The subject that I want to cover is The DR350 concerning failures of the engine due to a hole in the crankshaft that is suppose to lock the drive gear for the counter balancer to the crankshaft. This indexing hole is supposed to be drilled just deep enough to keep the locking pin that is pressed into the counter balancing drive gear from escaping. Well some where some one at the crank factory is drilling this hole clear through the right crank half. This allows the locking pin to move into the crank if its press fit happens to be marginal. When this happens to a point of escaping the drive gear the crankshaft and counter balancer are no longer timed the rod hits the heavy counter balancer weight and blows it right out the front of the engine. This destroys the cases, counterbalancer, cylinder sleeve and crankshaft.

The Danger in this to the rider on a busy freeway, or passing a vehicle with oncoming traffic coming at you plus numerous other possible scenarios is really frightening.

I am sending this as well as some photos that I took of the engine and parts that I sent to Suzuki.

I have came across quite a few 97, 98, and 99 models that have not yet self destructed and have made a repair to them by pressing a tight fitting pin to replace what was drilled out I give this pin a .002" press fit and it is .375" long the diameter is .320" and the hole is .318" so it should not allow the locking pin to move beyond its home in the crank. But quite a bit of work is involved to remove the crank to perform this task. I could order a new crank or crank right half but am afraid that I will get one just like I have and then will have to fight with the dealer and Suzuki to get it corrected.

Its is confirmed that '94-'99 are affected. 2 '96 models have grenaded in early of '05.

For damaged component pictures click here