Been tinkering with it a little more... went down to 1 & 3 on the secondary, & 1 shim (there was only 2 ) & then checked the belt freeplay with a straight edge.
Without the driven pully splitting at all, I have well over an inch & a half of slack.
(new polaris 3211077)
How hard is it to move the engine forward without screwing up the clutch alignment ??

 

to reduce belt free play, you might need to remove some shims inside the secondary clutch.

you will find them located between the sheaves. disassemble your clutch the same way you would when checkin the buttons etc. there could be as many as 3 shims in there. just make sure to leave the thinnest shim, but remove the rest of them.

re-assemble. this will allow your sheaves to be closer together, thus, removing freeplay.

X

 

Unfortunatly, there was only two, & I'm already down to the thinnest one.