First mod and first post...bought my new '05 MCS 2 months ago.
Unfortunately my first post is because I ran into a problem. My wife and friends got me an Ultrik CAI and Ultrik 15% pulley for my birthday this weekend. Everything was going extremely smooth with the installation until we torqued down the new pulley and realized there was a discrepency in directions. The 25 page directions printed from the Mini Mania website say to measure the distance between the stock pulley and the supercharger housing because we will use the measurement when installing the new pulley. We installed the new pulley to this measurement (~.10").
Unfortunately, the over-simplified 1 page of instructions that came in the box with the pulley say to gap the pulley from the housing to .180". This bigger gap is to compensate for the back flange on the new pulley being thinner. The belt is now too close the the supercharger by .08-.085".
Anyone know if I can take the pulley back off without damaging it? Kind of sucks since things were going so well and now I have no idea what to do (and the fact that my car is on stands in my friend's garage with the engine resting on a jack)!!
I wanted to let you all know in case you attempt this install on your own also!
I am going to call Mini Mania in the morning and I will post an update.

 

THis pulley?



It looks to me that those extra two hole would be used to push the pulley back apart if you ran into the troubles that you have....

I could be wrong, just a guess....

 

I agree with fishbulb.
That's typically what the other two threaded holes are there for.
Just take out all the cap screws then put two back into those holes. Turn them in equally a little at a time and they will push the pulley halfs apart so you can remove or reposition it.

Now if that was a Helix pulley you would have had a stop machined into the outboard pulley end. I know, most others are self indexing too.

 

 

Thanks for the help...I kind of figured that was what they were for, but I didn't want to tweak anything before I asked.
We used those holes and just got the pulley off pretty easily, no damage to it.
I called Mini Mania this morning and they were very helpful! Apparently the picture above is the old design, and that is what they shipped me. The new design has a smaller hole in the end so the s.c. shaft cannot go all the way through. On the new design there is no need to gap anymore, just slide it on until it stops. They told me to try those two scres to get it off and if I damaged the pulley in any way, they would send me one of the new pulleys for free!! I was pretty impressed!
I will get back to the install in a couple hours and post an update...I'm getting excited for a little extra boost!

 

sounds like you are making some progress now...good luck with the second go around!

And, after you get done beating the snot out of it, please, post back with results!

-jac

 

spot on saying The week i got my pulley, my car was saying, "what is it with this guy" . My right foot was constantly pegged to the floor.

 

Day 2 = SUCCESS!!
Got the pulley on in a couple minutes, put the car back together in 30 minutes, on the raod within 35 minutes.
It runs great...love the added boost and supercharger noise!! CAI and 15% and I am pretty happy.
Thanks again for all of the help!

 

Thanks for sharing this story. I'm about to place my order for the exact same mods, and I just happened to stumble across this post before I made the call. Glad to hear that the problem had a simple resolution, and I might go ahead and request one of the newer design pulleys, now that I know they have two versions out there.

 

glad to hear you got it sorted out....and that the pulley is working well!

 

Nothing like seeing a mini being driven off into the sunset and hearing the whine slowly fadding away. I love happy endings (snif, snif).