Welcome- Nice Hammerhead!!
I'm guessing you shredded the Hammerhead belt? To eliminate rust/debris as a suspect, you need to confirm that the surfaces that the belt makes contact with are clean/smooth.
Take a pic of the ATV's for us to see what clearance issues you're having-so we can provide opinions about modifications to fix them. Yes you can straighten the chain guard and yes most of us have had to straighten one or two when bent! Putting larger/taller tires shouldn't be a big issue, the change will require more torque to get rolling. Check the turning clearance with the tires you have now to determine how much taller you can have without adding spacers.Check for height clearances in the rear also.
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