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I have had a terrible time trying to get my timing belts done. The back plastic covers could not be removed because the brass inserts were free spinning. I finally had to break/melt one out and epoxy it back in. I hit the plastic with my Dremel tool to clean it up before I ran the epoxy and I accidentally nicked my timing belt roller. It isn't bad, but I want to know if it is safe to still use, or should I replace the whole gear?

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Sounds like a frustrating day at the office!
If it were me, I'd just be sure to file/polish down the tooth that you nicked so that there isn't a sharp edge that might accelerate belt wear - or lead to failure.
But other than that, it looks like there is more than enough 'tooth' there for the belt to run on. I'd feel comfortable running it.
 

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Sounds like a frustrating day at the office!
If it were me, I'd just be sure to file/polish down the tooth that you nicked so that there isn't a sharp edge that might accelerate belt wear - or lead to failure.
But other than that, it looks like there is more than enough 'tooth' there for the belt to run on. I'd feel comfortable running it.
I tend to agree. If you file, debur, and maybe even use a fine steel wool to polish it smooth, I just can’t see how that missing bit of the tooth will affect the belt.

However, if it was my bike, I’d just change the pulley. I’d drive myself nuts worrying about it, and the cost of the pulley is so small compared to the belt snapping and the engine piling up.
 

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I tend to agree. If you file, debur, and maybe even use a fine steel wool to polish it smooth, I just can’t see how that missing bit of the tooth will affect the belt.

However, if it was my bike, I’d just change the pulley. I’d drive myself nuts worrying about it, and the cost of the pulley is so small compared to the belt snapping and the engine piling up.
Yes yes and Yes, Yes it will be ok, yes remove any bur and make smooth, and yes it would drive me nuts till i replaced it,
 
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