How to Replace the Drive Pulley on a DeWALT Portable Band Saw

The drive pulley is the rear blade pulley on your portable band saw. It attaches to the sprocket and the chain to drive the band saw blade. The drive pulley consists of a metal pulley (with two bearings pre-installed into it), and a new tire pre-mounted as well. The drive pulley might need to be replaced if the screw holes for the sprocket become wallowed out. This can happen if the screws aren't kept tight. If the tires are not replaced when worn, the tire mounting cogs might wear down as well. Replacing the drive pulley is also a fast and easy way to get your saw up and running if the pulley bearings fail.

Let's get started.

REMOVING THE DRIVE PULLEY   1. Remove the drive pulley.

a. Remove the (3) small outer screws from the drive pulley.

b. Remove the screw from the center of the drive pulley.

c. Lift the drive pulley away from the saw.

INSTALLING THE NEW DRIVE PULLEY

  2. Install the drive pulley.

a. Align the tabs on the back of the new drive pulley with the notches in the sprocket. (It helps to have the sprocket centered as much as possible on the spindle before installing the drive pulley.)

b. Install the new drive pulley onto the sprocket.

c. Install the plastic washer onto the (center of the) drive pulley.

d. Install the metal washer over the plastic washer.

e. Secure the new drive pulley with the three outer screws and the center screw.