We bought a used Mini R53 S that had the Alta lightened 2% crank pulley installed already.

The front main seal started leaking so we removed the pulley to install a new main seal.
When we removed it, we found that the inside edge has a burr on it.

Does anyone know if this is normal for Alta pulleys, and whether it's safe to reinstall
(or should we, as a minimum file off the burr)?

Thanks!

 

That is most certainly not normal. To me ,looking at that bur and the condition of the bore on the pulley, it appears to have been spinning on the crank snout. What does the snout, that pulley was installed on, look like? I would say they pulley and crank shaft need thorough inspection. I would also go as far as to say the pulley is most likely no good in it's current condition. You could possibly have a machine shop over bore it and install a sleeve but that would probably cost more than just buying a new one.

I will say though that I have limited experience on the mini as I am a new owner but I have many years experience on other cars.

 

Thanks. Yea, that's my thinking as well after examining the bore of the pulley further. It seems like it wasn't tightened down properly and so was spinning/wobbling on the crank snout.
The good news, I suppose, is that since the Alta pulley is made of aluminum, the pulley took the brunt of the damage, and the crank snout seems like it's in pretty good shape still.