How to Replace the Sprocket on a DeWALT Portable Band Saw
The sprocket attaches to and drives the rear blade pulley. The sprocket is driven by a chain that connects it to the output spindle. The sprocket contains a series of plastic cogs, which act as a safety to protect the saw's drivetrain. If the saw is bound-up or overloaded, the plastic sprocket cogs will break off; protecting the more expensive (and difficult to replace) motor drive gears.
Let's get started.
REMOVING THE SPROCKET
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.
2. Remove the sprocket and chain.
a. Lift the chain and sprocket (as a single assembly) away from the output spindle.
b. Remove the chain from the sprocket.
INSTALLING THE NEW SPROCKET
3. Install the sprocket.
a. Install the chain onto the new sprocket.
b. Note that one side of the sprocket contains a smooth metal hub, and the other side contains a series of notches. The smooth metal hub should face the output spindle when installed. (The notches are threaded to allow installation of the drive pulley mounting screws).
c. Install the new sprocket and chain (as a single assembly) onto the output spindle (with the notches facing away from the spindle).
REASSEMBLING THE UNIT
4. Reinstall the drive pulley.
a. Align the tabs on the back of the drive pulley with the notches in the sprocket. (It helps to have the sprocket centered as much as you can on the spindle before installing the drive pulley.)
b. Install the 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 drive pulley with the three outer screws and the center screw.