Aerox 50cc starter clutch and variator got me beat...

Hello again if you read my introduction!

I am the proud owner of a $300 Yamaha Aerox 50cc. It came with a broken starter clutch, which I replaced with a Chinese version... then my problems started.

Apparently, the Scooter, which I believe to be stock except for a Leo Vince handmade exhaust, has a Malossi variator kit (please excuse my lingo, this is all new to me) with a red spring in the rear and 4.8g roller thingies as well as a Malossi belt.

My problem is that when I put it all back together, it almost seems like my crankshaft is to short to fit it all on and when I tighten the crankshaft nut to more than finger tight, I am locking everything into place.

I am going by the workshop manual and I seem to be using all parts... but as soon as the kickstarter bendix goes onto the shaft, I am out of room. Alternatively, when I leave it out, the (stationary) half has room to move. I don't get it...

 

Hmmm, just saw https://www.yamahapartsonline.com.au/product/90208-10012-washer-conical-spring/ , seems to be a special spring washer that maybe limits the pressure? I think I am missing that and am using a normal washer... is that the problem? It is part 21 in the picture: https://ypicweb.epconline.com.au/Image/getImage/582488/type/2

On second thought, that couldn't be it, it's really just a $12 spring washer...

 

OK, just for completion's sake. It wasn't the spring washer but for some reason the starter clutch wanted a shim or washer so my order on the shaft is: spacer - the washer!!! - starter clutch assembly - variator assembly - "axle" - other half of variator (no washer, I used it as "the washer") - star shaped drive thingo - kickstarter bendix - any old washer that doesn't cost $12 - nut. Thanks for reading!