Boost here.. Badnit showed me the post.

While I don't have the Intense puller..it'* nearly the exact same thing. When you pull the pulley, you use the NON threaded insert to center the puller. This may be why Paul has broken pieces each time he pulls a pulley and my puller has pulled 10 or more without a problem.

When you are putting the new pulley on you use the threaded insert, it pulls the pulley onto the nosedrive shaft. Thinking to how the pulley gets pulled, you are turning the puller shaft which is pushing against the nosedrive shaft, the nosedrive shaft needs to stay motionless for this to work properly and if you've threaded that piece in....you'll be turning the shaft and pulley while applying an amazing amount of force to the pulley and that threaded piece.

I don't believe that the breakage being seen by Paul and Hans is puller related at all, I believe it is probably a slightly incorrect method being applied to pull the pulleys. Use the non threaded insert to pull and the threaded insert to push the new pulley/hub onto the nosedrive shaft.

Boost

Drilling the hole through it wasn't working?

I checked in Intense site..it doesn't mention a non threaded piece although.... It seems to me that it would be necessary.

hey um bill...THE WHOLE STUD IS THREADED, I DONT HAVE THE ZZP PULLER..

I have used this puller to pull three times before with no problems until I pulled the Gen V pulley.
There is no non threaded insert. Never was. The kit came with two spare threaded inserts incase one broke. It is common for them to break if they are allowed to rotate at all during the removal process.
Remember at WCBF05 when we pulled Shadd'* original pulley off and the threaded insert pulled out the threads of the SC shaft.

That may be a good solution to allow centering using a non threaded dowel when removing a pulley.

In similar situations, when I needed some good bite on a small piece like that, I've used a small pipe wrench. Everything else will slip. That will bite right into the metal.

what are you talking about? i HAVE NOT tried to drill it out for fear of having it break off inside.

the puller was used per the instructions.

Well, if you can't get it out, you gotta buy a new one anyway, right? Then you gotta go with the way most likely to get it out. And since it is more or less round now, you're gonna have to do something to the portion that is sticking out to get a better grip on it.

weld the vice grips to it then hope like hell they dont slip anymore.

you will be - one set of vicegrips but also - one stud

He'* broken two vice-grips as of yesterday on this problem.

My advice via phone yesterday was to replace the nosedrive with a rebuilt one anyway. He'* got MANY miles on that. 170,000 IIRC.