First post for a long-time 4 wheeler. Just bought my 4th suzuki samurai and may have more than I bargained for. I'm looking for some input regarding my 86 tin-top. Was troubleshooting a knock in the front of the motor and noticed the timing belt was grooving into the cover. Removed belts to find timing gear could be hand-rotated without the crank moving...Removed gear to discover keyway is seriously wallowed and key is worn beyond use. Does not appear crank can be saved and wondering now what else might have been screwed up when the last owner changed the gear. I'm debating changing the crank and hoping for the best vs a complete teardown. If I tear it down I suspect the rebuild will cost about the same as a reman short block. Any comments would be appreciated. I'm not planning to race, aggressively off-road, or anything else that will require extra horsepower so don't really need a swap for power. Anyone bought a long block from a rebuilder lately? Thanks for the input. BTW...1st suzuki was a 1979 LJ purchased in Guam...800 CC motorcycle motor! What a ball that was.

On the plus side, the 1.3 is a non-interference engine so you don't have to worry about the valves smacking into the piston.  The issue probably came from when he replaced the front seal on the engine.

I'll let someone else debate the engine swap vs rebuild though. 

I got lucky when I found this same problem on my 87 Sammy.

I was able to save it by using "Gray Loctite" on the crank gear. (It's still holding a year later)
This is special Loctite to fill in voids along as securing two pieces together.
                                                          - OR -
Also, if it is TOO SCREWED UP, you can get a new gear, pull the crankshaft out and have a shop cut a new
woodruff key 180 degrees opposite of the screwed up one. install the new gear and set the timing knowing that
the drive sprocket is 180 degrees out.

Just a couple of Ideas to help you out.

CAPT

Actually Capt, that is a good idea, but the timing really isn't affected, as the
pistons position doesn't matter, only the cam position would determine the
timing, and ignition timing mark that is on the front belt pulley, so you can
set everything the same as you normally would.

This is a great way to save a crank for a small amount of cash

Tech point for you 

Wild