1) My chain appears to be indicating “replace” on the adjuster (14k mi on the bike), while my sprockets do not look worn. Should I just go ahead and pony up for the sprockets now?

2) While shopping for new sprockets, I notice none of the replacement front sprockets include the cush drive rubber dealio. Is this not necessary? When replacing the sprocket, do the replacements come with spacers to take up the gap? (the cush drive OEM sprocket is surely wider)

3) When replacing the OEM 16/41 sprockets with a 16/43 arrangement, will the same length (number of links) of chain work, or do I need to add a link?

4) What should I look for when shopping for a chain rivet tool? Does anyone have any feedback for frist hand experience with the ~$90 tool Cycle Gear sells?
( http://www.cyclegear.com/eng/product...kit/web1006916 )

 

1. It seems unlikely that you used up the stock chain at 14k mile, check service manual.

2. There is no cush drive on countershaft sprockets.

3. 16/43 will work with stock chain (see knowledge base)

4. The Cycle Gear/Stocton Tools chain breaker/installer work s just fine. It's usually on sale for @40.00 It's also available from other sources. The best one I've ever used is the Honda oem breaker but it's now $230.

 

+1 to HRCA#1
Does chain slack change as you spin the back wheel? Are there any seized links or rust? Any missing O or X rings? If not, you may be able to get by just with an adjustment.
All things being equal, a new chain will last longer when it is installed on new sprockets. The world won't come to an end if you install a new chain on slightly worn sprockets.
The rubber disc on the stock front sprocket is there to reduce noise. It doesn't function as a cush drive.
A good quality aftermarket sprocket won't require spacers. Provided the sprocket is tight on the splines of the countershaft, a bit of lateral play isn't a problem.