Last week when Jaime and I replaced a broken belt on the SC, I wanted to swap out my 3.33 pulley for a 3.125 I just got. Long story short, the previous shop that did the install airgunned the allen bolt holding the pulley on and it stripped out when Jaime tried to remove it. So exactly how do I get the bolt off? Just take it to a shop and have them drill it out? if it were just an exhaust stud or something easy like that, no problem, but I'm guessing this one is kind of delicate. Thanks.

 

Okay, this is sort of my territory I have good azz experience in. Now if it aint completely rounded then you still in luck, if it is completely rounded inside, you still might be in luck.

What I did on my bike when this happened on the frame slider allen bolt (big bolt) is I took the allen set and got one that just barely would fit. I essentially banged it in there and then got it loose. You have to be patient. Just fine the allen that is about 1-2 sizes up and just big enough that you can bang it in and get enough grip to tear it loose. I would start off bigger first, if it dont fit, go one step down.

Key is getting it right the first time, if not, then you will really screw it up.

If you cant find allens that fit or end up steping in sizes that or too big in increments, take the smaller one and wrap it in masking tape. Put a good load on it and get it in there, and then try it. Once you fill up the "space" created by the stripped internal, the masking tape acts as a force while turning.

Believe me, sounds ghetto, but works. Drilling it out is too hardcore since it requires alot of work and right tools.

Dixit