Ok so the hex cap on the rear brake pad retaining pin has been rounded off (the hex bit won't turn the bolt). I can undo the caliper bolts and slide the caliper forward but that won't let the caliper slide off

Need to get the caliper off and this pin needs to be removed first so any suggestions?

Cheers.

Huh? You can't get the caliper off without removing this pin?
That pin only holds the pads.

what he says^^

the pin only needs to come out if removing the pads.

yeh i want to clean up the rear caliper and change the pads but the caliper just wont come off even with the mounting bolts removed...i can slide it but it just slides around the disc. can't actually pull it off for some reason

Lever the pads back into the fixed and sliding caliper, there may be a ridge on the disc edge.

when you say the hex cap on the retaining pin. is is actually the head of the pin thats rounded or the small lug that screws in on top of the retaining pin
number 18 on the diagram
http://www.cmsnl.com/honda-rvf400rr-nc3 ... t/F12.html

if it is the actual pin, have you tried banging a torx bit into the rounded head

nah its not the slotted cover, its the head on the retaining pin where I believe a 5mm hex bit should go in. I'll try your suggestions.

I had to use a impact tool on my pin, loclite or somin was on it!

Probably just corrosion liz :) it's in a pretty good place for getting manky.

I had a similar battle with another bike, ended up cutting a chunk out of the pin itself to the pads could come off, then wrenching it out with a set of molegrips, hopefully hammering a Torx bit (as opposed to the allen bit it should have) wil jar it enough to loosen it, and give enough bite to undo it without resorting to (serious) violence.

yeh tried the torx bit suggestion but it didn't work so I went hammer time on the caliper and it came off (begrudgingly of course)...so I then took an angle grinder to the pin for some self satisfaction...now that it's off, I think an easy out should do the trick