Riding lawn mower motor pulleys are made of metal and can rust, especially in an older mower and a mower left exposed to the elements. The crankshaft spins the motor pulleys, driving the belts.
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Riding lawn mower motor pulleys are made of metal and can rust, especially in an older mower and a mower left exposed to the elements. The crankshaft spins the motor pulleys, driving the belts that power the transmission and the mower deck. If a pulley is rusted and can't turn properly, the mower will not operate properly. A rusted pulley can seize to the pulley shaft, but you can use penetrating oil, pulley removal tools and basic hand tools to coax the rusted pulley off the pulley shaft.
Set the riding lawn mower's parking brake, and place wooden blocks in front of and behind the rear tires to prevent the lawn mower from moving. Disconnect the engine's spark plug lead wire from the spark plug by hand, preventing unintended engine starting. Remove the riding lawn mower's engine deck to gain access to the desired rusted pulley to be removed.
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Lay a plastic sheet or a drop cloth on the ground under the riding lawn mower. Brush loose and scale rust from around the pulley hub, pulley retaining bolt and pulley shaft with a wire brush.
Spray a liberal amount of penetrating oil onto the front and back sides of the pulley hub until they are thoroughly soaked. Spray the pulley retaining bolt and pulley shaft with the oil. Allow about 30 minutes to two hours for the penetrating oil to loosen the rusted pulley and other parts. Spray additional coats of oil as needed until the parts loosen and can be removed, allowing 30 minutes to two hours between each application of the penetrating oil.
Wrap a strap wrench around the pulley. It will allow you to hold the pulley still when you remove the pulley retaining bolt. Unscrew the pulley retaining bolt with a breaker bar and socket wrench or with a pneumatic air gun and socket. A pneumatic air gun and socket is very powerful and can help remove stubborn bolts, but the extra power also often results in broken bolts. If you break a bolt, replace it with a new, identical bolt.
Unscrew a pulley removal tool's center bolt, rotating the bolt counterclockwise until it bottoms out or stops. Set the pulley removal tool on top of the pulley, aligning the pulley removal tool's center bolt with the pulley shaft.
Align the pulley removal tool's ear slots with the pulley threaded bolt holes if your lawnmower pulley has threaded holes. Insert the pulley removal tool's ear bolts through the pulley removal tool's ears. Screw the pulley removal tool's ear bolts into the pulley's threaded holes. Tighten the pulley removal tool's ear bolts with a wrench. Rotate the pulley removal tool's center bolt clockwise by hand until the pulley removal tool ears are flush with the pulley removal tool's ear bolts. Hold the strap wrench with one hand while tightening the pulley removal tool's center bolt with a socket wrench in your other hand until the pulley pulls free from the pulley shaft.
Drill two holes slightly bigger than the pulley removal tool's ear bolts through the front of the pulley by using a metal drill bit on a power drill and placing the holes directly across from each other on each side of the pulley hub. Space the holes far enough away from the pulley hub to fit a nut next to the back of the pulley hub, but the spacing should not be wider than the pulley removal tool's ear slots.
Unscrew the pulley removal tool's center bolt until the bolt bottoms out against the pulley removal tool. Set the pulley removal tool onto the lawnmower pulley, aligning the pulley removal tool's center bolt with the pulley shaft. Align the pulley removal tool's ear slots with the drilled holes. Slide one pulley removal tool ear bolt through each pulley removal tool ear and through the holes drilled in the pulley. Screw a nut onto each pulley removal tool ear bolt's threads fully by hand. Pulley removal tools require either two or three nuts, depending on the specific brand. The nuts should be flush with the back of the pulley.
Tighten the pulley removal tool with the socket wrench until the pulley pulls free from the pulley shaft.
A former cake decorator and competitive horticulturist, Amelia Allonsy is most at home in the kitchen or with her hands in the dirt. She received her Bachelor's degree from West Virginia University. Her work has been published in the San Francisco Chronicle and on other websites.