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'08 DF 50...3 crank sensors or 1 ?

C

catfishin_welder

Contributing Member
I pulled flywheel to see if key had sheared. My factory manual shows 3 crank sensors under flywheel. I read a post online where someone else with the same year and model had 1 sensor on theirs as I do but it was located facing directly forward just behind the starter motor. Mine sits around the 7 or 8 o'clock position. Can anyone verify what is correct for this model? Ive reached out to Suzuki with no reply. Thanks for any input.
 
catfishin_welder said:
I pulled flywheel to see if key had sheared. My factory manual shows 3 crank sensors under flywheel. I read a post online where someone else with the same year and model had 1 sensor on theirs as I do but it was located facing directly forward just behind the starter motor. Mine sits around the 7 or 8 o'clock position. Can anyone verify what is correct for this model? Ive reached out to Suzuki with no reply. Thanks for any input.
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I tried to attach photo under my flywheel but it says file is too large
 
It will crank, occasionally pop, like it wants to fire. Ive been completely through VST fuel pumps, injectors, sensors, plugs, ecm, fuses. It all checks out proper. Cleaned fuel system, new filters. I can pull plugs, spray fluid in cyls and she will fire. I assumed timing was off and key might have sheared on crank shaft. It was not sheared but its tapered shaft and it appeared it wasn't seated all the way and it might have been misaligned on the keyway according to mark I made on flywheel before pulling it. It's got 200 199 200 for compression. I ran my Suzuki diagnostic software on it and see no codes thrown. Motor only has around 240 hours on it
 
The mark i made on flywheel before pulling it is 1" + difference ( clockwise ) when putting it down fully on taper and lining up keyway shaft and reinstalling to 122 ft lbs. The previous owner had it looked at by marina shop. I got his paperwork from marina stating checked flywheel, coils, drained fuel, changed NGK plugs, checked compression. They SUGGESTED to replace starter and factory harness. They couldn't get it to start so he sold it to me and put new 90hp on his toon. I never thought to pull flywheel first. I went back through everything I could think of except flywheel. It seemed out of time so apparently marina either did not check flywheel key or did then reinstalled it incorrectly. Im gonna wait on a definitive answer on the 3 ckp or 1 sensors, then button it up. Im thinking the flywheel was the problem
 
Assuming your check system on startup is working you should be getting a 4-2 code if your CKP is reading outside of specs. Failure symptoms is the ECM does not output the ignition and fuel injection signals. You stated in post #4 it will fire if you spray fluid into the cylinder, that would lead me to believe that your CKP sensor is working. I’ve never had my flywheel off but according to my service manual there is one CKP sensor and flywheel removal isn’t necessary to access the CKP sensor. My service manual is for a 2009 DF90A, different engine than yours but similar in age and technology.

Have you poked around the Starting circuit? To me it sounds like you have spark but you haven’t mentioned fuel delivery(or lack of)

Sorry I can’t be more help. Good luck.
 
William01 said:
Assuming your check system on startup is working you should be getting a 4-2 code if your CKP is reading outside of specs. Failure symptoms is the ECM does not output the ignition and fuel injection signals. You stated in post #4 it will fire if you spray fluid into the cylinder, that would lead me to believe that your CKP sensor is working. I’ve never had my flywheel off but according to my service manual there is one CKP sensor and flywheel removal isn’t necessary to access the CKP sensor. My service manual is for a 2009 DF90A, different engine than yours but similar in age and technology.

Have you poked around the Starting circuit? To me it sounds like you have spark but you haven’t mentioned fuel delivery(or lack of)

Sorry I can’t be more help. Good luck.
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It's getting fuel to the injectors and tested out within spec of psi according to manual. The flywheel was not seated down on the tapered shaft and was over 1" clockwise of the mark when I repositioned it over the keyway slot and torqued it down to 122 ft lbs. I think the timing was off and crank sensor not recognizing the flywheel at correct time. Im going to button it all back up and try her this wknd. I appreciate your reply. Does your manual show your ckp directly in front of starter or at 7ish o'clock position. My starter is dead center 6 o'clock on my motor
 
IMG_7730.jpeg
 
Doesn’t surprise me. If memory serves 2009 was the year that Suzuki came out with the series A and moved the 90 hp from the 50-60-90 hp family to the 115-140 hp family.
 
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