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Re: 2009 KOP sprocket issues
We had this same problem with some small sprockets. We found that the set screws that we used were a bit too long. This allowed the chain to ride on top of the set screws and would not allow the chain to seat properly in the sprocket when it was touching the set screw. It was a tough one to find since the chain and sprockets were inside a tube and hard to see. if you have a digital vernier you can measure between every 4 to 6 teeth and compare the measurements all the way around the sprockets. keep looking I'm sure you will find the problem.
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