Dave wrote on 06/08/15 at 12:22:10:if he machined it wrong it won't fit between the engine case and pulley cover without rubbing.
It's not rubbing anything. I've quadruple checked EVERYTHING 10 times.
Dave wrote on 06/08/15 at 12:22:10:Did you have the back wheel off and maybe interchange the spacers on the back axle?
The back wheel has been off exactly once in the life of the bike. When I replaced the rear tire a few months ago the first thing I did was mark the spacers L and R with a paint pen. They are installed correctly (assuming the factory didn't screw up).
Dave wrote on 06/08/15 at 12:22:10:Did your machinist weld the cover plates on instead of knocking down the tabs with a punch......
Nope. Pulley is completely unmodified (except the machine work and I put 1 light coat of black paint on it).
Dave wrote on 06/08/15 at 12:22:10:Take the pulley off and see if the stock pulley and Kawasaki pulley both engage the loose belt the same way when you roll the pulleys in the belt by hand.
I actually tried that before I turned any wrenches. I rolled the Kawasaki pulley along the belt and didn't feel/hear anything out of the ordinary. Everything seems to mesh correctly until I put tension on the belt. Without any tension (rolling belt on pulley by hand), it all seems as smooth as glass. Do you think an overly tight belt would cause this? I did the 90° twist method but I think it might be a little tight.
Dave wrote on 06/08/15 at 12:22:10:we are not there to look at it with you.
See ya for dinner? Breakfast maybe?