Yamaha Aerox KickStart Pinion doesnt engage

[teaforest]

Hello, my english is not the best, but ill try my best to explain.
 

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) 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 ) and it leads to another problem that new kick start pinion cant engage to the variator because  cranknut is blocking it from engaging since crankknut 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) 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.

[bud]

That new pinion looks correct. Have you a picture of the crankshaft?

Has someone spaced the variator out too far?

Edited May 30, 2022 by bud

[V650]

Looking at the photos of the old and new the hole that you have drilled does not look to be the same angle ( less Steep )

if you had a bench grinder you could possibly modify the angle of the drill bit but it may be difficult and your pinion is probably hardened 

Edited June 6, 2022 by V650