I've been working on not just the belt tension but the alignment now for a couple weeks, every morning, small changes. I had the belt too tight, I heard/felt it, so I loosened it to approximately the proper deflection. But my issue is the chirping. I made 3 small changes today and I'm using a depth gauge to keep my sanity, from the nut to the end of the stud. By making them the same to start, I had an idea, it would be close. The hardware isn't made with tight specs so there may be differences in stud length but that's not the point, I needed a starting point so I set them both at 14.97mm. Once I did this, I rotated the wheel forward and backward and it did track as the manual suggests. So I torqued everything back down and checked again, everything was good. Took it for a test drive and what I see/hear is this: During acceleration, the belt moves to the outside of the pulley and starts chirping. When I pull in the clutch it seems to stay there. If I close the throttle, the belt moves to the inside. I surmise this is because during acceleration, the transmission is pushing the wheel and during deceleration, the wheel is pushing the transmission. I get it, makes sense in my head.
I am watching as I do this. I see that the pulley isn't true, it's got a bit of movement. Given this information, I can assume the belt would move left and right slightly during normal operating, not really concerned. But the amount of movement during open throttle acceleration and closed throttle deceleration is pretty severe, and it's immediate. I hate the chirping, at 43k it's gotten to the point I almost don't want to ride. I'm frustrated because I make small incremental changes and it either doesn't seem to affect it or it affects it in an extreme way. Could it be something other than simple alignment and/or pulley out of true?
I think my next step would be replacing the pulley and if I do that, I'll replace the belt. And if I have to remove the exhaust to get to the passenger peg, I'll probably pull the heat shield and see if I can get them to line up better. But holy **** pulleys are expensive. I won't go with OEM cast, I'll get aftermarket Billet or something, but I might need to sell a testicle or 2.
On a side note, what if I take the pulley off and rotate it 90 degrees? Maybe it'll fix the problem then. (I hope you realize I'm joking here)