Isn't the woodruff the internal key... I went to.theblocal shop here and both them and their sister store don't stock this also I measured mine at 3.25-3.5 mm

And is it twelve o'clock to the bike or twelve to the top of the cylinder head

 

Square key. I said 5,but believe it's considered 4mm.1995 2013 Polaris Magnum Xplorer Sportsman Scrambler 500 425 335 Crankshaft Key | eBay Two different keys on the crank,one for the flywheel,one for the crank gear that runs the counterbancer. Item #22.

 

So.alll those models use the same key?

Is it possible the crank gear sheared to?

 

Yes all the models from the 325 up use the same key,but the 500 was the one major engine to shear them.I Never had a crank gear woodruff key shear that I can remember on all the ones I worked on over the years. Several reasons why the 500 was the worst on shearing flywheel keys. If the flywheel wasn't torqued down properly,plus another is if one happens to back fire.This puts an added stress on an already weak link which is the flywheel key. My two cents is that they should have been wider and stronger from the beginning.

 

So now it fires up but wont hold an idle

 

Make sure that you have 1/8" slack MAX at the thumb throttle or the etc contacts in the throttle housing can touch and kill the machine. If throttle slack is good and carb idle adjuster wont help maintain an idle,then you may have to go into the carb and clean the jets. Primarily the pilot jet if maintaining an idle is the main problem.

 

Yeah I checked that but I've discovered I have fuel coming out the carb... into the intake

 

So reset timing reset valves cleaned carb... new plugs bkr6e and a bkr5e still won't idle it'll hold at about 1000-1100 then die

 

Make sure compression is between 55-95 psi. Shouldn't get too much higher because of the cam decompression device.If this is ok,then get a good Shindy carb kit.Shindy Carburetor Rebuild Kit Sportsman Scrambler 500 2003 2004 2005 Carb | eBay Looking back on your previous posts,shows that it's been modified to some extent by first owner with a different cam? and exhaust system? May or may not be part of it of the problem.

 

Sorry for the lapse..

I finally got around to doing a compression test. It would seem that I'm getting 100psi no choke and about 110 with it pulled out. I'm going to assume that this is bad...