SR 50 won't start and noisy variator please help

hey guys, it's my first post here, I ride a 2005 Aprilia SR 50 R Carb model, and recently i've had a few problems...


the variator fan had some extensive wear on it, so i replaced it with a new one, fittdd variator back together, and then after about two or three rides (approx 50 miles i'd say) it decided to stop starting. I took the casing off and the starter motor had spun right out and was lying in the bottom of the casing. i put it back in place and checked everything, the brand new fan already had sufficient wear on it, and the kickstart was stuck in the vertically down position as the spring had jumped out.
I put it all right and re assembled it. it still wont start on electric start... only just starts on kick... and stalls if you leave the revs off for more than 5 seconds (even when engine is warmed up)
it's not even attempting to turn over, the starter does nothing, not a sound or anything. the battery is fully charged and is still charging fine, and when i drive and let off revs a hear a violent rattly vibration coming from the variator casing somewhere.
Drive belt has been on for the last 10500 miles and some of the thread on the side is starting to come away.

Does anyone know what could be the problem?
what will i need to replace?
will i need a new drive belt?
would a 9 roller variator kit fix the problem?
could be as simple as a spark plug?


Any help would be greatly appreciated.

thanks a lot.

 

if the plastic fan has been rubbing on something, then something is not seated correctly inside your tranny case...

The most common mistake fledgling scooter mechanics make, is not locating the centre piece properly on the plastic fan before tightening the variator nut up, this causes the fan to sit crooked, and in some instances the fan can fall off completely...

other things to look out for is making sure the starter pinion is located properly, and making sure the kick start mechanism is greased up to prevent the kick start sticking in the downwards position

 

hey mate, i made sure it was straight when i put it on as the same happened to a friends fan wheel.

it also makes a sort of whirring sound like an electric fan gone mad since i fitted the new fan

 

ordered the following parts, hopefully it'll work better and faster now:

Stage6 performance variator
Stage6 pulley (kickstart only style)
new kickstart shaft
new kickstart spring
lock nut washer (for kickstart)
kevlatr drive belt
new variator caasing bolts
new kickstart lever
new mirror
oh and a cdi unit that will get rid of the rev limiter.


gonna probably spray the variator casing black at work, should hopefully look good, i may even post pics when finished