Yes you can have too many washers behind the rear clutch also,plus the clutch alignment tools for the most part are junk. Hard to get an accurate reading/adjustment,plus many times doesn't help if you go by them. That's why all of mine usually stayed on the tool wall.Yes pulling the front engine mount outward puts less stress on the belt,gives a tad more slack.On these older models the one way side to side play along with not having the belt too tight was critical. Just something you may have to do several times as the more time you put on it. Didn't have to do this as much on the 700/800 atvs,just mainly the Sportsman 500s with 2001-2002 models seeming to be the worst on creeping problems.Saw this as a trend on these two models over the years.

 

I went out for a two hr ride today in the mud/snow and slushy crap with my son on the back. It works like it's supposed to now!! Keeping my fingers crossed!
Thanks for your generous help again OPT!!

Kevin

 

I'd cross my fingers for ya if I could..

 

haha.....thanks for thinking of trying it!