1984 kawasaki tecate crankshaft woodruff key help

[nonesense]

My first Kawasaki tecate and I'm stumped on this one. Got it with a sheared key. Pulled the stator cover to find a Ricky stator in OK condition. I ordered two different keys from two different dealers and they both are no good for the slot. Helpppppp! Look at the crank shaft it looks different and the key slot has more detailed grooves. 146954

[tri again]

My first Kawasaki tecate and I'm stumped on this one. Got it with a sheared key. Pulled the stator cover to find a Ricky stator in OK condition. I ordered two different keys from two different dealers and they both are no good for the slot. Helpppppp! Look at the crank shaft it looks different and the key slot has more detailed grooves. 146954

Can't really tell what you mean about the detailed grooves from the pix.
So the key was actually sheared into 2 pieces?
That's kinda what they are for, on some engines they are aluminum so they don't wallow out the groove.

In the extreme, it could be welded and recut.
What's the condition of the mating piece? Flywheel groove?

If it was mine? and I had few options and little $?
I'd find a soft key that fit as tight as possible and try it.
Any hardware store or autoparts usually has those flip top boxes with 20 different sizes in each one
20-30 cents each.

If it already sheared once, and it happens again, it almost can't make anything worse.

My bet is that who(m)ever replaced the stator, couldn't figure out how to torque it properly
so it spun.

Some engines, especially lawnmowers that hit rocks and shear crank keys
or even mangle them a bit, (like a .0010" dent) will throw off the timing enough so they won't run but not sure about your machine.

I'm getting lazy so if something requires more work than I care to do, I'll just wait for another whole trike for 100 bucks
and make one out of 2, so all is not lost.

I bet you can make it work.

[just ben]

its just half moon a woodruff key.I bought one just yesterday at the hardware store for my 85 tecate. they do fit tight so you may have to gently tap it in,a drop of oil helps too.

[nonesense]

I have the right key 92038-001 but it doesn't even come close to fitting. I was hoping someone would recognize that it's an aftermarket crankshaft. The key slot is very different from stock.

[just ben]

besides the chewed up end, it looks stock.

[jeswinehart]

X's 2, as Ben said.

[nonesense]

I found this picture in another thread. His key slot looks perfect for the key i have. Why is mine so different? It's not near as deep or round. Unless my eyes are playing tricks on me and there is still half of the key in there. One half was lodged in the flywheel. Oh the damage on the end of the shaft is from me :D I was about to grind it in a fit of rage when I realized what I was doing [ATTACH=CONFIG]146975

[jeswinehart]

I decide to go out and have a look at the fly wheel on the crank of a T-3 parts motor i have under the bench. Not as clear of picture as the one you posted Andrew but none the less.
I also have some fly wheel upgrades I am working on and decided to snap a shot of that key way slot.
Are you getting the metric flywheel keys ?
146976146977

[nonesense]

Im using the official kawasaki part number the guys pulled up for me at escondido cycle center and north county house of motorcycles in san diego. See how your key way is much deeper and rounded for the half moon shape? I Have a ricky stator flywheel with sealed magnets but the key way slot is identical to the one you have. But its the crank im puzzled as to where to look for a key that matches it.

[just ben]

I think part of the key is still in the crank.I bet if you work both ends of the keyway slot with a small punch it will loosen and come out.

[nonesense]

Just ben you knew all along didn't you? I beat it with a chisel and it unwillingly slid out. It sheared in such a way that it looked like it was part of the crank. Well this is why I joined the forum. Thanks fellas.

[just ben]

Glad you got it sorted out.