We removed the circlip and set screw but we have yet to be able to get the pulley off. I assume it is a press fit but you would think not too hard a press fit otherwise why have the circlip and the setscrew. Our next step is either heat or cutting it off. Anyone got it off yet ? How ?
Use a gear puller to get the pulley off.
Eric
You should heat up the pulley with a heat gun. The pulley is held in place using an adhesive that loses strength with heat. You do not have to heat it so hot that the shaft changes color, but a few hundred degrees with a standard hardware stor heat gun will do the trick.
-Paul
Our shop teacher tried twice to get this pulley off with a puller, leaving a dimple in the end of the motor shaft with each attempt. Realizing that there must glue in the works, we got the torch and set it up ready to go. With the simple threat of heat from the torch, when the puller went on for the third time the pulley came off without actually having to apply heat. I guess the pulley knew with the gig was up and let go!
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You can also get the gear up by heating it up with a bunsen burner and then pry it off with two screw drivers. Just FYI.
We used a bolt/nut crunching tool. it just crumbled off.
This method works GREAT! In fact, it is so good, that our biggest problem was removing the snap ring from the shaft, not the pulley. (Although that beefy spring caused more anxiety)
1351’s attack strategy:
Take the nut off of the tensioner screw. Nudge the tensioner off with a few blows of the hammer.
Take the clip off of the shaft. Use two screwdrivers to pry off the pully. As you get farther up, you’ll need spacers. Combo wrenches around the shaft work well. The earlier attempts with a torch may or may not have affected the adhesive prior to the screwdriver operation.
If you only plan on using one of the motors, you can also pull the long tensioner screw off of the other one so that you have two on one motor. It seems like it might be a good way to mount it. However, we’re unsure of the legality of this.
we pushed it out in a hydraulic press. No heat required.
when we were trying to get it off, our screw from the gear puller snapped in half. so we took a blow torch and that melted the adhesive and then it slid right off! 
We use a blow torch and a gear puller (heavy Duty)
We used a heat-gun and two flat-head screwdrivers to pry it off. Worked great.
Phil,
I would only recommend this as a last resort. By using the endplate as a wedge, much of the pry force is placed on the bearing surface inside the end plate. As the force transfers to the bearing, additional stress is placed on the endplate securing the bearing in place.
Yeah, we realized that and it was our last resort. Well…after you get it off, there’s not much need to investigate other options…
Our gear puller couldn’t grab the pully correctly. We tried clamping the pully in the vise then hammering on the shaft, but it kept slipping. The press was considered, but it didn’t look safe. There was also some talk of trying to either cut or crack the pully somehow. After a few hours, we settled for just prying it off.