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4 x 2 Gator Secondary Clutch Rattles
The only way I have ever seen a driven clutch rattle is the rivets holding the sheave to the hub will loosen up, and the sheave rattles on the hub. A drive clutch can rattle when it gets worn inside and the moveable sheave will wobble around on the post of the stationary sheave, also the three bolts on the cover will loosen up and the cover will rattle.
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4 x 2 Gator Secondary Clutch Rattles
You can look at it and tell if it is together right. The only way you can get it completely apart is with a press, so I doubt if it was all the way apart. The only new parts that are available for them are the buttons. They ride on the helix angles. There are three that ride up the angles and three that are stops when the clutch is all the way open. In the normal state the buttons should be resting on the helix angles. There should be around 15 lb. tension on the spring when you try to move the sheaves in opposite directions. I've had them apart, but it's not easy getting them back together. And you definately need a press.
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4 x 2 Gator Secondary Clutch Rattles
The buttons can be changed without taking the clutch apart, but you have to spread the clutch apart i.e. get the buttons away from the helix angles so you can work on them. I guess you could say the belt should be jumping around at idle, at least it should be turning at idle. You are pretty close on your assessment of the clutch. The drive clutch does the work and the driven clutch keeps the belt tight. Thats the simple way to say it. As rpms increase the rollers on the clutch spyder start riding up the flyweights and the belt starts riding out the drive clutch. Since the belt length is constant, the driven clutch will start to open. The way it opens is governed by the helix angles and the tension on the coil spring that is inside the helix. The angles and spring tension are tuned to the motor so the clutches shift out smoothly. So the purpose of the driven clutch is to keep tension on the belt so it doesn't slip.
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4 x 2 Gator Secondary Clutch Rattles
I've never seen an after market belt work on a Gator. You need a RE28721 belt. It will make a big difference.
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