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Kick start shaft install question

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Ok so now im rounding the home stretch on my girlfriends electric start conversion. So i go to put the last washer on the kick start shaft before installing the cover and guess what it doesnt fit. Ok heres the funny part. When I pulled the cover off the washer was stuck to the inside of the cover. So Im thinking I must have the wrong washer because it doesnt fit. So i order another one from service honda, and guess what its the exact same washer. Even if you stick the washer to the inside of the cover and try to put it on, the shaft wont fit through the washer. The shaft will fit through the cover with out the washer. &%$#@!. Do I need a different washer even though the parts catalog says to use the one I have.

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