Well guys....I hoped I would not have to chime in on this topic again, but it seems it just will NOT go away. I'm the author of "Squeaky Ass Belt". As I see I'm not the only one that thought he had the solution only to have the problem return. I've aligned and purposely mis-aligned to get the belt to travel off the edge. Rolling the bike forward and backward will even demonstrate....in my case....reverse would chew it up.
The Teflon pulley I guess is the answer, but until I've got the money to spend, I'm going to do what I have been doing for the past 2000 mile, silicon spray. Over the weekend it started again, minor, but I knew it would get worse. I pulled into a BMW motorcycle shop and asked for a shot of silicon spray. The guy had Dry Teflon spray instead. It seemed to work well....not for the first couple of miles....but then silence.
My question is: What's the best alternative to pulley replacement? Is there a good Dry Teflon that might last longer than a couple hundred miles. and does it come in a small "little dab will do ya" container to carry in the tool bag.