Correct me if I am wrong here.
1. The secondary should NEVER open enough to allow the belt to drop down into the secondary far enough to hit the straight cut on the sheeves and definiatly not to the point of hitting the helix. (take out your spring, leave all the shims and spacers in, drop a new belt into the secondary with it all the way open it if will drop past the taper, you have a problem.)
2. Do the same thing on the primary, if you remove the spring and close up the primary the belt should ride out of the primary about 1/8" max. If it goes more then you have a problem, or if it won't go that far you also have a problem.
As long as your deflection is correct, your motor mounts are solid you should be able to run the sled pinned, for a bit, without the belt hitting the helix or jumping out of the primary. You will be in TOP freeking gear at this point, thats why lake racers like those steep helix so they can hold it to the bar, stay closer to 1-1 ratio and let the helix do the work. We have our mountain sleds geared to BACKSHIFT so we run a shallow helix, and then on the trail with minimal load we shift out all the way and BAM their goes the belt.
To have a clutching combination that works best for both will NOT happen. You are a lake racer or a mounting rider, you can't do both with the same clutch setup.
And IMO it all comes down to the helix. You need to get your RPM's set in the primary. And from the little I understand on the BC kits on the 1100 a 330 finish rate spring will not do it (you will still over rev with 93 grams with a 330 finish rate spring). You need something in the 300 range to get your RPMs in the 8100-8300 range.
If it was mine I would put in a 130/300 primary spring and weight it up so I reach my peak rpms. then I would start with a shallow helix angle like a 38 straight, then I would keep adding angle I find my RPM's dropping off on a climb, that would be the top end of the helix, (I bet it will finish out around a 40) then I would put a small multi angle to it just for a bit of fun factor, so I would run a 40-46 helix, and I would use a stock secondary spring.
Again I don't really know crap about the 1100 and the new sleds, but for the most part clutching is clutching.
And just one last time, I would set the primary up first, then get the secondary dialed in.
I agree with Eric that alignment, belt deflection, are issues, but these aren't the cure all issues.
And sorry but I don't think a tied secondary is going to fix it. You must have the correct angles and spring tension to get it to work also. Will it be better in the end. Most likely. But until it is setup for YOUR riding style you will be in the same spot as everyone else. Frustrated!
Thunder