Sheared Off Rear Pulley Bolts
Tourer
Joined: Feb 2011
Posts: 351
Likes: 2
.
.
.
I don't remember now.
.
.
.
.
.
.
maybe try the telephone.
.... http://arp-bolts.com/
1 800 826 3045
if you download their catalog it is way easier to navigate
pages 10 - 24 are well worth the read.
and from Smokey Yunick on page 98..
.
.
I don't remember now.
.
.
.
.
.
.
maybe try the telephone.
.... http://arp-bolts.com/
1 800 826 3045
if you download their catalog it is way easier to navigate
pages 10 - 24 are well worth the read.
and from Smokey Yunick on page 98..
Road Master
Joined: Jul 2010
Posts: 822
Likes: 0
And lets not forget a new pulley - hard to believe anyone would suggest reusing that wheel, repairing it will only be a band aid until the next time it fails (much sooner) which could hurt (or worse) if it happens at the wrong moment - both the wheel and the pulley belong in the scrap pile.
Tourer
Joined: Feb 2011
Posts: 351
Likes: 2
And lets not forget a new pulley - hard to believe anyone would suggest reusing that wheel, repairing it will only be a band aid until the next time it fails (much sooner) which could hurt (or worse) if it happens at the wrong moment - both the wheel and the pulley belong in the scrap pile.
Elite HDF Member
Joined: Apr 2010
Posts: 4,990
Likes: 9
From: Marina del Rey
The bores where the un-threaded portions of the bolts register have been buggered and are out of tolerance, now; no amount of Heli-Coil-ing will fix that. It can be Mickey Mouse'd but should be replaced.
Tourer
Joined: Feb 2011
Posts: 351
Likes: 2
Actually, if you reamed two of the counter bores and two of the pulley bores to fit locating dowels like those on a bell housing you might solve the problem.
Last edited by dynabobster; Jul 15, 2012 at 02:35 PM.
Elite HDF Member
Joined: Apr 2010
Posts: 4,990
Likes: 9
From: Marina del Rey
It has absolutely nothing to do w/ the Heli-Coil. The un-threaded portion of the bolts should bear directly on the un-threaded portion of the hole, which it can no longer do because the holes are no longer round.
This falls under the heading: Mickey Mouse-ing.
This falls under the heading: Mickey Mouse-ing.
Last edited by lo-rider; Jul 15, 2012 at 02:40 PM.
Tourer
Joined: Feb 2011
Posts: 351
Likes: 2
The counter bore is larger than the major diameter of the thread and the factory bolts have no shoulder and even the shoulder on the bolt that is pictured is smaller in diameter than the counter bore in the hub, so, there in lies the problem from the start!
And I have not found a bolt that has a shoulder that will fully engage the counter bore and also not bottom out in the hub before it is properly torqued.
In my opinion, It is the shearing action from the torque on the pulley, precisely because the bolt is NOT supported in the counter bore, that causes these to fail. Especially if the installation is half assed.
If you know what your are doing and know the proper procedures for the removal of broken fasteners and thread repair then the repair I recommended is no worse than it was coming from the factory and I would stand behind the repair for myself and I would not do anything that would put myself or anyone else in harms way.
That said, it is also my opinion that the best solution would be a stud installed into the hub that has a shoulder that engages both the counter bore of the hub and the bolt hole on the pulley.
This falls under the heading: Mickey Mouse-ing.
Elite HDF Member
Joined: Apr 2010
Posts: 4,990
Likes: 9
From: Marina del Rey
The Heli-Coil is well established for thread repair in many cases including this one. But unless the bolts shoulders take the shear loads, it will just fail again.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Cruiser
Joined: Nov 2011
Posts: 176
Likes: 0
From: Berkeley, CA
I am in agreement w/ dynabobbster...
I've pondered this one a lot...why is the counter-bore a generous clearance hole. This condition also exists @ the upper shock bolt (I've sheared this one once). The support solution for each would be a sleeve sized correctly.
Specific to sheared pulley bolts, I'm in the camp that riding style likely plays a part. Throwing big shifts, and even more importantly, blowing big downshifts puts a lot of force on the pulley. This is the stuff that can scissor cranks, too.
I've pondered this one a lot...why is the counter-bore a generous clearance hole. This condition also exists @ the upper shock bolt (I've sheared this one once). The support solution for each would be a sleeve sized correctly.
Specific to sheared pulley bolts, I'm in the camp that riding style likely plays a part. Throwing big shifts, and even more importantly, blowing big downshifts puts a lot of force on the pulley. This is the stuff that can scissor cranks, too.
Tourer
Joined: Feb 2011
Posts: 351
Likes: 2
Again, I have never had a problem with the OEM bolts and I have swapped them out several times.
Never the less, I do see something that I feel can contribute to this problem and that is the point you are raising and it is an inherent flaw in the design, at least in my opinion.
If you look at the way the hub is machined you would think, at least I do, it was machined for a stud and I think that would be the ideal solution.