I nearly had to buy a new rear brake caliper housing ($540) because of a Brake Caliper Retaining Pin socket head being rounded out, and the 5mm allen head socket not being able to remove it. I drilled the pin, and used an easy-out and broke the tip of the easy-out off inside the bolt. 4 lessons learned:
1) Perhaps the worst thing you can do is to break off the tip of the easy out inside the hole in the bolt. Then you have a hardened steel bit right in the center. Also, in many good size towns there is a "specialist" who will come to your place and do it for about $60, if you have not already broken off an easy out in the hole. Call your nearest motorcycle or auto repair shop for a local specialist's name.
2)be sure you use a very good 5mm allen head socket, not just an old "Craftsman". Perhaps even buy a new one. Even a slightly rounded tip will round the bolt hole socket.
3) a very good mechanic got the bolt out by hammering a suitable sized torx bit into the socket head hole, slightly heated the surrounding caliper (not enought to destroy the rubber brake piston seals), and then used an impact wrench and a hammer to loosen it. Total cost: $38. Total saved: $540-$38. The mechanic was already gone when I drove to the shop to pick it up-but if I see him again (Paul at KC Powersports in Huntsville) I will give him a good tip. I wish there was a Triumph dealer around here with a good mechanic like that, or even just a Triumph dealer.
4) Periodically replace the Brake Pad Retaining Pins. Cost of consequences versus cost of pins could be very expensive.
