Pulley Mod Problem

[99ISrdr]

I'm working on the tensioner pulley mod. I've got the Gates Pulleys and fasteners, but having a tough time getting the backing plate off the OEM tensioner. I've drilled it with a 1/2" bit at least 1/8" in, got a pry bar in there and it's not budging. Just tried punching it out. I can't get the grinder cutting wheel down to the shaft. Maybe I'm missing some kind of trick or something here. Any suggestions before I just say screw it and order two new OEM pulleys at a ransom's price compared to the gates. Any suggestions would be very much appreciated. Thanks

Update: Just bent the backing plate trying to pry it off again. From what I read I didn't expect the plate to bend. Oh well...I guess new OEM tensioners it is.

[-mike-]

Hm.. I have no prob drilling them out. I use a 10mm  metal drill in a drill press and get the old pulley bolts out easily.
The OEM bolt is 10mm dia, too, so drilling deeper without damaging the plate is possible.
I then use a countersink drill bit to finish the hole before putting the new bolt in.

see for pics:
https://www.valkyrieriders.de/site/forum/index.php?thread/44803-original-spannrollen-ersetzen/

-mike-

Edit: I've read of your bent plate ... maybe one of our fellows here can provide you with another one for free.

[99ISrdr]

Thanks for the info Mike. I was denied access to the site's pics, but it seems you just drilled it out. I read to drill about 1/8" in then finish with a pry or punch. Maybe I could have just drilled it out on it's own.

Greg

[John Schmidt]

There's enough room to get a hacksaw blade in between the back of the pullet and the mount. I just used that and cut it off, took a while but got it cut enough so I could pry it off the rest of the way.

[99ISrdr]

There's enough room to get a hacksaw blade in between the back of the pullet and the mount. I just used that and cut it off, took a while but got it cut enough so I could pry it off the rest of the way.

I wasn't as lucky with the prying. I'm working on the other one, to possibly save me from having to get two. I don't have a good hacksaw blade around here. That may be my last resort. Thanks for the suggestion.

[Avanti]

The piece that is bent is supposed to be flat; make it flat again.

[99ISrdr]

The piece that is bent is supposed to be flat; make it flat again.

You're right about that. If I ever get that pulley out of there I'll give it a go.

[-mike-]

Sorry, I forgot you have to be registered with your VRCC number to see the content.

Just 2 pics from the whole instructions page:

Drilled out plate with new pulley:


Assembled:

I've started an exchange service for our VRCC branch in Germany - there's always a modded set ready on the shelf. I send it out for a fellow in need who sends me back his worn out pulleys after service. Just for parts cost plus shipping. Wouldn't be financially efficient shipping overseas, though.

-mike-

[99ISrdr]

Sorry, I forgot you have to be registered with your VRCC number to see the content.

Just 2 pics from the whole instructions page:

Drilled out plate with new pulley:


Assembled:

I've started an exchange service for our VRCC branch in Germany - there's always a modded set ready on the shelf. I send it out for a fellow in need who sends me back his worn out pulleys after service. Just for parts cost plus shipping. Wouldn't be financially efficient shipping overseas, though.

-mike-

Thanks for the pics. That's a great service you're doing for fellow Valkers over there. It's too bad, but you're right...it wouldn't be feasible for me. I'm going to work on the other pulley today and see where it gets me.

[RonW]

The backing plate is just preened to the tensioner pulley. And you can't ground off the flare with a ½-inch drill bit drilled ⅛-inch deep? A ½-inch drill bit is 12.7 mm.
Mike said the OEM bolt is 10mm dia. so a ½-inch drill should eliminate the flare. I think. True, it's just not so in your case. Are you able to post some pics?

[99ISrdr]

The backing plate is just preened to the tensioner pulley. And you can't ground off the flare with a ½-inch drill bit drilled ⅛-inch deep? A ½-inch drill bit is 12.7 mm.
Mike said the OEM bolt is 10mm dia. so a ½-inch drill should eliminate the flare. I think. True, it's just not so in your case. Are you able to post some pics?






I must be doing something wrong. I've drilled it with a 1/2" bit deeper than 1/8", put a recip saw to it, punched it(with a punch that is), and the only thing I've accomplished, outside of bending the backing plate, is to dislodge the two stamped pieces and scar up the backing plate with the recip. Frustrating b/c everyone seems to say what an easy mod. At this point I think it's a white flag for me and to shell out the bucks for a couple new OEMs. Well...if nothing else it forced me to HF for a couple new tools that I'll have now.

[RonW]

I must be doing something wrong. I've drilled it with a 1/2" bit deeper than 1/8", put a recip saw to it, punched it(with a punch that is) .....

Everybody's been there with something or another.

[99ISrdr]

Finally got the plate off and mounted the new pulley. These pulleys roll smoothly but have drag and don't spin freely like the OEMs. Just making sure that's correct?

[Ken aka Oil Burner]

As long as the pulley itself isn't making contact with the mounting plate and causing the drag, you should be good. The new pulleys still have fully-packed fresh grease in the bearings. The old pulleys had worn-in that grease a long time ago, so they have less drag.

[99ISrdr]

As long as the pulley itself isn't making contact with the mounting plate and causing the drag, you should be good. The new pulleys still have fully-packed fresh grease in the bearings. The old pulleys had worn-in that grease a long time ago, so they have less drag.

I bent the plate prying off the OEM and scarred it up pretty good with the recip saw. I  got it straightened out in the vise and cleaned it up a bit with a grinding wheel and the pulley's free of the plate. So, like you said, it's probably the packed grease then. Thanks for the info.