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pulley alignment appears fine, belt is fine, but htf does this happen. It's still a fairly new mower with 126 hrs on it. I've already replaced the pulley

Somewhere a long the lines of that's not how any of this is supposed to happen... The motor to deck belt is getting tighter and tighter to put back on at it throws the belt, don't even need to engage the idler pulley it so tight have the correct belt size B-85, with a B-86 belt it flips the belt...