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When I apply the front brake and push down on the forks I hear and feel a faint clicking. Turns out its the caliper. The caliper has two halves held together with two pins and one of them has some "play" in it that rocks back and forth as the forks are compressed with the front brake locked-up. Its the pin/bushing that has a 12 mm hex nut. The hex is tight against the caliper housing and I'm wondering if this clicking-free play is normal or the pin/bushing is worn out?

I say it is normal. Seems like mine did that, too.

If they work all right, I wouldn't worry about it

1 make sure you pads are not completely gone
2 check the pins, they maybe slightly grooved, the pads won't release properly, might be your issue there. replace them they're cheap insurance if you have any doubt.
By the way, "two halves held together with two pins" it's your brake pads held with the pins
your caliper (the whole unit) should move side to side by hand, you can clean the assembly and grease it. It's a good opportunity to give it a good cleaning and remove any junk that could be trapped around the piston too.

Not to mention the rotor is a split design... most people hear the two half coming together....

Indawoods wrote:Not to mention the rotor is a split design... most people hear the two half coming together....

+1

The pads and the pins that go thru them are new. The caliper has two halves and I can flex them because one of the bushings that the two halves are held together with has a little "play.". One of these bushings has a 12 mm hex nut built into it and that's the one that wiggles. These bushings have rubber boots and they allow the two halves to slide which is how the pads tighten on the rotor. There needs to be some play, but when I checked my ktm's caliper it was solid.