SuzukiSavage.com - How do you get the front pulley off?

Skiprrdog YaBB Newbies Offline are we there yet? Posts: 46 Tucson, AZ Gender:	How do you get the front pulley off? 02/19/15 at 06:55:54 I was going to swap out the front pulley on my 2009 s40/Savage last week; got the nut off of it, but then could not get the pulley off the shaft. Do you guys use a puller to get them off?
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Serowbot

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OK.... so what's the
speed of dark?

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Re: How do you get the front pulley off?
Reply #1 - 02/19/15 at 07:07:02

I've never had to use a puller,... just tap tap tap, wiggle, etc... and penetrating oil...
...But,... if it's really rusted stuck,.. I suppose it might need a puller...

Hardest part for me was always getting the nut off...
Now I just use an impact wrench...

The fact that it is so hard,.. is probably a good sign... (the splines are still tight)...
Wink

...

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How do you get the front pulley off? Reply #2 - 02/19/15 at 07:14:08 Yeah, as many problems as we've seen, getting it off hasn't been one. Unless you're sure it's necessary to replace it, you do the math..
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Re: How do you get the front pulley off?
Reply #3 - 02/19/15 at 07:30:29

Why are you changing the pulley?

I have never heard of one wearing out....even Youzguys with more than 100,000 miles might still be running his original pulley. (He has replaced his belt).

If the existing pulley is good...leave it alone. Clean up the threads, apply some threadlocker, torque that sucker back down....and bend up the lock tab.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How do you get the front pulley off? Reply #4 - 02/19/15 at 08:42:42 If it's stuck,then something is corroded. Eliminating that would create a sloppy fit,most likely. Unless you have a REALLY good reason to get it off, .......
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: How do you get the front pulley off? Reply #5 - 02/19/15 at 09:03:53 The flanges are just sheet metal, don't use them to pull. find something to around behind to pull off. but unless you really need to replace something... leave it be. They are darned hard to get tight.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How do you get the front pulley off? Reply #6 - 02/19/15 at 12:03:58 And any less than All of the shafts diameter and All of the pulleys insides would not make for an ideal setup.
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Skiprrdog

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are we there yet?

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Re: How do you get the front pulley off?
Reply #7 - 02/19/15 at 18:18:49

Thanks for all of the replies, everybody. I have read on this forum about the issues with these pulleys, and taking it off is not something I would undertake lightly, but the PO (or the JBWeldKing, as I like to call him

) for some reason I cannot begin to fathom, has JB Weld *liberally* slathered on the outside of the pulley, on into the inside. Almost as if the outside flange just fell off, and he JB Welded it back on. I had the big nut off, and the splines on the shaft and the ID of the pulley look okay, so I don't immediately think the mountain of JB has anything to do with a spline issue. Ill take the cover off tomorrow morning and take a couple of pics and post them, maybe you have seen this before Cool

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How do you get the front pulley off? Reply #8 - 02/19/15 at 23:40:36 If it's ON and not chattering, if it's working, and you don't like it, I suggest leave it alone until IT demands attention.
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Re: How do you get the front pulley off?
Reply #9 - 02/20/15 at 06:58:59

If you need to get it off....then a puller is most likely necessary. Pulling on the outer flange may be how it got to the condition where it is now covered with JB Weld. If it was mine, and I had to get it off...and I didn't have a way to get a puller behind it - I suppose I would have to arc or mig weld some tabs or nuts on the pulley so I could attach a puller to it. A little heat may help - but there is a rubber seal behind the pulley and I would not want to use too much heat and bake the seal or start smoking the oil that is going to be on the shaft. (I would not want to stick anything behind the pulley and pry against the case...that sounds like a way to break even more stuff).

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How do you get the front pulley off? Reply #10 - 02/20/15 at 09:01:22 Skip skipped..
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: How do you get the front pulley off? Reply #11 - 02/20/15 at 11:41:34 justin_o_guy2 wrote on 02/20/15 at 09:01:22: Skip skipped.. Skip skips occasionally.....he'll come back!
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