I discovered the brake pedal was 100% solid, like a footpeg, thought maybe it was rusted up? So, soaked it in penetrating oil 3 days, then acetone & ATF 2 weeks, beat on it until I had to fix the splines again, not a hint of rotation. Heated the casting: nothing. Tried drilling into the body so as to add a hole for oil and/or later a grease zerk: could not drill to the shaft, hit something real hard.
What to do?
Went to my friendly local 100 ton hydraulic press, presuming it would destroy the casting, closed my eyes and pressed the button, and the pedal shaft with its captured steel sleeve slid slowly out of the casting intact.
It was completely rusted onto the shaft, being steel-on-steel (like the current Honda swingarm bushings and their collars
) with no way of lubing it unless you annually remove the pedal and grease it yourself. Sheesh!
So, I cut away the old sleeve, made new bronze bushings (dimensions shown in the pictures below) and pressed those in, tapped the pilot hole I had tried for a grease zerk, then spun the pedal shaft and polished the rust off until it fit the installed bushings with 0.001" clearance. Works perfectly, and with a grease fitting, will outlast the engine!
