It should never be necessary to remove the pulley to install the belt. Slip the belt over the crank pulley and water pump pulleys first, then slip it over the generator last, and as Jackson said, only make it tight enough to not slip when the lights are on. When the lights are on, the generator is working the hardest, if you use a voltage regulator. If you use the stock generator with third brush regulation, the generator will not work harder unless you move the adjustable third brush for more output.