Hi GG. Welcome to the Zone!
I'm guessing you didn't TELL Michael you were going to use the G540, or order the CNCFusion kit WITH the "CR" option--which would have given you TWO different pulleys than the normal version. Sometimes the single SDPSI pulley that I used to recommend does this, as some timing belts are longer than spec.
You have three choices:
1 Ask Michael to sell you the 2 CR Pulleys that he provides with CR option. They are designed to work with regular timing belt and stay within adjustment tolerance.
2. Ask Michael for SDPSI part numbers and buy 2 new pulleys yourself.
I can't speak for Michael, but he's a good guy and MIGHT even exchange your stock pulleys for "CR" pulleys.
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3. Try to cut longer slots into Z motor mount for more adjustment
I recommend #1 or 2.
Not sure why you posted this in the SYIL forum instead of Benchtop machines.
CR.
http://crevicereamer.com
Too many PMs. Email me to my name plus At A O L dot com.