There are only a handful of folks that have used this pulley, and as far as I know there have not been any problems.  Serowbot used one for a while but did not like the gearing change.  MMRanch has used one for a couple of years, and is still running his.  I have used mine for about 4,000 miles.

I read your thread and went out and looked at my pulley and belt.  They both look fine, no wear marks on the belt, the pulley has the top of the teeth all polished up and shiny from the belt....every thing looks just like it should and the wear marks match the marks on the stock pulley.  I also measured the teeth on the Kawasaki and Suzuki pulleys and the width of the tooth and space are exactly the same....the Kawasaki teeth are slightly taller - but that should not affect anything as the top of the teeth ride in the grooves of the belt....the belt teeth do not touch the bottom of the pulley (that is why the bottom of the pulley teeth are never polished shiny by the belt).

Look closely to see if there isn't some bolt sticking out and touching the belt someplace, or a part of the belt guard that doesn't like the larger diameter of the pulley.  I can't see anything about the pulley teeth that would not mesh with the belt.  You can take your pulley off and see how the belt fits into the teeth if you still believe something about the pulley teeth is wrong.

I know it's the pulley that's the problem. I can see the belt trying to mesh with the pulley. If you look from the back of the bike along the belt as you spin the tire, you can see the belt jumping a little each time it tries to mesh with the pulley teeth. I think the grinding sound is the belt teeth not playing nice with the pulley.

This is even after aligning the rear tire with the adjusters and a tape measure. I can watch the edge of the pulley while it's spinning and see absolutely no wobble. I even just barely touched the edge of the pulley and spun it (with belt connected for tension) to try to see if I could feel a small wobble. The machine work is dead on. It spins absolutely true.

maybe there is a difference in the years of the LTD tooth of the pulley.

I am currently having this done with a machinist and he showed me a difference in the width of the teeth on the pulley to the stock one.

If I remember it was something in the likes of .002in smaller at the top of the teeth. He didnt think it would make any difference but he did say there was a possibility that it still wouldnt work.

Is it possible the guard not reinstalled back correctly, missing a rubber spacer or something?

Is it grinding with the cover guard off? Could be the smallest thing and I would imagine those nubs would make a horrible grinding sound hitting metal and they are in sync with the teeth on the pulley so might appear that its the teeth.

Might not matter, but I'd mark the direction of the belt rotation before I pulled it.
Heyyy, maybe that IS the problem, the teeth are slightly tilted from accelerating...

Well, the belt guards are not installed yet and the bike is still in the air. I did ride it once to the end of the driveway and back. It's pretty loud. You can spin the rear tire by hand and watch each side of the belt try to engage the pulley teeth. 1st left side then right, etc. It's like the belt is wobbling over the teeth.

When I set the belt tension I did check to see that the rear tire was running true with a tape measure. I measured the leading edge of the swing arm pivot to the the center of the rear axle bolt. The rear tire is not cocked to one side or other. The belt should run just as straight. I have zero problems with the stock belt/pullies.

The Kawasaki pulley looks completely undamaged in any way shape or form. The teeth are nice and smooth and show no signs of abuse. The stock belt only has ~4500 miles and I don't abuse it. Both sides of the belt teeth look the same. The belt doesn't even look worn.

What ifhe got it too narrow?