I'm not sure how the sprocket change and tyre size is related.

I guess what darkknight is trying to say is that a chain that has run >20k kms will have the chain adjuster pushed as far back as possible to maintain the chain slackness. Now, if you put it in a wider tyre without decreasing the aspect ratio, the tyre the will touch the front part of the swingarm as in dggopal's case since the chain adjuster cannot be pushed further back.

hmmm

so are you saying that if i put an new chain in my bike I can increase the distance even more between my swing arm and the tyre?

No you got it wrong. The chain adjuster should not be used to increase the gap between tyre and the swingarm! It is only for adjusting chain slack. We must make sure that we buy the right tyres instead.

easy fix

The best solution what i figured for both the cases specially spiders case is put the new sproket and let the old chain be the same or add an extra link to the new chain that will fix all the issues

Thanks for the info dk

Thanks for the info dk

The green paste appears to be what is known as Janta Paste and is an older version of M-Seal.

I'm afraid you could have compromised the strength of your frame. A swing arm is an integral part of the motorcycle frame and cutting holes/shaving off and then filling them with Janta Paste is not a good idea. I wouldn't want to be at 100 kmph on a long sweeping curve, nicely leaned over when the swing arm decided to twist itself out of shape because of the Janta paste holding it together (I know I'm exaggerating here, about the JP holding it together).

Unless you know for sure what exactly was done - which doesn't seem to be the case. Can you be sure if the metal shop took a whole swath of metal off or simply buffed the area where the 'bump' was? If you're not sure, then just change the swing arm. I would if I were you!

While I'm not sure(if it is recommended), I believe adding one chain link would have lengthened the chain suitably and given the tyre the necessary clearance.

If changing the swing arm go for the p200 swing arm. P200 has 120/90 tyres stock.

P200 stock rear tyre size is 120/80 R17.

darn

yeah I don't really know what the metal shop guys did... I gave the bike to my local mechanic and he got it done... but as I know now... mechanics are sometimes dumb here and don't know what they are doing... The bike seems stable enough... I dunno what to do now... I mean its riding really nice right now but again I don't want to be going fast and all of a sudden it decides to buckle... how big and expensive of a job is changing the swing arm? anybody know of a good place to get it done in Bangalore?