- Pulley Replacement Kit:
- 2 x Pulley Set Screws
- Drive Belt
- Thread Lock
Tools and Materials:
- 3mm Allen T-Handle
- Skate T-Tool
- 2mm Allen T-Handle
- Heat Gun (or Hair Dryer)
- Oven Mitt
Use the Skate T-Tool to remove the axle nut and outer speed washer.
Pull off the Drive Wheel away from the drive train. If they get stuck pull the drive wheel spacer and flanged bearing off as well. Put to the side. One speed washer should remain on the axle.
Use the 3mm Allen T-Handle to remove the two screws holding on the belt cover. Put the belt cover and screws to the side.
Remove the belt put it to the side.
Plug in the heat gun. Hold the heat gun 1”-2” from the pulley, and heat it for up to 120 seconds.
Use the 2mm Allen T-Handle to remove the two screws holding the pulley onto the motor axle. Put the two screws to the side.
CAUTION: Pulley will be hot!
Heat the pulley for an additional 60-120 seconds.
Once the glue holding on the pulley is thoroughly heated and deactivated, use the over mitt to pull it off. Be careful it will be very hot! Put the pulley to the side.
Wait 60 seconds while the axle cools.
Orient your motor axle pointing up. Place the new pulley onto the motor axle with one screw hole pointing up (aligned with the flat spot) and the other screw hole pointing away from the truck hanger axle (where the drive wheel goes).
Push the pulley onto the axle until the inner edge aligns with the end of the flat spot. If correctly placed the pulley will hang slightly over the motor axle.
Grab the new pulley set screws. Put a drop of thread lock onto the threads of one of the pulley set screws. Use the 2mm Allen T-Handle to insert and tighten. Repeat for the second screw.
Note: Be careful not to strip the screw heads. Tighten securely, but do not over-tighten.
You should not have to force these screws in. If they are not going in easily then they are likely not aligned properly. If they are getting jammed before they reach the bottom, back them out, adjust, and tighten again.
Replace the drive belt.
Use the 3mm Allen T-Handle to replace the screws securing the belt cover. Put a drop of thread lock onto the threads near the end of each screw.
Note: Do not over-tighten the screws
Replace the drive wheel. Install the rear wheel spacer (taller than the front wheel spacer) and then the flanged bearing.
Make sure this flanged bearing is pushed all the way in and is sitting flush.
Make sure the inner speed washer is present.
Slide the whole wheel assembly onto the axle. You may need to twist the wheel while pushing to get the drive gear teeth to catch the belt.
Make sure the drive wheel teeth properly catch the belt.
Install the outer speed washer, then the wheel nut.
Use the Skate T-Tool to tighten the wheel nut. Tighten it to the point where there is no horizontal play.