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I have been a professional master mechanic for over 35 years and am happy to help you with this.
Did you get a good look at the crankshaft slot where the key fits and see if it shows any sigh of damage?
Are you putting the key in the crankshaft slot or are you trying to put it in the pulley slot?
The correct way is to use the crank slot.
so i take it that it will go in a little bit?
If so have you tried tapping it in further?
note: it wont go all the way into the slot, only about halfway.
Thats about the only thing thing could have happened if it wont go all the way in.
Below is a pic of the inside and i can see how that could happen..
yup, unfortunately you are going to have to remove that dam cover and see what slipped out of position.
I bet its hitting the face of the gear inside and just needs moved a little.
My pleasure bud. Hope I helped a bit.
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I can remember being in that spot before with that long key. Usually they are shorter.