Swapped to the Kawasaki pulley...AGAIN. This time I'm leaving it on there for a while until I can figure this out!  

I gave it a little more slack this time and it ran better but still not good. I left the back end in the air and ran it up to around 20-25 mph in 3rd gear. It was a little noisy about 95% of the time. Just belt noise I guess. Maybe that's normal? I've never "ridden" 25 mph and stood beside the bike listening before!  

The other 5% of the time got really noisy for about a second. Kind of a grinding sound like the belt wasn't engaging the pulley correctly. It doesn't seem to be a specific part of the pulley or the belt. I rolled the tire in the air by hand and watched for when it was "grinding". It seemed to be random.

Also, after having aligned the rear tire, I noticed the belt rides all the way to the left of the rear pulley. I pushed it to the center and spun the tire by hand and it went back to the left. The Kawasaki pulley has no gap at all between the flanges and the side of the belt. Is this normal?

Yeah, that's what I did. I'm very frustrated with this!

Kris01 wrote on 06/10/15 at 18:53:21:



Well, marks did what?

Here is a little wear on the belt from 3 hrs or tinkering with the tension.

Took the bike for a hour ride today, this was pic before the ride and it looks like no other wear on the belt was done.

I checked the alignment and rode no hands at 30 and 40 to see if it was any wobble or pulling to either left or right. All seemed a ok.  

Is there any burs from the milling on the outer side of the gear where the gear attaches to the trans shaft? I had to work mine on and off to chisel off the burs to get the gear all the way in where it was supposed to be.

Those marks in the belt looks like you have a rock or stone wedged in the bottom of the teeth....on either the front or rear pulley.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1349970207/30

Hmmm, I guess I'm not alone. This is an old thread but informative nonetheless. No update yet. I'm still working on it. There's definitely more noise than stock. I really don't want to ruin my belt.


mjs3790225 wrote on 10/17/12 at 13:17:29:

Thanks WD but I took it off last night and put the stock pulley back on. I'm tired of messing with it. I've tried everything I know and still don't feel comfortable with the way it's sounding. Maybe I'm just paranoid with it being louder than stock but something in the drivetrain is complaining. I'll probably sell it and go with chain. I'm just too frustrated with it to deal with it anymore.