Removing key from keyway

[Douge]

Need some help fellas.
I am replacing the two pulleys on my Ridgid 2420. The one on the drive moter and the one on the arbor. I have not been able to get the drive pulley off the motor. The pulley will come off about halfway and stop. I have tried pulling the key with pliers but I have burred the edges, which may be the reason I can not get it out of the keyway and the pulley off the shaft. Any ideas on how to get the key out of the keyway?
I am going to install a pair of V-slotted pulleys from Woodworker.com. Is there a better source for machined balanced pulleys?
Your help is appreciated in advance.
Doug

[BHD]

you may need a "gear puller" either a two or three arm, the three arm is better and it has a screw in the center of it to apply pressure to the shaft of the item you want the "gear or pulley" off of. it may be burred or the set screw (see if there are two set screws) some use one on the key and one 90 or 180 apart, I doubt if there are two but some times there are on some pulleys, or gears,

[Frankiarmz]

Doug, those keys really get stuck in there and a little rust makes things even worse. Instead of pulling with regular pliers, I would clamp on vise grips and tap them with a hammer. The vibration and stronger grip should help to break it loose. A little penetrating oil or heat might help as well. Sometimes even with the key out you will find the pulley frozen in place or not moving on the shaft. I have used emery cloth to clean the shaft of rust and oxidation and some penetrating oil to help the pulley slide off. Good luck.

[Douge]

Thank you those are some great ideas and I will try them tomorrow when I get home.
Douge

[Andrew M.]

Nut Buster, some light tapping on the back of the key with a punch, tapping the key toward the motor will make it tighter. A burr will form on the key sometimes from the set screw too. Do not use a puller on the flange where the belt rides or it may bend.
BTW the TS3650 pulleys and belt system are very good. You might want to check the price.