OK guys here are a few pics of what happened.
This the speed control shaft. Normally all you see is the bit with the handle on it. You can see the damage that was done to it, the spline is totally burred.
You can see where it goes here
Once you have taken the handle and the grub screw out this shaft will slide out easily.
You then need to undo the nut on the 2nd shaft and take out that grub screw. The 2nd shaft is the one that actually pushes the pulleys in and out.
These two pulley wheels are independent. The outer one is fixed to the shaft but the inner one should slide (note I said should!!) to widen the gap between them.
Here you can see the shaft with the outer pulley removed.
When running at slowest speed this is the way the pulleys are all positioned
When in top speed they should look like this with the belt riding at the top of the motor pulleys and the bottom of the speed control pulleys.
Mine was stuck in this position and in trying to move it I burred the teeth on the cog as in the first picture. The metal must be really soft. All because there wasn't enough lubrication on the shaft.
To release it I had to gently mpve it a fraction at a time ading PTFE spray. (Use a mask here as it put me on back for 24 hours!!!)
It will gradually work loose and then just keep manipulating it until it moves freely. It is a very tight fit and runs along the shaft on a key. If you feel that you need to apply any extra pressure open up and lubricate. It doesn't take much to burr these splines. Having said that, the spline on the 2nd shaft didn't have a mark on it so perhaps mine was a one off rogue. However tempting it is don't use any force on the pulleys themselves. They are extremely fragile. The bottom one can be pulled out with your fingers but the top set won't move.
Hope this is of use and prevents any one else having these problems.
Fortunately for me I had you lot and Axminster to help. Thanks to everyone
P.S. Any weird spellings is because I need a new Keyboard and I am too tight to get one
Pete
