High-G FJR Junkie!
Join Date: Jan 2013
Location: Millgrove, ON, CA
Brake Pad Pins - Replacement GenII & III
I posted this elsewhere, but copied here in case you need it.
This applies to Gen II & III only, as Gen 1 has a different brake pad pin with cotter pins........... If you have rounded out the 5mm hex in the brake pad pins when it is seized in the caliper.... I suspect one cause could be the galvanic corrosion that occurs between the stainless pin and the aluminum caliper. A manual impact driver is your friend, hopefully you don't have to go find an extractor. My recommendation is recognize early that you're starting to round it out......
One fix is to buy a new pin but they are quite expensive (~$30) and oh by the way don't break or lose the metal spring for the pads (~$27). Or, you could find a used caliper on ebay (I found one for $25). Or, you can use a different pin that costs a lot less........ the difficulty is finding a pin long enough, but I have found a Honda pin that will fit the bill (~70mm). This pin has a hex head which will take an 8mm hex socket, much more robust than the 5mm internal hex. Honda Part No. 43215-KZ4-J41 is in the top part of the photo, with the OEM Yamaha pin below for comparison. Note extra thread length, etc. but the important part is the length to capture the brake pad. You don't have to have the little O-ring if you lose one, it only serves as a guide as you insert the pin. See also the photo of both installed in an FJR front caliper.
The Honda pin costs ~$3.40, application is rear brake caliper of '08 CBR1000 and CRF450, perhaps other models. If you prefer a 5mm hex, perhaps try 45215-MAJ-G41, also 70 mm, but I have not verified this with a part in my hand.
Keep yer stick on the ice....
2014 FJR1300A - Root Beer (sold)
2009 CBF1000A - Sienna Red