Broken brake return spring, bolt won't remove

[Wvbuzzmaster]

I need some help with replacing the brake pedal return spring on my Yamaha G1. (could be later G model pedal) I took the nut off the pivot bolt, but the bolt won't remove. I clamped the assembly in a big vise and beat the bolt senseless with a big hammer. The threads are now smashed, and the bolt has not budged yet. What am I missing in this disassembly struggle?

[cgtech]

Missing all the rust you cant see inside the assembly. Its a fairly common thing for them to be stubborn, but you dont usually have to beat the crap out of it. Does the bolt spin at all, or completely seized? Might have to cut the threads and bolt head off, drill a little, get the pedal out of the assembly, then continue your assault.

[Wvbuzzmaster]

Pedal pivots, but not on the bolt. The bolt pivots in the bracket holes, but does not spin in the pedal. Is heating the pedal with a torch to continue beating the crap out of the bolt an option that will not ruin the pedal?

[Mike Mac]

The bolt goes through a sleeve, then the sleeve goes through the brake pedal arm. You may have to cut the head of the bolt off to get the pedal assembly out of the frame. Then I would use some kind of penatrent to loosen the frozen parts over nite.

I think that is a special bolt that goes there, maybe cgtech can help with a part # to get new from Yamaha.

Then on reassembly, use "anti seize" on all parts there!!

[Mike Mac]

This may help!!

[panteramatt]

Originally Posted by Wvbuzzmaster

Pedal pivots, but not on the bolt. The bolt pivots in the bracket holes, but does not spin in the pedal. Is heating the pedal with a torch to continue beating the crap out of the bolt an option that will not ruin the pedal?

YES!!! I just went through the same thing. The bolt head actually broke off mine. I got the pedal out, put it in a vise, heated the pedal really good and used a punch and a sledge to get the bolt out.

[panteramatt]

Oh and mine just has 2 steel bushings inside. What I did is went a bought a 14mm bolt that slides right into the bushings, drilled the pedal mount for the larger bolt and used antisieze.

[tbortiz03]

video on how to change a brake torsion spring on a g19 yamaha golf cart

[CAMPERCART2013]

Originally Posted by Mike Mac

The bolt goes through a sleeve, then the sleeve goes through the brake pedal arm. You may have to cut the head of the bolt off to get the pedal assembly out of the frame. Then I would use some kind of penatrent to loosen the frozen parts over nite.

I think that is a special bolt that goes there, maybe cgtech can help with a part # to get new from Yamaha.

Then on reassembly, use "anti seize" on all parts there!!

Nice vintage can Mac

[smallblock450sl]

I'm going to ad something I saw on "Cuban Chrome" tv show. With the pedal in the vise, use a torch to get it red hot....imediatly pour cold water on it...then hit it with a hammer/punch! I have used this method several times and it is amazing how it works PS, this does not work well with rubber bushings!