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Ski-Doo: XP Sleds 2007.5-current, all models in the XP, XT and XR chassis
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Old 01-21-2016, 02:31 PM
yonmoore yonmoore is offline
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Default unable to remove allen bolt that holds brake pads

I'm stumped here with what should be a very simple brake pad replacement job.

The allen bolt that holds the brake pads in place is loose and unthreaded but still won't come out. I've tried grabbing it with needle nose pliers to get it out but it keeps hitting something that won't allow it to come out.

Does anyone have any ideas??
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Old 01-21-2016, 02:37 PM
DND DND is offline
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Here's my procedure -


1.Remove brake disc cover
2.Remove brake pad spring clip holding bolt in place
3.Remove brake pad bolt (allen head shoulder screw)
4.Remove brake pads ( Pull them toward the rear then up and out)
5.Reverse steps to install
6. Pump brake lever until slop is pulled out of caliper (Check Reservior Level)


I guess the question I would ask - spring clip removed to allow bolt to come out?
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Old 01-21-2016, 07:56 PM
FEZ FEZ is offline
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Yes, remove the clip that holds the pin in place.
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Old 01-22-2016, 10:15 AM
yonmoore yonmoore is offline
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Yea sorry I forgot to mention that there's a little wire clip that I removed and I still can't get that allen bolt out.

Here's a pic, if you can see it.

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Old 01-22-2016, 05:10 PM
DND DND is offline
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Pic didn't work for me.


If the clip is out, there shouldn't be anything stopping the bolt from coming out. Perhaps just corrosion and buildup?


Does the bolt move at all? In and out that is?


Does it seem to bind on a pad? Or the caliper body?


I'm starting to think vice grips and a good pull, while twisting. Protect the threads from the vice grip with something.


All else fails -
pull the caliper and pads off the shaft, with the rotor
remove rotor from caliper assembly
drift the bolt out from back side of the caliper once you're at the bench - I'm assuming there's an access hole, haven't confirmed that.
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Old 01-25-2016, 10:54 AM
snobinge snobinge is online now
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Quote:
Originally Posted by yonmoore View Post
Yea sorry I forgot to mention that there's a little wire clip that I removed and I still can't get that allen bolt out.

Here's a pic, if you can see it.

What year sled? My 13' and 15' sports have a plastic stirrup vs. the old aluminum style on the brake side. The allen bolt will not come out without stirrup removal however you can move it far enough to remove the pads. Remove inside pad first then you should be able to sneak out the outside pad. Have done it quite a few times.
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Old 03-21-2018, 02:53 AM
uglyfugly uglyfugly is offline
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Quote:
Originally Posted by yonmoore View Post
I'm stumped here with what should be a very simple brake pad replacement job.

The allen bolt that holds the brake pads in place is loose and unthreaded but still won't come out. I've tried grabbing it with needle nose pliers to get it out but it keeps hitting something that won't allow it to come out.

Does anyone have any ideas??
Just for future anyone coming across this. I had pribelems taking the Allen bolt out too. There are two lips on the bolt itself where the trainer pin sits. The ridge closer to the sled itself is too high and must be filed down with a tiny file. A couple minutes of filing it down with a triangular file and it slid out no problems. Horrible design.
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Old 06-20-2018, 02:48 AM
Valonmxz Valonmxz is offline
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Default

Quote:
Originally Posted by yonmoore View Post
I'm stumped here with what should be a very simple brake pad replacement job.

The allen bolt that holds the brake pads in place is loose and unthreaded but still won't come out. I've tried grabbing it with needle nose pliers to get it out but it keeps hitting something that won't allow it to come out.

Does anyone have any ideas??

I have run across this myself. Should be very simple to remove that anchor pin. If you try to remove the anchor pin / bolt before removing the spring clip when you are turning the bolt out you will burr up the grove in which the spring clip rides in. If this happens to you will need to screw it back in and get a file or use a die grinder to de-bur the groove in the anchor pin. just rotate and grind. doesn't take much.


When you re-install the anchor pin use some grease on the threads and snug up the pin. don't over tighten it as the spring clip will hold it in place....
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