I found 2 of my pulleys to be tight on one side and fine on the other. Initially I filed off the cut-off burr that had increased the diameter of the shaft marginally and that allowed me to slide the pulley on. However, on the shaft ~0.5mm away from the chamfer to the main body, it became too tight to slide any further by hand. I’m not sure whether it was down to worn tooling (though there was also some stepping on the chamfer) that meant it was slightly larger in diameter but the work around I used was to press fit the bearing to the shaft with a small g-clamp. Take note that in doing so, the shaft and the bearing may not be co-axial if you’re not careful.
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I found 2 of my pulleys to be tight on one side and fine on the other. Initially I filed off the cut-off burr that had increased the diameter of the shaft marginally and that allowed me to slide the pulley on. However, on the shaft ~0.5mm away from the chamfer to the main body, it became too tight to slide any further by hand. I’m not sure whether it was down to worn tooling (though there was also some stepping on the chamfer) that meant it was slightly larger in diameter but the work around I used was to press fit the bearing to the shaft with a small g-clamp. Take note that in doing so, the shaft and the bearing may not be co-axial if you’re not careful.