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"Adding a spacer will change the pulley to belt alignment" The spacer goes under the head of the bolt, like a washer.

And increasing the grip lengths will prevent that breakage.

"You really don't want to use a spacer and a longer stud as it will put more load on the stud due to leverage on the stud at the base (cantilevered)." This is wrong. Increasing grip lengths increases the resilience of the connection. Adding spacers to problem joints will reduce loosening and...

I don't mean to thread them in the hole deeper. Put a spacer under the head of a longer bolt like a washer.

If you have room, put a spacer under the head of the bolt and use a longer bolt. This will solve most breakage problems. Longer grip lengths make for tougher connections. If you want a stronger bolt, metric socket head cap screws are available in class 12.9. If you want to use high strength...