Thanx all for comments on sprocket sizes. I had a 17T 4 stroke Husky left over in my bits which I thought had no hope of fitting. I tried it last night & it will just barely go on if I modify the swingarm chain slider but the chain may tend to lick the engine case at the point where the clutch shaft fits in. A 17T sprocket with the proper 'berg centre bosses would be worse. I think you are right that 16T is about as big as you can go.
For change with respect to changing sprockets:
1. Divide the number of teeth on the rear by the number of teeth on the front for each sprocket set to be considered eg 42/14=3.000, 42/13=3.231. This is the number of turns the front sprocket makes for each turn of the rear wheel.
2. Divide the number from (1) for the set intended to be fitted to the bike by the number from (1) for those already on the bike eg 3.231/3.000=1.077. In distance this is the number of turns more (a number less than 1 means less) the front sprocket will have to rotate for the same travelled distance of the bike with the new setup. In speed this the increase in speed (a number less than 1 means decrease in engine speed) the front sprocket, and hence the engine when in the same gear, will have to spin at to travel the same road speed. This means that the engine will spin 1.077 times faster for the same road speed.
3. To work out the change in road speed with the new setup, divide 1 by the number calculated in (2) eg 1/1.077=0.929. This is the amount the road speed will decrease (a number greater than 1 means an increase in road speed) for the same engine speed.
As far as selecting sprockets to use, larger sprockets (both front & rear) will cause the chain to circulate faster (perhaps increasing wear?) but will reduce the tension or pull in the chain (perhaps decreasing wear?). Your guess on the overall effect on wear is as good as mine & I would not let that influence my choice too much.
I have not seen rears any larger than 52 teeth or smaller than 42, but they may be available. The larger the rear the more chance of it hitting rocks It also tends to wear the chain guide a bit more.
I don't think you will find a front smaller than 12T. Going this small will be hard on the chain slider around the front of the swingarm. The 13T on my bike looked barely OK. As said before, 16T is about as large as you can comfortably fit on a pre2001, don't know about later ones.
The 17T I tried came from a 17/48 I had for a long road trip on a Husky & I ended up doing much of the trip in 5th gear. I had to keep it revving due to a combination of problems.