Several of you have stories about how difficult it is - after a crash - to remove the threaded part of the lower Jesus bolt from the hub. Some have replaced this bolt with a longer bolt and nut. Anyone who has stripped the threads in their Muscle Pipe muffler are familiar with this add-a-nut strategy. I’ve decided to document this mod with a description and a few photos.
First, disassemble the parts and drill out the threaded part of the T/R Pulley Hub with a 1/16” drill bit. This allows a standard 2M bolt to be used. You are going to replace the stock M2x12 bolt (130-041) with an M2x14. You’ll notice that there is insufficient room for a nut because one of the five M2x4 bolts (130-035) that hold the T/R Pulley Hub to the Plastic Drive Pulley is in the way. Get out the Dremel tool and cutoff wheel and make some room for that nut by grinding a flat on the T/R Pulley Hub (130-180). In addition to providing the clearance, it provides a flat bearing surface to snug the nut up against. See the photo – remove about 2mm of material.
You will also need to remove some material off the Plastic Drive Pulley (130-185) to provide clearance for the nut. Do all the Dremel work prior to assembling the T/R Pulley Hub to the Plastic Drive Pulley. Proceed with the assembly of these parts as in the manual (Pg 27 step 2C.1.p) but instead of the 2Mx12 bolt, use a 2Mx14, apply blue Loctite and install the nut. I didn’t use a washer. Not too tight – snug is fine.
This mod should save the T/R Pulley Hub in the event of a rebuild where the lower Jesus bolt is sheared off, as you will not need to struggle to remove a threaded section per the original design. Hope it works for you.
Rap 903D, Rap50s, T-RexSE, MA Furion, JRx9303