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Frozen pins in 1200I brake caliper
Trying to replace front brake pads. Pins are frozen. Applied penetrating oil and hammered but no luck. Suggestions? Thanks
#1 12-25-2006, 06:52 PM,
Of course you've removed the retaining clip on the other side of the pins right? If so, Remover the caliper from the hose so you can take it to a work bench. Use a small punch. If you get them to move out even a little bit you might be able to get some vise-grips on them and twist them! The twisting and pulling seems to get them to move along with a punch you should be able to get the pins out.
Hope this helps.
#2 12-25-2006, 07:31 PM,
Best bet is a very solid, hard surface to work on. Use a brass drift to avoid belling or burring the end of the sleeve. I had pretty good luck with an 1100 caliper by heating the caliper as hot as I could handle it and then squirting a bit of WD40 on each end. Did it a couple times and left it with a good dose of WD overnight. After that treatment use a large hammer and a brass drift and thump it on one end, turn it over and thump it on the other end working it back and forth until it begins to move a little, shoot a bit of WD in and keep working it back and forth and eventually it will come out. It's important to clean the bore hole in the caliper as well as the sleeve to make sure it's got some clearance and can drop through the caliper by it's own weight. Liberally grease the bore and the sleeve, inside and out with brake grease or any waterproof heat resistant grease.
Current: GL1100 GL1500 Previous: GL1200SEI
#3 01-08-2007, 11:24 PM,
I was able to take off my calipers (same problem) - I got them vertical on the bench and used pb blaster for a couple of days. Then did the punch routine very carefully so I would mash the end of the pin. I got them out cleaned them up and used anti-seize for the next time.

Patience here can go a long way. They will come out - but it may take some time.

Good luck - let us know how you make out.
85 GL1200A
#4 03-18-2007, 10:52 PM,
If someone has hammered with a punch on the those pins you may need to order new pins and cut the old pins in the middle to get them out otherwise you risk damaging the calipers.

The pins are very soft and the hammering rivets the ends into the caliper.
Ed (Vic) Belanger - 1954-2015
Founder of

#5 03-19-2007, 10:00 AM,
I replaced my rear pads yesterday on my 1986 Interstate that has 115000 miles on it. Once I removed the pin retainer, I used a 16 penny nail and a 4 ounce ball peen hammer to drive mine out. If they are stuck as hard as yours are, I too recommend a penetrant be applied,such as PB , WD, or one of those initials.

#6 03-25-2007, 06:11 AM,
Just be careful when hammering those pins so that you don't rivet them in place.

If you tap them in from the opposite side you can turn the pins with pliers and then scrape off the rust so that the pins will drive out smoothly without jamming on the rusted sections.
Ed (Vic) Belanger - 1954-2015
Founder of

#7 03-25-2007, 06:29 AM,

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