| loverobot>
When you say "the holes dont look to line up exactly" I take it you mean the tapped holes in the sprocket and the holes in the retaining plate if you offer it up.
That's the point of the groove with no splines on it on the shaft. Can you see the groove in front of the sprocket? The retaining plate sits in the groove, and it has to be rotated a little in the groove so that it lines up with the tapped holes in the sprocket (this is on re-assembly, if you see what I mean). if these holes weren't offset, there'd be nothing to stop plate and sprocket sliding along the shaft, past the groove, until it started rubbing on the grey plastic cover.
But presumably if you've taken the plate off, you know this already?
My guess'd be that the splines are clogged up with gunge. | 
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