Sorry, I'm really confused. All of the front clutch parts fit nicely and line up on the crankshaft. The only issue is the keyway does not protrude out to lock in the face plate. Were would all the metal build up come from you're telling me to file/torch off? The flared part of my crankshaft look like it was manufactured that way. I feel I'm about to loose my fight with this little machine.

 

Sorry dude but the only issue you have at this point is that you won't pull that starter gear. The crankshaft was not made that way. I guarantee it.
That roller plate notch needs to go on the key. If not, it'll spin(like it has been).
Once off, I'm sure you will be able to clean the starter gear center up and see/understand more then.
What state are you in?

 

 

Can you explain exactly what I need to grind/torch to remove the starter gear. Do I need to grind around the key to expose and remove it first? Just guessing. I don't want to start going down this path till I know exactly what I'm doing. Thanks for all the help so far

 

To be honest sir, I'm guessing also. I've not seen one this bad.
Yes, I'd start by grinding the old key. The starter gear should be flat. Careful of the crankshaft. For what it's worth, I'm a fan of heat. I'm wondering if you got a torch in there if that flair thingie would sorta expand and fall off.
Been thinking on it. You asked where the flair would come from. It has to be from the old roller plate or the starter gear has sorta melted on the end there from the clutch spinning on the crankshaft.
One of us may need a road trip. LOL

 

Ok, I think I finally understand what I have going on. I looked at an image of the starter gear realized the wider part of crankshaft is actually part of the starter gear. Correct? Can't believe I didn't realize this sooner. I kept thinking my crankshaft was different because I couldn't see a seam around the damaged starter gear flair and the crankshaft. I agree on heating it up and see if it expands enough to pull off. Does anything besides the key hold the starter gear in place? Thank you!

 

Nothing holds it on. The key stops it from spinning. It's supposed to pull right off.
As you see now, the edge where your flair is, is supposed to be flat.
I can guarantee you that your crankshaft is the same as all other LT80's.
You're on the right track now.

 

Solid! I'll report back after I work on removing it. Thanks again

 

I spent an hour getting no where surgically grinding the flair with a dremel so I decided to sacrifice the starter gear. As you can see I cut the keyway out and took two vise grips to break the starter great loose. Looking at the starter gear you can see the metal burs created by the clutch face plate spinning. The burs were bitting into the crankshaft not allowing it to pull off prior to twisting the gear loose. New keyway and starer gear on the way to get this machine finished up. Thanks for all the help LT80

 

You did very well!!!!
It was a tough job!