Bret - I don't know the Star in particular, but looking at internet search pictures it looks like the same secondary design as all of the 80's -90's Polaris sleds.
If that is the case (and it sounds like it) - they were tight radially on the key, but if you had the bolt out of the end of the shaft, you could easily slide them back and forth on the shaft by hand - I remember I would put a light coating of grease on the shaft when I had those style sleds for ease of maintenance.
Another thing I was taught and did (not sure if this was right), was to put spacers under the shaft bolt that were slightly smaller than the OD of the shaft so that the secondary could "float" for better alignment with the primary. Like I said - not sure if that was right or not, but remember doing it.
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