Tried it again, no luck. When I put the belt on and the washer, I run out of crankshaft to thread the remaining parts onto. But I realized, the restriction isn't with the spacer, its with the moveable drive or gear. The clutch belt goes OVER the spacer, which is pushed up against the moveable drive, which is pushed up against the gear, then against the crankshaft spacer/sleeve thing. Hopefully that makes sense.
I think the problem could be with the crankshaft. Does the crankshaft spacer/sleeve thing(see attached "crank" pic) need to be tapped in further, since that prevents the gear from sliding further down the crankshaft? See the pics below. (sorry, did not resize them small enough)

 

The last pic, of the crankshaft, please supply a cpl better pics. Something may not look right!

 

Will do. Should have them up in a couple hours.

 

see attached. Appreciate all the help

 

What I noticed was 2 things,
1) why are you putting it back together not being cleaned?!
2) your seal is beat ta heck up! I'd replace that now. Seals are like 3-4-bucks each. I have them.
All else is fine. I suspect that you are not pushing the belt down in the rear clutch so there is room on the front.

 

I will get it cleaned up. Just ignorance, actually thought i did clean it up there was a mouse nest in there before.
I will get a seal.
I read you mention pushing down the belt on the rear clutch in some other posts with similar issues, and I am not clear what you mean by that. The belt length is just fine, doesn't need any adjustment. Its the width of it, if anything. I am not sure how pushing it down on the rear clutch makes the belt narrower or fit up against the movable clutch any tighter. Can you word this differently or please explain.
thanks.

 

Ok, maybe and hopefully I am following. I pulled the belt forward pretty hard, which allows the clutch to sit deeper into the rear clutch. The washer can be seated further in so the the clutch actually rides on the washer partially. I can assemble the front clutch with plenty of room, hopefully that is what you were saying.........if so we are good to go. How quick can you get a seal sent to me?

 

To put it differently, the belt now sits more or less on top of the washer instead of sitting directly next to it. This allows more space to fit the remaining parts.
I cleaned and assembled. Will need to disassemble when the oil seal arrives but hopefully you got me past that issue.

Cleaned 1

Cleaned 2

Assembled

 

 

I got my 4 new rollers, removed the 6 in the movable drive and threw away. Cleaned out the movable drive and placed the 4 rollers in. Assembled the front clutch, top end with newly bored cylinder at .5mm out. I used some assembly lube on the piston/cylinder and bearing. Oiled and installed new air filter, premixed fuel 32:1 and dumped in gas tank. Kinked the oil hose for now. Attempted to start, and a couple things to bring up.

When I turn gas on, occasionally the carb will begin leaking gas, I pick the front end up and drop it, and this tends to stop the leaking. Float gets stuck??
The lt80 started up after a bit of cranking, adjusted the idle as it seemed way to high.
When I give it gas half throttle it is good, but full throttle it cuts out.
I also heard a loud shrieking sound, like metal on metal a couple times, very briefly when the engine started up. I noticed it particularly loud when the engine dies. I should have recorded video of it, as its difficult to describe. Did I not put enough assembly lube in? Needs more oil? Hopefully I didn't do any damage.

Thanks atvconnection and lt80 for sticking with me on this one. We are hoping to hit some trails this weekend, so would love to have this machine running strong by then!!!!!!