Table saw motor clicking loudly under load

Hi. It's me again. I'm still fussing with my table saw after replacing the belt. The pulley stays in place now, I think thanks to a good cleaning. But no matter where I position it on the shaft, I hear a loud clicking when the motor is running. I think (but I can't be 100% sure) that the sound is coming from the motor and not the saw arbor. If I run the motor without the belt it runs smoothly.
This is a 2hp motor and a Rexon RW10 table saw. I bought it in 1993. Do you think one of the motor bearings needs replacing? What's normal for wear and tear? Sure it's been 14 years, but it probably only sees a few hours of duty per month. I hope I don't have to shell out $300 for a new motor!
- Owen -
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Sounds like you are still having trouble with that pulley Owen. I have had that problem with a jointer pulley. You have to make sure the sets screw is TDC on the key.
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TDC? Top Dead Centre?
So you think the pulley is rocking/wobbling? I really cranked the set screw and the pulley isn't wandering. I'll be very happy to try a new pulley/key/set screw before taking more drastic measures if you really think it'll help.
- Owen -
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Yes
In the beginning I thought it was my motor also. When I tightened the set screw the problem would disappear for a little while. I found that if the set screw does not push down on the key and or flat grind on the shaft at a 90 degree angle, TDC, it can loosen again.
Mine made a distinct metallic clicking/ticking sound with every revolution.
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One other trick that I forgot to mention. The object is to have the set screw press squarely on the key. If the screw is not flat on the end, if the end is at a slight angle, you can lightly file the end so that it contacts the key squarely. The set screw can have a conical end but the entire end should make contact with the key. Or buy a new set screw.
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If I can get to the store on Monday I'm going to buy a new pulley (etc.). You've given me some confidence that it will fix the problem. Thanks, Leon!
- Owen -
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Owen
Stay away from cheap pulleys. If possible get a steel or cast iron one.
Bob AZ
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Owen,
As long as you're going thru all that trouble - may as well replace the belts. I don't recall which cabinet saw you got (Delta or Jet) but if you can get matched belts that would be best. Last year I had a thin cutoff fall through and evidently got into the belts somehow. Put a bump on one belt that ruined it.
Bob S.

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replace the key also. the pulley should come with a new setscrew.
get a good machine quality pulley. ace hardware and home depot are unlikely to have them- go to a bearing and belt supply type of place.
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Whirrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr!

I got the new pulley and key this morning from the saw vendor (Busy Bee Tools). I forgot to check for a set screw, and didn't find out it was missing until I got home. Oh well. I installed the new pulley with the old set screw, realigned everything, put on my new link belt and powered it up.
No problem! I made a few cuts and already it's smoother than it ever was. It's a bit premature to declare complete success, but let's just say I dabbed a bit of loctite on the metal interfaces, replaced the belt guard, and torqued down all the bolts.
Thanks, guys! You're the best!
- Owen -
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I agree. Does the pulley fit really snug on the shaft? If not, the set screw on the key gets it tight at the top and bottom, but you still have slack on the sides, the tension of the belt will cause the pulley to wobble as it turns, causing it to click against the shaft with each revolution.
DonkeyHody "I'd rather expect the best from people and be wrong than expect the worst and be right."
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