1990 EZ-GO Starter Generator Removal

[kgfalter]

I have a 1990 EZ-GO Marathon 2-cycle gas engine model. The starter generator needs to be replaced. I followed the removal instructions, but the Pivot bolt is stuck and will not come out. This is the version that the pivot bolt has a stop attached to the end to prevent rotation. It says to use a large screw driver to pry the pivot bolt out after removing the nut, but as I said, it won't budge... Any ideas?

[shadowman]

welcome to BGW........have you tried threading the nut back on and tapping it with a hammer to break it loose? not sure what kind of room you have but even if you can get a punch on it and just a few good taps......................

[kgfalter]

Thanks shadowman. I did try that with a punch, but it's pretty stuck. Only 3 - 4 inches of room inside the frame, so luckily there was a hole in the frame that almost lines up with the bolt. It must be rusted in place. I picked up a 3/4" x 18" steel spike that I am going to try to hit with a sledge and see if that will do the trick..........

[madoc1]

kg that is what that hole for i think. at least i used it. spray it with pb blaster or other solution and let sit over nite. it will work. good luck!

[BrewCityMusic]

gutter nail for me, LOL ... Definitely use the PB, miracle stuff!

[shadowman]

Originally Posted by BrewCityMusic

gutter nail for me, LOL ... Definitely use the PB, miracle stuff!

on the PB blaster i never leave home without it....................

[ScooterMcTavish]

If you can get a replacement, you could always dremel the bolt in the middle, then wiggle it out.

PB is miracle stuff though.

[kgfalter]

Finally got around to trying out all the suggestions. In the end, I had to use my grinder to cut the bolt head off and cut off the bracket on the old starter/generator. Once I did this, I was able to spray more PB Blaster in that end of the bolt. The bolt ended up A couple good wacks with the sledge hammer on my 24" steel rod and she broke free. I'll have to admit, PB Blaster is amazing stuff because that bolt was rusted in there pretty good!

Got the new starter/generator installed and am doing a few more renovations while it's all apart. I'll post some pictures of my cart once I get it put back together.

Thanks again for all the great advice!