If I had to guess I would agree that the key is the problem. It is actually called a woodruff key, and it is very important you don't just buy any key. You should use the correct one for a propeller shaft...it is able to shear down the centerline in case of a prop collision, thus allowing the prop to stop and take the damage rather than the shaft, drive, gears, etc. If you use a standard key from a hardware store, and your prop has a collision, the damage to the drive system can be very expensive if the key does not shear.
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