The # is your pitch not link/length. I buy 41 chain in 4 ft lengths and cut to size. From the angle of the picture, I can't picture your chain clearing the frame rail going back to the underside of the sprocket but it might just be the angle I am looking at. As DJ mentioned, you need to place the tensioner on the bottom (slack side) of chain- this might also allow you to clear the frame rail that I mentioned. I can't answer the other questions because my eyesight is failing to see what you are asking but sounds like you need a heavier return spring on the throttle, it might be binding somewhere, or you have some missing pieces. Is the throttle mount on the engine free or snugged up for the manual operation?