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Thanks to everyone who replied. I wasn’t sharp enough to realize what a smaller rim meant.

I think you nailed it. It is an 8 pin sprocket with a diameter of about 41 mm. A 7 pin sprocket I looked at online has a diameter of 35.5 mm. THAT difference would be enough to make the chain fit. Follow up question: is it better (cheaper) to buy a new sprocket, or start buying 25” chains...

I know! But I’ve never had this issue before and I don’t have any other 24” chains to measure against to check the length. So frustrating. I want to return the chain for being defective, but I want to be sure it’s the chain that’s defective and not me...

When I try to put it on as one piece I come up this short (see pic). I have never had this issue with any bar/chain.

The bar is stamped for 84 links and the package for the chain is 84 links. I just can’t figure out why it won’t fit.

I am fixing up a Stihl MS 460 and I bought a 24” Oregon bar and a 24” chain for it. The chain slides in the rails smoothly, fits the nose sprocket fine, and fits the saw sprocket fine. The issue is it seems like the chain is ONE link too short! The chain is the correct 84 drive links (I...