You state, "We had to set them on first fitting," and I was looking for the second sentence that would tell me
how you set 'them'. Initially I believe I had the outer nut against the Belleville washer too snug so the washer
would not spin on over-ride as it should. Later I backed it off and set it by feel. Then set it by inch pounds. Then I've set the gear drive into the primary chain, high, low, center, etc. and still knacker the drive gear and have never hurt the
primary, so it's obvious I haven't come up with the right formula for setting the unit itself. I've been running with a worn out drive gear for a very long time and 'if it ain't broke don't fix it,' is my attitude now. The unit still charges just fine.