We're replacing the belt on our Scrambler 500 with a Dayco HP2003 and it seems that the new belt is wider and is therefore riding too high on the driven clutch (about 1/8" above the top edge) and is rubbing on the plastic cover. Unless we get the belt to seat flush with the top of the clutch, it will soon destroy the new belt and the cover. We need to add some shims and the manual says to simply pull the driven clutch off the shaft. Doesn't come off as easily as the book would have you think. Any tips on the driven clutch removal and thoughts on the the belt width issue other than adding shims? Thanks.

 

It is normal for the belt to stick out of the driven clutch that far. Try pushing up or down on the cover to see if you can get some clearence between the belt and cover.

 

If this is the case you are going to want to add some shims to your sec. clutch. Are you sure you got the right belt? If you have never had you sec. clutch off it may be hard to get off and will most likley need to be cleaned and greased.