Hi all,
I just completed a winter stripdown and overhaul of my 9 month old bike. I split the chain with a Park Tool CT-5, pushed the 2 original pins out and after cleaning and relubing the chain (Prolink Gold) I rejoined it with a genuine KMC 9sp missing link. It all went smoothly, and all works perfectly except... on 9th rear sprocket the chain now jumps, rather like a worn chain, but twice. Once as the link goes onto the cog, and once as it comes off the other end.

Chain: Shimano HG50 9 speed. <0.75% stretch (way less)
Link: KMC 9sp missing link, bought from a reputable, large high street store
Cassette: Shimano HG 11-32 9sp

What appears to be happening is that the 2 pins on the missing link stick out a *tiny* amount from the plate, and stop that segment from sitting down into the sprocket. Why only on 9th I don't know.

Has anyone come across anything like this before? I'm 99% positive I've not missed out any spacers between 8&9 or suchlike, so I'm wondering whether to file to end of the pin down

Cheers
Jon