Yamaha Aerox Scooter KickStart Pinion doesnt engage

[forestea]

I have yamaha aerox 2007 with stock transmission, however after some time my Kick start pinion started sometimes not to engage which lead to damaged pinion (photo of damaged pinion https://prnt.sc/PNcI9UjBlAl4 ) and now it slides through not engaging at all.

Well obviously I bought a new one and here is the problem: new pinion doesnt have hole in it as the old one (photo of new pinion https://prnt.sc/bZLUPnIFxuMl ) and it leads to another problem that new kick start pinion cant engage to the variator because cranknut is blocking it from engaging since cranknut doesnt have a hole to fit and holding pinion too far from the teeth.

I dont have much experience with this stuff but my conclusion would be that the old pinion was drilled because the crankshaft is not original? does that make sense?

I tried to drill a hole on a new pinion and it was pain in the ass. Unfortunately no luck since I probably centered it poorly and the conus was not right (photo of my drilled pinion https://prnt.sc/_4qlOYTUtdXq ) and it doesnt engage too.

what are my options? where can i find a right pinion for me? Thank you for your time in advance, looking forward for your advices.

[Nobby the Bastard]

So let me get this straight. Your old one was worn and stopped engaging.

You got a new one but couldn't work out how to put it together.

So... and this is the best bit.... you replicated the same wear on the new part in order to get it to fit and now that doesn't work.


Have I missed anything out?
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[forestea]

[WD Forte]

Just use the electric start
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bikers smell of wee

[Nobby the Bastard]

Why would the crwnkbbe swapped? Its rare that you can fit one from a different model.
You mentioned a Crank nut. Maybe someone assembled it incorrectly in the past and you are just trying to refit as you found it.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[forestea]

I just used angle grinder to make nut slightly more round to fit and it works like a charm, thanks for replies anyway.

[Nobby the Bastard]

[forestea]

[Nobby the Bastard]

If you need to take an angle grinder to something that should be in that position and came from the manufacturer something is wrong.

Bear in mind you also fucked with the other part to make it fit as well.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[Easy-X]

I dunno what's going on here but if a part is worn and (assuming you have the reassembly correct) the new part doesn't fit you've either bought the wrong part or something else is worn beyond spec
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Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[sickpup]

Did you phone the supplier and tell them the part supplied was different to the one in the engine?