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January 14th, 2013, 01:28 AM   #11
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From: Blue Mountains NSW Australia

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Re: 2003 SEM stator into 2004 Kokusan CDI electrics

Hi all,

A little more information and hopefully a leg up for anybody else attempting the project. Please see photos that I hope are self explanatory

Shots of 2003 motor with original SEM flywheel with motor at TDC[attachment=2:rapmfhel]Photo of 2003 SEM flywheel motor at TDC.jpg[/attachment:rapmfhel][attachment=1:rapmfhel]2004 flywheel on 2003 crank at TDC metal strip at 9 o'clock.jpg[/attachment:rapmfhel][attachment=0:rapmfhel]2004 flywheel on 2003 crank at TDC metal strip at 9 o'clock shot 2.jpg[/attachment:rapmfhel]

Sorry that the shots are so restricted but I had to keep cutting them down to fit (read:monumental pain in the #$%&).
I tried to keep some bolt holes in the shot to give some idea of the location. I am happy to send you the full shots in all there detail just send my an email address.

Regards to All.

Anthony
Attached Thumbnails
2003 SEM stator into 2004 Kokusan CDI electrics-photo-2003-sem-flywheel-motor-tdc.jpg   2003 SEM stator into 2004 Kokusan CDI electrics-2004-flywheel-2003-crank-tdc-metal-strip-9-o-clock.jpg   2003 SEM stator into 2004 Kokusan CDI electrics-2004-flywheel-2003-crank-tdc-metal-strip-9-o-clock-shot-2.jpg  
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January 14th, 2013, 01:40 AM   #12
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Re: 2003 SEM stator into 2004 Kokusan CDI electrics

Hi Anthony

On the first photo that you have with the SEM flywheel, you say you are on TDC. How did you checked that ??
Those line should have been to the left of the srew hole of the casing.

About the 2004 flywheel, if thats on TDC, your pick up coil will need to be just before the metal strip at TDC, so it will be in a very low position. I think you might have to change a bit the flywheel.

Just some thoughts.

My mail is zaga600@gmail.com


ZAGA
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January 14th, 2013, 05:43 AM   #13
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Re: 2003 SEM stator into 2004 Kokusan CDI electrics

Hi Zaga,

Checked tdc the old way with a screwdriver down the plug hole !
There is a few degrees of crank rotation where there is virtually no vertical piston movement and this is the position the crank is in for the photos.

The main problem remains in positioning the pick up far enough towards the centre of the engine so that it is in alignment with the pick up strip on the flywheel. there are only a few options.
1. move the flywheel out with some sort of spacer
2. move the strip out on the flywheel (I have no idea if thats even possible)
3. use a narrower pick up if such a thing exisits
4. machine back the cases to get the pick up back further toward the centre of the engine.

I later thought that if this side of the engine casing could be machined back 6-7mm the pick up would align with the pick up strip and a 7mm thick conversion plate would then position the coils of the stator in exactly the correct spot using the 2004 stator cover. Remembering that my 6-7 mm plywood trial plate bolted on standard cases left the stator 6-7 mm too far out of the flywheel and I spaced then back into the motor with washers.

At this point the splicing of the 2003 motor with 2003 SEm ignition/flywheel/stator/regulator into the 2004 wiring looked like the best option and this has been completed in rough form engine run and is now being tidied up with propoer connectors etc etc.

I'll post more photos if taken. Best of Luck to anybody that wants to go the next step.

Regards,

Anthony.
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January 15th, 2013, 04:26 AM   #14
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Re: 2003 SEM stator into 2004 Kokusan CDI electrics

Hi Anthony

For me the best option would be to move the metal strip, and its not just me, the others that have done that also chosed that option.

About the TDC, those few deg were you think that the piston has no movement is were you have to get it right, because there is, its just very little.

Here are some pict from my galery about it

[attachment=2:1ilv2x1m]Ignit_tim_1.jpg[/attachment:1ilv2x1m]
[attachment=1:1ilv2x1m]Ignit_tim_3.jpg[/attachment:1ilv2x1m]
[attachment=0:1ilv2x1m]Ignit_tim_4.jpg[/attachment:1ilv2x1m]
Attached Thumbnails
2003 SEM stator into 2004 Kokusan CDI electrics-ignit_tim_1.jpg   2003 SEM stator into 2004 Kokusan CDI electrics-ignit_tim_3.jpg   2003 SEM stator into 2004 Kokusan CDI electrics-ignit_tim_4.jpg  
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January 15th, 2013, 04:30 AM   #15
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Re: 2003 SEM stator into 2004 Kokusan CDI electrics

Here are some gides for the pickup coil position

Husaberg
[attachment=1:1bh9t8fk]Berg_04_ignit_set.jpg[/attachment:1bh9t8fk]

KTM
[attachment=0:1bh9t8fk]Ktm_timing.jpg[/attachment:1bh9t8fk]

Hope it helps

ZAGA
Attached Thumbnails
2003 SEM stator into 2004 Kokusan CDI electrics-berg_04_ignit_set.jpg   2003 SEM stator into 2004 Kokusan CDI electrics-ktm_timing.jpg  
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