Strange Problem w/Rear Brake Pedal Shaft

[Ohio Mike]

The PO of my 01 had installed homebrew floorboards with a decent heel & toe shifter (also homebrew) and a poorly modified rear brake pedal. It looks like the arm had been cut and rewelded to move it closer to the frame and that is where the problem lies. It rubs on the foot peg bracket and hangs up, along with not letting you get full rear brake - not good. Decided to eliminate them so next owner (when I finally find one) will not have to deal with them - they can put them back on if they want.

Anyhow, when I pulled the bolt out of the brake pedal, the shaft sucked back thru the plate far enough that I cannot get the bolt back into the groove to secure the pedal. Anyone seen this before? If so, how did you get the shaft back out to the correct distance? I suspect there may be something broken or missing in the assy but am clueless beyond the suspicion that there is more to the problem. The full force of that big return spring is trying to pull the pin back out of the plate! We (3 of us - 2 on the right and 1 on the left) fixed the problem once before but it took all 3 of us and none of us remember what the secret was, other than brute force and awkwardness, luck, and desperation!

Any help or ideas greatly appreciated.

Ohio Mike

[Mr Jensee]

Mike, contact Carl Leo the voyager guru who posts here from time to time. He has worked on Voyagers for a ton of years and has encountered about every problem posted. You can reach him by emailing a copy of this post to Voyagerparts@bellsouth.net. Leave your phone number and he can call you back.

[Bill O]

The PO of my 01 had installed homebrew floorboards with a decent heel & toe shifter (also homebrew) and a poorly modified rear brake pedal. It looks like the arm had been cut and rewelded to move it closer to the frame and that is where the problem lies. It rubs on the foot peg bracket and hangs up, along with not letting you get full rear brake - not good. Decided to eliminate them so next owner (when I finally find one) will not have to deal with them - they can put them back on if they want.

Anyhow, when I pulled the bolt out of the brake pedal, the shaft sucked back thru the plate far enough that I cannot get the bolt back into the groove to secure the pedal. Anyone seen this before? If so, how did you get the shaft back out to the correct distance? I suspect there may be something broken or missing in the assy but am clueless beyond the suspicion that there is more to the problem. The full force of that big return spring is trying to pull the pin back out of the plate! We (3 of us - 2 on the right and 1 on the left) fixed the problem once before but it took all 3 of us and none of us remember what the secret was, other than brute force and awkwardness, luck, and desperation!

Any help or ideas greatly appreciated.

Ohio Mike

Mike,
This has happened to me many times. When the bolt is removed, the peg can recess into the frame and then the large return spring behind the frame can drop a winding between the pegs lever and the frame not allowing the peg to fully extend out for the brake lever. Sometimes with a large screwdriver you can get under there and work the spring winding back into position. I find it easier to remove the whole rear brake assy plat from the bike so I can get better access to the return spring. It really is a pain, but when you look, you see what I mean.

Bill O

[Ohio Mike]

Thanks Bill. I never gave that angle a thought. Sooo, how do you keep it from snapping right back into that situation while you put the arm back on (assuming you can put the assy back in place with the brake pedal already on)?

Ohio Mike

[Bill O]

Thanks Bill. I never gave that angle a thought. Sooo, how do you keep it from snapping right back into that situation while you put the arm back on (assuming you can put the assy back in place with the brake pedal already on)?

Ohio Mike

After I get the spring back in place, I use a very large screw driver under the frame to hold the brake pedal shaft tight against the frame while I press the brake pedal arm back onto the peg.

Once you've done it, you'll remember the next time you need to take the brake pedal off.. Lesson learned!

Bill O

[roadkingrich]

Ha! I took that fixture off 7 or 8 times last weekend! Just about the time I slowly and carefully put it back in place, the spline would suck in or the return spring would pop out!! After cussing loud enough for the neighbors to hear and taking a break, I went back at it and managed to keep the spline in place. The small fragile brake light spring can be an issue. I'm still trying to get more brake due to installing floorboards. Maybe I'll get at it again on my day off. I did buy a new rotor and waiting on new pads.

[krasmu]

I"m guessing the PO of my bike had the same issue. I've noticed that somebody has drilled a second notch in line where the new pedal position is now, with what I believe is the same issue with the spring winding you have. I've heard it's a bear to fix so I just have not taken the time to tackle it yet.