Super Weird Problem with Primary Sheave/Clutch (Rhino 660/Hisun 550)

[skittle021]

So I've got a Hisun 550 (clone of a Yamaha Rhino 660) that I was doing some work on that required removing the CVT and it's housing. Upon attempting to reinstall the clutch, sheaves, etc, I found that the belt no longer fits - it's far too wide. None of the parts have been replaced, they're all OEM. Exactly the same parts as what I took off a few weeks ago.

To be more specific, my belt is 1.25in wide, but the gap between the clutch and the primary sheave is only 7/8in wide. I'll include a few photos to explain.

Has anyone ever experienced such a bizarre problem? Any help at all would be appreciated, I've been stuck on this for a month. I'm open to just about any suggestion.

Photos: 

[Mech]

Here's the instructions for the 550..

 

Hisun..pdf

[skittle021]

Those are the instructions I followed from the service manual, but the belt does not fit properly. It’s too wide. 

[Gwbarm]

That is strange it doesnt fit, unless there was a spacer that fell out, you tighten the bolts to move the shieves father apart.

[Mech]

Well if it's the same belt, and same parts that came off there, there's only one conclusion I can come to..

You've assembled it wrong.

Take it apart and inspect every part for wear marks that might coincide with some other wear mark and  indicate where it had sat before. There's generally some visual indication that parts have been in contact before. Then if you can't find anything, reassemble it following the diagrams. If the service manual doesn't have a very clear diagram look it up in a parts place online, they usually have good diagrams, and sometimes they say what thickness washers etc are.

Other than that, see what there is in the way of spacers or sleeves that have got muddled and  could/might account for the 3/8 discrepancy.