guys can i get an accurate measurement using a 3/8 keystock bar and vernirer callipers? i understand the x and y measurements but when i jam the bar in the secondary it doesn`t even touch the inside sheeve, is this a good indication it`s out of alignment?

With a doo or pol secondary, it can work. With the cat, it's kinda hard.

The bar is not going to touch the primary sheave. Just go by the measurements.

does the bar rub the inside sheeve on the primary clutch to give proper alignment, while the secondary holds the bar tight?if this is the case, the motor *will have to be moved a bit towards the pto side. the sled is 780 mach z. thanks

No, it does not. You will find that if you install your belt with that alignment, the belt will also be right against the primary sheave. You will also find that your belt will run hot, and may squeel. It may also come apart on you. If you have the book, just use the measurements given. Make sure that the bar is properly pinched between the secondary sheaves and is straight. You should then be able to check X and Y.

From the '98 book (I believe this will work for you):

X (back of primary, towards secondary): 35mm (1.38in)
Y (front of primary, towards hood hinge): X+1.5mm (.060in)

f111 mtn, thanks for the good info. guess i was looking too close at the picture and not paying enough attention to the given measurements.thanks