A couple of things about the drive chains and possibly skipping a sprocket tooth (older Stainless sprockets):
1) If the chain skips a tooth the easy way to get the chain back on the right tooth is to press hard on the opposite pedal from which it originally slipped. Once it is on the right tooth again tighten the chain properly.
2) The proper way to tighten the chains is to make sure that the front chain is tighter than the rear. The front chain will be tighter than the rear when there is proper tension in the Idler cable (goes over the drum up front, from side to side). Any tension in the Idler cable will add tension to the front chain and reduce tension in the rear chain. Whenever the chain skips a tooth it is always the front sprocket. We suspect some people are tensioning the chains and are overlooking the Idler cable.
3) If the chain skips a tooth the drive will still work – the stroke will be shorter and unbalanced, but it will still work. We would not recommend disassembling the drive on the water.
4) The newer injection molded plastic sprocket has done a good job of eliminating the skipping problem.
Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA