Stuck hanger pin pad on front brake

Set out this morning to install new pads in the front brake of my newly acquired 2004 Silver Wing (non-ABS). Had new EBC pads, Brakleen and Syl-Glide at the ready.

Apparently the previous owner was a Tommy Toughguy type who never met a torque spec he liked. I had to use a breaker bar to loosen the caliper mounting bolts.

The pin pad holding up the brake pads, torque spec just 13 ft. lbs, was hopeless. I (stupidly) ended up stripping the hex bit top and now I can't get it out. The front had a pop on cap. The rear has a flat blade screwdriver cap that I can't budge either, and that's before I even reach the rear pin pad.

I'm thinking I can order new pins from a dealer at $6.42 each, or make sure they have them in stock for my service visit, and take the bike in. I don't want to muck it up too much because a new Nissin sub-assembly costs $499.

Pin pad is #18 in the diagram. Thanks for any info and insights.

Um… How about concentrating heat on that caliper area and then hammering a torx driver into that rounded out pin head? Sounds drastic, but if were mine, I’d judiciously use the flame point of a Bernzomatic (propane) torch.

Chances are that pin is stuck because of corrosion rather than Denny Dickfingers doing it. The caliper bolts —that’s probably because he used an impact wrench.

Cosmic_Jumper wrote:

I’d judiciously use the flame point of a Bernzomatic (propane) torch.

Interesting. Never did that before but I've seen it mentioned many times for stuck bolts and screws. Seems doable and would beat schlepping to the dealer.

Looks like my first Bernzomatic purchase is in the near future. Luckily I have a decent amount of pad left so there is no urgency. Mostly I wanted to get in there to clean and lubricate. Long ago I recall a rider recounting how his front caliper locked up on the highway and threw him over the front of the bike with painful consequences. I have checked my front brakes out thoroughly on every bike since then.

UPDATE: Solved! This Swiss Army knife for Allen wrenches let me get a good bite and use serious leverage (basically, my whole body) to crack the bolt. An hour before, I put some WD40 in there to work its magic before I went for it -- once I got the wrench locked in, I worked it left and right gently to make sure there was no wiggle and maybe "prime" the bolt to move. Now I don't have to burn the neighborhood down with the Bernzomatic!

ATF and Acetone 50/50 mix makes an excellent " liquid wrench " be careful with its use.