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Tern GSD Pulley — image 1
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Tern GSD Pulley

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Three part Tern GSD replacement pulley

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Front side is notched to allow for the chain to pass in/out while the pulley is screwed in, so you can put the chain on/off the pulley while the pulley is installed.

Sides printed at 100% in ASA. Center core printed in TPU.
I've done about 100 miles on mine and it continues to look good.

Improvements:

  1. Notched front face so chain can be inserted/removed while pulley is installed
  2. Covering more of the bearing face and allow for waterproof grease at the face
  3. Reprint at home



Instructions:

  1. Use original Tern bearings, clean them so they spin nicely. You want to use the originals because they seem to be a tighter tolerance to allow it to bind with the post for spinning. I haven't found 608 bearings that don't end up spinning on the shaft rather than spinning on the bearing. Tern has a smaller ID somehow on the bearings they supply so it binds but also allows it to slide.
  2. Put waterproof grease in each side of the bearing pocket. I use Phil Wood.
  3. Press fit the bearings into each side using a flat faced wrench/plier or mallet.
  4. (Optional) Apply CA glue on the OD of the center sleeve. 
  5. Press fit the entire assembly together, you should see the two inner faces meet when fully pressed
  6. Attach to bike without chain passing
  7. Pass chain into notch
  8. Ride

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