Chain Run

Fitted a new 38T rear sprocket and fitted an old chain to calculate the length of new chain needed, but ran into a few issues previously overlooked or missed. 

I really need an 8mm offset front sprocket which will line up with the rear chain on a standard un-shaved carrier and also clear the inner face of the chain tunnel of the swingarm. I was hoping a 4mm offset would work but the chain is too close to the swingarm.

Running the 8mm offset or any offset for that matter creates 2 problems, (a.) the chain will hit or run too close to the exhaust and (b.) the chain and sprocket will be too close or hit the clutch pushrod actuator on the inside of the side case.

Problem (a.) can be over come with a secondary chain roller ?????

Problem (b.) ?????

What lies beneath

After polishing the hell out of the Frame, Swing Arm & Hangers [Images to follow] I made a start on the rear wheel. I have the old Tyre off and attempted to remove the brake disc, to no avail. 2 of the studs are corroded in place. 3 of the 5 I removed with an Impact driver but the driver has just damaged the allen head of the studs.

There is also a lot of work ahead in stripping the paint from the wheel and removing the corrosion underneath and then recovering . . . and the same with the front also.

Heavy Corrosion

Here is the second batch of images before the clothes are stripped.

There is a lot of corrosion to all the metals and some general observations below.

1.] the chain and sprockets need to be replaced, I was going to clean the chain in Kerosene but its too far gone.
2.] the rear shock is leaking and heavily corroded.
3.] the l/h gearchange and footpeg hanger seems to have been bent.
4.] the brake discs dont seem to be too bad, although the brake surfaces are rusted they are not
heavily worn
5.] the brake hoses seem good but we would be looking at changing them for braided lines.
6.] almost every nut and bolt while originally being galvanized or coated in some way have been attacked by rust to the plan is to replace them all with stainless steel.