When I took my flywheel off my Grande for the first time (last week) I discovered that the woodruff key holding it to the crankshaft had been sheared right in half. I figured it was old and worn so I put a new one in. When I opened it again yesterday to replace wires on the stator plate (electrical issues) I discovered it had been sheared in half again!
The bike only ran a total of 5 minutes before I opened it again, but I spent a lot more time than that turning the engine over by hand and riding the bike down the driveway to check for spark or see if the engine would start.
As for damage that I can identify, there seems to be some scoring of the flywheel where bits of metal were ground up as the crankshaft spun, and a little "notching" where the flywheel should push up against the woodruff key. It's not much though, the woodruff key still pushes up against the flywheel solid.
Does anyone know if I'm doing something wrong, or why it might be breaking?