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Update

Bought a new race variator kit from Scooter Assassins for less than 40 shipped.  Bam!  Takeoff problem solved.  Still have no clue on the kicker.  Just got done trying my new spring.  Still haven't tried shimming the cover though.  Anyone know the proper recipe on the shims?  Washers aren't terribly expensive so I guess trial and error on that is my next move.  Only thing is, that would entirely defeat the purpose of a gasket.  So all kinds of crap that doesn't belong would be headed for the belt and the parts around it.  Anyone want to buy an electric starting ZX 50 in Sacramento?  Goes 55 on slight downhills.  50 on level.  All the lights work!  Everything works, just not the kick start.  Lots of nice new parts on it.

What a mystery machine.  You know what?  I'll just have to get back to you guys on this.  I mean, I drove it at least 10 miles and there's no smoke coming out of the exhaust.  So, what I'm thinking the reason for my slow takeoffs is either:

1. faulty fuel valve (I have a rusty fuel tank)
2. too much grease on the slider weights
3. carburetor issue

You can see a nice amount of oil leaking out the air filter, which I would expect from twisting the throttle.  When you twist the throttle, it opens up the oil pump as well as the carb.  So I don't know, sounds like a fuel issue.  We'll see.

Good points, there.  Well I followed the video on installing the dr. pulley sliders, rethreaded my crank, installed together with new kymco washer and nut.  Put the cover and gasket on, and nothing.  Same problem.  True I have a Malossi variator, and a straight boss, BUT it all worked together before my belt snapped.  It had worn out roller weights in it, seems to be the only difference.  Slightly worn starter gear parts.  All I can think of now is maybe I should replace my sliders with rollers?  But why?  Why would my sliders not work?  OK I lied, there's another thing I can think of.  The 3 piece slide parts I got for my variator.  I got them because when I took it apart, there were none.  Unfortunately I got them from a generic scooter part supplier and they barely fit the plate.  So I guess my next move is order the stock piece slides and stock roller weights and then see what happens.  I'll try it first with the no piece slides with stock roller weights.  Then if that doesn't work I'll try stock piece slides with stock roller weights.  Then if that doesn't work I'll try stock piece slides with sliders.  Then if that doesn't work I don't know what else I could be doing wrong.

Edit: just saw that shimming technique you guys posted.  Might have to try that first!

OK well the special washer is part 98.  It is described as WASHER SPECIAL 12MM.  Anyway, if the washer I got at the hardware store is any different in specialness / thickness, then that could be when my kick start doesn't work.  Same with the nut.  But, since my engine doesn't want to turn over smooth (since installing the new sliding rollers), then I very well could have installed those wrong.  Easily.  So thanks for the vid there, I'm definitely going to use that soon.

Side note:  The reason the threads got stripped, so I thought, was only because I mistakenly used an impact wrench on the nut.  But, in retrospect, stripping the threads was made easier by the fact that whoever was in there last, left out the washer!  So they snugged the nut all the way down the shaft, effectively screwing up the end of the threads.  Lazy.

I finally installed the kick start mechanism properly in the belt cover.  The video really helps, and using the kick lever to rotate the kick gear really helps too.  When I put it back on the engine, it won't move.  When I got it, it was missing the "special washer" that goes behind the crankshaft nut.  Not realizing how special it was, I bought a regular flat washer and threw it on.  That could be the whole reason why I'm not getting movement - not enough clearance between the crank nut and the driven gear.  So a new special washer is on the way.  The other thing it could be - correct me if I'm wrong, it's not right in front of me - is the 3 slide pieces I just installed on the variator plate.  I got them from partsforscooters for some reason.  Oh yeah, getting parts from kymcopartsonline is a nightmare, that's right.  Anyway, those were an extremely tight fit and not the exact shape they should be.  Not sure if the thickness is any different though.  It's a Malossi, and when I got it, those pieces were missing.  Would that hurt anything?  I'm thinking it's better to have no slide pieces than the wrong ones, maybe.  On top of that, I ruined the threads on the crankshaft, twice.  Might be looking at a new one of those, too.  Wish me luck!

I tried different ways of putting it together.  As far as spring placement on the half moon gear, I tried one maybe both of the notches, I tried the hole.  I tried preloading the spring, I tried not.  No matter how I put it together, it won't kick over when I put it on the bike.  So that makes me think.

I eventually consulted the manual and found the correct way to hook up the spring, but it's just a 2D view and doesn't account for how the spring should look under the half moon gear.  Very frustrating.  I tried shoving it down and around the shaft bushing area (kick starter spindle forcing part, according to the manual) on the case, but that seems impossible.  All it says about a screwdriver is "If the hooks of the return spring can not be installed properly, use a screw driver
to press them into their locations respectively."  And that's not my issue at all, putting the spring hooks where they belong is easy without a screwdriver.

All I know is a) my spindle has endplay b) my spring won't wrap around the forcing part (isn't it supposed to?) and c) no-go on the kicker!

Hey thanks for the tip.  I know the relay is functioning because the starter does crank.  I will check the brake switch and re-check the start switch.  Sounds like a logical place to look if the relay is new and sufficient, just like the starter.  After reading the manual, I do believe the fuse is 7.5A.  The fuse is still good.