Is the rear sprocket wearing away at the sides of the teeth. If it is it sounds like an alignment problem.
I guy I was helping once used a lazer align and it was a plastic one that was no use to man nor beast as it flopped around that much on the sprocket he was setting it way out thinking it was true.
In my experience even with new carriers, sprockets, axles etc they tend to be slightly out. I have found the best way is to set it with a good straight edge and then lie underneath the kart looking up at the chain and rear sprocket. If you can see daylight between the sprocket and outer link of the chain on only one side then adjust it so you can see it on both sides.
I have done this for years and my chains and sprockets will easily last a season.
Hope this helps.
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