Join Date: Nov 2018
Location: Texas Hill Country (1hr NW of San Antonio)
Mentioned: 2 Post(s)
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Sorry to hear of your troubles with the 520 conversion. Usually not an issue, so not sure what's gone wrong. Did you buy the sprockets and the chain as a 'set' (meaning, all together, as a package deal) or did you buy each piece separately? I only ask because it seems like every now and again, you go to order a sprocket and get the wrong tooth pitch sent and it wasn't your fault and there is no way to know you got the wrong thing until...it doesn't work out.
Hopefully you can just switch back to the OEM setup and move on. I tried a 520 conversion on my CBR929 and felt absolutely no difference, which was kind of disappointing. In THEORY, I should have noticed easier/quicker acceleration from the lighter chain, but that didn't prove out in real life.
What's most sad is breaking your sprocket cover. Dang! Did the countershaft bolt come loose? Not sure how the GSXS is setup but most bikes have a washer you bend over on one of the nut flats so the nut can't undo itself. If that's not the setup, then I'm think blue loctite becomes your friend. So sorry for the issues you're having. It can certainly be frustrating when new parts don't work out as planned. Hopefully nothing else was damaged and you can get fixed up and back on the road quickly.