Something sounds wrong, here.
Are you sure you have he sprocket carrier mounted the right way around? Can you remove the sprocket WITHOUT removing the carrier?
The reasons it sounds confusing is that it is usual for the shoulder (the widest part of the sprocket carrier) to be on the INSIDE of the sprocket. That would usually make IT contact the end of the bearing itself before the bolts of the hanger/bearing-clamp intefere.
Are you SDURE you have this the right way round?
Secondly, are the bearing clamps correctly constructed? Usually, the order would be for the bearing to go INSIDE the bearing carrier. The next point is that the HEAD of the bolts should be on the OUTSIDE of the hanger, not the end of the bolt with the nuts on it. Are you sure you are not using too large a head, hanger clamp bolt?
Next, you ARE putting the sprocket bolts from the INSIDE of the kart so that the nuts (and any over-hang of the bols themselves) go on the OUTSIDE of the sprocket.
Next, if you are using cap head (allen) bolts, then they don't usually have a washer on the INSIDE as that is straight only to the carrier. Some people fit washers on the OUSIDE of the bolt (between the nut and the sprocket) but by NO means do we ALL do that.
Your last choice is to photograph your set up and post it to a free picture hosting site. Then post THAT address here so that we can see it. Don't forget the 'user name' and 'passowrd' if you use a picture site which needs one.
Here's and example of such a site:
myphotoalbum.com
Ian
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