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Ian Parsons

I have checked the thickness of my low gear sprocket and it is 0.181 in or 4.60 mm. This is correct for the chain I mentioned. I suspect that your sprocket is a replacement made out of the incorrect thickness material. I wonder what the width of you flywheel sprockets are.

I fitted a 40T low gear sprocket to my 2 speeder. I got this and chain from Sprockets Unlimited. http://www.sprocketsunlimited.com

The English chain size is 1/2 x 3/16