The old grease channel should be removed and the grease cleaned out and inspected for any
damage to the shaft. The new grease channel should be pressed into the same position.
There are two sizes of grease channels, one has a 3/8 x 3/8 cross section, while the other is
1/2 x 1/2. Use the appropriate size, that fits snug into your keyway. There is an 1/8” groove in
the channel, this should face down or into the key slot. The channel is approximately the same
length as the straight part of the keyway.
The channel is slightly taller than the keyway. This is done on purpose, so that the channel can
be sanded to match the radius of the shaft to form a tight fit under the bearing. Once the grease
channel is firmly seated in the keyway, sand the top of the plastic channel to match the shaft,
and remove any dust created in the process.
If a retainer ring is used to hold the bearing to the shaft, a groove will need to be cut in
the grease channel to match the retainer groove in the shaft. It is easiest to do this before
re-installing the bearing.
When putting in the retainer rings it is best to spread the ring with a screwdriver. Push one end
into the groove then run your finger around the diameter, pressing sideways on the retainer ring,
nudging it into the groove, then spiral it around until it snaps into place.
To reassemble the pulley, reverse the steps.
The seal carrier should be set so that the edge of the bevel is flush with the bearing housing, see
Appendix C for details.
Rev 0 Seal Carrier
The Rev 0 seal carrier used a 3/8” diameter sponge rubber cord between the bearing
and the seal carrier instead of a second o-ring. This is Seal 2 in the figure to the right.
This will need to be replaced instead of the 2nd O-Ring on the ID of the seal carrier.
