Havasu Dave,
What are the pros and cons of going from #35 to #40 or #41?
As I looked at the chains it would seem to be better to go with a heavier chain. But I don't know if it is a detriment or a plus going that direction.
Too bad they don't have a setup using a belt like on motorcycles. LOL
From my point of view, all of the chains have the required strength for the average mini bike. What I like about the 40 series is that they're wider, which gives a bit more wiggle room on alignment. They also have less tendency to twist, but the Gold chains in 35 work well too.
You can change clutch sprockets. I just had a custom made Max Torque done up by Jim Donovan with a 35 chain and 10 teeth. (Two stroke application) As far as the rear sprockets, availability has more to do with bolt alignment per bike type, than with number of teeth.
Where size and application issues prevent attaining a desired gear ratio, there is the jack shaft option. Fixes alignment problems and allows use of shorter chain sections and swing arm suspensions too. (I like JS) There is also the TAV option which gives you centrifugal driver gear ratio, and torque-sensing rear driven ratio all at the same time. This belt application is then transmitted to the rear sprocket via chain drive. No reason a belt pulley couldn't be used with a bit of fabrication.
Just a couple of thoughts- all of these options are mostly dependent upon the type of bike. I am not the expert, just posting what I've learned along the way.
