Just had the dealer rebuild my primary, I rebuilt the secondary, both have new springs and busings. Don't know what the gap betwee the belt and the primary sheaves was before the rebuild but since I have been reading up so much on all this clutch stuff I decided to check it. It is something like 0.060" to 0.070".

The belt rests against the non-moveable sheave when stopped so the dimension that I mentioned was all on the other side.

The clutch does seem to engage a bit harshly, but I'm not sure if I'm noticing the difference solely because the springs are new and the sheaves are clean. Clutching is stock, it is an 02' ProX 600.

I have read on this forum that the gap should be a lot less? What is the recommend range for this measurement?
What is the best way to check it? I just pulled the belt tight and stuck feeler gauges between the belt and sheave.
The belt I am using has about 700 miles on it, does that make a huge difference?
Other than a harsh engagement, what are the performance ramifications of having a wide belt gap?

with a new 080 polaris belt your side clearance should be .015" ~ .020". with it on the tight side it may heat up the primary some if its let idle for a long time. Smoother engagment and more top end speed is some of the benifits for having this set correct. The higher speed may only be true if your geared down from stock , most stock gearing you would need a 10% down grade and a 50 mph tail wind to get full shift out of the clutches!