surely appreciate the advice regarding the one that's buggered up, but I still want to know the correct size so I'm only dealing with one such pin. ;)
 
#7 ·
My 2000 750 with Tokico calipers uses a pin with a 5mm allen head.
Thanks, bobl! Now that it's daylight out, I can tell that they're actually both enlarged; just the right one actually still has a pretty good hex shape somehow. I've purchased some SteelStik, and will fill in the head with that, and as it's drying, I'll push a torx bit into it (I figure that'll give a bit more traction), and hopefully it will still be usable in the future.

Thanks for the help, everyone!
 
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#8 ·
Update: I let that SteelStik set up for 1h40m, and it says it only needs 1 hour. Well I went to give it a turn and that stuff crumbled like cheap old plastic. The only thing I can think of is that I only needed a very small portion, cut from the end, and I noticed on one side the core material wasn't solid like on the other side. Maybe it didn't have the right mix proportion. I'm giving it one more try, and might let it set until tomorrow morning before giving it a try.

Has anyone else used this stuff?
 
#9 · (Edited)
No experience with steel stick. When people use torx on damaged allen head bolts, they usually pick a size that is slightly too large for the hole, and pound the torx bit in. Some heat may help too, but I wouldn't use a propane torch because of the rubber seals in the caliper. A heat gun may help.


Edit: Another thought; Dismount the caliper, and remove the anti-rattle clip (two 3mm screws), push the pucks back and try to break the pin loose with a small pair of vice grips or channel locks. After the clip is removed, the pin is accessible. Probably the best shot. Once broken loose, it should come out.
 
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