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Discussion Starter #1
I have a Kohler Magnum twin with a really stuck pulley on the crankshaft. I got the pulley to move about 2" on the shaft, and I have about 1" more to go. I can't use a puller because the pulley is too flimsy and bends easily, and the method of using a flatbar and a hammer is no longer working at this point. I can't think of anything else to try :banghead3
 

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Hope you have not deformed the end of the crank by beating on it with a hammer. That's one sure way of locking pulleys on a shaft and no puller out there will remedy that. May be a good time to clean the crank up before proceeding farther.
 

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Discussion Starter #4
Hope you have not deformed the end of the crank by beating on it with a hammer. That's one sure way of locking pulleys on a shaft and no puller out there will remedy that. May be a good time to clean the crank up before proceeding farther.
I can't really clean it before I keep going, there's only like 1/2" or less of the shaft exposed at this point. Also I have not been beating on the shaft so that should be fine. I'm still kicking myself for not cleaning the shaft before I started pulling it off :bonk:
 

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Try cleaning the shaft behind the pulley and pushing it back on a little bit...then clean the forward part...use very fine sandpaper or emory cloth to do it and try some heat on the pulley ( not the shaft)...if it does not work try pushing back on and just put a 50/50 mix of acetone and ATF on it and let it soak...overnight or for a few days if necessary....Bearing separators are kind of expensive but work well and you can make one if you can do a little welding...I made one by taking a piece of steel about 8" by 8" and drilled a hole in the center about an eighth of an inch bigger than the shaft ..I then welded 3/8 inch pipe about 1/2 inch in from each end, parallel to each other on the same face of the steel...then I cut the whole thing in half, perpendicular to how I had the pipe attached...right through the center of the hole I had drilled with a saw hole cutter for the shaft...I placed each piece behind the gear I was pulling I then got threaded rod and passed it through the pipe and used nuts at each end to hold it together behind the gear...then I lined up my flywheel puller and drilled holes in each piece of steel for the puller bolts ( I used nuts n hem...I did not thread the holes as you would find on a flywheel) and got it off that way...primitive, but cheap and it worked
 

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Heat the part of the pulley on the shaft with a MAPP torch and then apply some candle wax where the shaft protrudes from the pulley. See the video on utube. You can then Punch or pry the pulley off the shaft. I do this all the time and seems to work every time. Yesterday I did this to remove a fan blade from a condenser motor that had been exposed to the elements for 15 years.
PREVIEW
7:41
Remove a stuck transaxle pulley in less then 5 minutes WAX
YouTube · RedneckComputerGeek
May 2, 2013
 

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Discussion Starter #7
Try cleaning the shaft behind the pulley and pushing it back on a little bit...then clean the forward part...use very fine sandpaper or emory cloth to do it and try some heat on the pulley ( not the shaft)...if it does not work try pushing back on and just put a 50/50 mix of acetone and ATF on it and let it soak...overnight or for a few days if necessary....Bearing separators are kind of expensive but work well and you can make one if you can do a little welding...I made one by taking a piece of steel about 8" by 8" and drilled a hole in the center about an eighth of an inch bigger than the shaft ..I then welded 3/8 inch pipe about 1/2 inch in from each end, parallel to each other on the same face of the steel...then I cut the whole thing in half, perpendicular to how I had the pipe attached...right through the center of the hole I had drilled with a saw hole cutter for the shaft...I placed each piece behind the gear I was pulling I then got threaded rod and passed it through the pipe and used nuts at each end to hold it together behind the gear...then I lined up my flywheel puller and drilled holes in each piece of steel for the puller bolts ( I used nuts n hem...I did not thread the holes as you would find on a flywheel) and got it off that way...primitive, but cheap and it worked
I tried your idea of cleaning the shaft behind, pushing back, and then cleaning the front... And it slid right off. Thanks for the advice!:thThumbsU

Also I tried the candle wax last night because that has always seemed to work for me as well, but it just didn't work this time :dunno:
 

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Good job! If the cleaning didnt work.. I'd sacrifice the pulley using a 3 jaw puller. Just get a new one. Or a steering wheel puller where you drill holes in the pulley. Hammering and heat would not be good for the crank and seal.
 

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Good job! If the cleaning didnt work.. I'd sacrifice the pulley using a 3 jaw puller. Just get a new one. Or a steering wheel puller where you drill holes in the pulley. Hammering and heat would not be good for the crank and seal.
Well I would not sacrifice the pulley, I am too poor, stingy to do that. I drill 3/8" holes thru the steel pulley across from each other far enough out from the hub to get a nut on the bolts. Drill matching holes in a pc of 3/8" or so flat steel stock 1-1/2" wide or whatever you have. Place a pc of round stock on the end of the engine shaft, socket works well. Use 2 bolts long enough to reach thru the steel plate and the pulley with round stock in place, thread on nuts and start tightening bolts evenly. I usually buy grad 8 bolts if a really hard pull is expected. I have pulled and saved many steel pulleys this way. The 2 holes do not harm the pulley. I happen to have an automobile puller with one center bolt and slotted arms which makes things simpler, no need for spacer on shaft and no need to make flat puller plate. .

If really hard pull, leave a little more space and use a washer under nuts, ground off one side of washer for clearance if needed.

Walt Conner
 
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