As said - replace them.

Seriously, we are talking 10 dollars here lmao

 

I wouldn't replace these with "grade 8" bolts. These are meant to stretch a certain amount when installed. This stretching was engineered into the system, to provide for a properly tightened pulley.

The reason you can't re-use them is because stretching them is plastic deformation, or cold working the material. Cold working the material will increase, it's hardness, and reduce it's ductility. Basically, the material becomes more brittle. re-torquing the bolts will continue to cold work them, increasing brittlness, and increasing the likelyhood that they break.

 

So how common is it to have to remove the pulley and rotor each time a tire change is needed?

 

You should not have to remove the rotor and pulley to have the tire changed. Rotor and pulley don't even have to be changed to change bearings.

I have only removed mine once for powder coating.

 

What if it's the only way to get the wheel on and off. At least the rotor I'm thinking.

The Deuce caliper is garbage anyways. It's held on by the axle and a rubber piece in the bottom. I can't believe that's it. Plus fitment with the OEM wheel was terrible to where I could barely manage to get the caliper off since it was so big. Is there an after markey caliper I can buy that's smaller and fits better?

 

Every dealer is different. First dealer that replaced my tire, replaced the bolts. Second dealer didn't, told me first dealer was a crook. So I called the first dealer for an explanation. He told me they had a machine which required pulley removal earlier, but a newer machine they used now didn't.

If you read threads on here where the bolts sheared, you would spend the $10 for a critical fastener.

 

You should not need to remove the brake rotor, or the pulley from the rim to remove the rim from the bike..... I have a Fatboy not a duece, but I think the brake caliper, and wheel on both should mount the same way.

 

Swimming upstream on this one. Removed pulley bolts and reused them. Called PM Wheels and they said I could reuse their chrome bolts. red loctite em.

 

I reused my pulley and both rotors bolts when I changed my tires myself about 400mi ago. NOW I'M WORRIED!

 

$10 change them