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Discussion Starter · #1 ·
Hey guys,

I have replacement power steering pump the I need to install. I have rented the tool from Autozone to remove the pulley but I am having troubles getting the pulley off. I can get the tool on but I don't have much room to get a tool over the bolt that screws in to remove the pulley. The hose from the coolant reservoir is somewhat in the way. Have any of you removed a pulley on a 2003 Vulcan and can share some insight and maybe what kind of tools you used to assist.

Thanks in advance.
David
 

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Discussion Starter · #4 ·
Thanks guys for the replies. Is it possible to somehow take the power steering pump and pulley off as one unit. I thought I had to get the pulley off first to get at the 3 bolts behind it. I have to figure this out soon because this darn thing is whining bad.
 

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The pulley has to come off to remove the pump.

The tool I use (K-D) has enough clearance to remove the PS pulley from a Vulcan and my current Essex.
 

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If there is not enough clearance with your puller, you can go the other way and remove the alternator and the entire cradle and pull it out with the pump and pulley still attached. There are some you tube videos on it. I have also seen one where he drained the coolant jug and removed the hose and was able to fit the puller. Once the pulley is removed you can get at the three bolts holding the pump to the cradle.
 

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Got pulley off with the puller. Decided it was best to drain and remove the overflow jug. It’s pressurized so removed the cap first. That also gets rid of the large hose from the jug which is in the way of the end of the puller and would make putting a socket on the end impossible. By the way,my puller was not metric. It had a 1/2 inch end on the screw and a 13/16” nut.

Now pick the spacer that screws into the shaft. Test fit each one. I found it was the shortest one I had with the proper thread. Screw that in until it bottoms out. You screw the longer side into the shaft. Then you screw the large diameter screw into it, with the nut on it. I’ll post a picture. Then you place the two half shells together and use the metal circular outer ring to hold it together. Back the nut off so it is snug and you know the shells are grabbing the puller.

Now I am am going to share with the novices the big secret to making it work. First turn the large screw from the end until it is bottomed out. Then, hold the end of the screw and turn the nut, so it rides back up the screw dragging the two half shells with it. Some folks say it makes no difference and you can hold the nut stationary and just turn the screw. Unless you are using an impact gun to turn the screw, it is easier to hold the screw stationary and turn the nut.

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I’m going to edit my comment on assembling the puller. I should have been using the non threaded pin in photo 3 instead of the threaded bolt. Then it would have worked fine rotating the puller from the end. My bad. :)
 
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