Notice that the motor shaft which the gear is attached to has 2 flat sides. You might have to look at the shaft eye level to see the 2 flat sides.

The shaft has 2 flat parts and the gear has 2 screws

Each screw MUST be perfectly lined up with the 2 flat parts or you will still have registration problems.

Please look at the following examples where in the first example the screw was CLOSE but not perfectly even with the flat point. In this example, the customer still had registration problems even though it LOOKED even. Upon further glance and eye level we noticed that the screw was just barely off which continued to cause problems. Notice that the yellow and red lines have different angles. This was very hard to see that they were barley off and even in the pictures it a bit difficult but if you look closely you can see the screw is barely off to the left of the flat point.

In our second example we correct this problem and now the arrows are perpendicular and the screws and flat parts are perfectly lined up.

The easiest way to line up the screws with the flat parts (with machine OFF) is to begin by loosening the gear completely. Once the 2 screws are loose, use a pair of pliers and GENTLY hold the front part of the shaft still why moving the belt left or right. The gear with the screws should move while the shaft with the flat parts remains stationary. Move the gear with the belt until the screws line up perfect center with the flat points. If they are not perpendicular, the problem may continue.