I am replacing the transmission on a 1997 xplorer 300 and the manual says to check the clutch offset and alignment. I have access to a full machine shop and would like to built the alignment/offset tool but can't find anywhere what the offset is (have seen 1/2" and 5/8" in some forum posts) or where it is measured from, although it looks like in the manual it is from the inside edges of the drive and driven pulleys.

 

I wouldn't worry about building an alignment tool! After replacing transmission install original spacer washers behind driven clutch and check if belt is fairly centered on front clutch with equal space on each side of belt against clutch sheaths. Plus if not creeping,usually pretty close. If offset too much or too little,can add or remove spacers behind driven clutch!

 

I used a different transmission and this ATV was beat on (and worked on badly, that is why the replacement tranny) by the previous riders. Being that I have to assemble the whole thing and get it running then take it apart and guess at the correct shim then put it together and hope it is right, I'd rather have the tool and know it is done.