Thanks Dianne, my other Elna has a new pulley and she does have a light growl that I call the "elna Growl" and she sews beautifully but this noise is definitely a problem.
The Elna's have such tight tolerances as to be almost non existent. So it doesn't take much to cause problems. It may be that reducing the size of the rubber wheel to remove the flat spot has made other machine parts in the area not align quite right???
I am ordering a new pulley ( hubby said so) and I will try that before anything else. I will report back when I get the new pulley installed.
Lorraine