Husaberg
Go Back   Husaberg Forum > Mechanical and Technical > Electrical

Electrical Electrical Forum - wiring and more


Thanks Tree48Thanks
Reply
 
LinkBack Thread Tools Display Modes
June 1st, 2014, 03:50 AM   #1
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
SEM KOKUSAN Conversion

has been done by a few people

I like this one Kokusan in Husaberg









more threads HRBmans pics are in the gallery so they don't show up

Cross Ref KTM/BERG - KOKUSAN

Sem to kokosan rebuild possible?

more results via google https://www.google.com.au/search?new...21.Mo3fRJVH4G8
Thanks from makazica
bushmechanic is offline  
 
June 1st, 2014, 04:01 AM   #2
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
I'm using the husaberg Kokusan ignition system to put in 2002 650 cases simply because that's what i have to work with.

the easiest way IMHO would be with the FC stator and flywheel as they will easily allow the pulse coil to fit inside the 02 ign cavity, the FE flywheel is bigger and pushes the pulse coil out into the cavity wall

FC flywheel 80039005100 $200 USD and stator 80039004100 $160

this build of mine is made up of my spare parts so im using the big flywheel

I put both 02 and the newer cases in the mill and clocked all the important bits then put the pulse coil in the model, see PDF

on these 02 cases the required centreline of the pulse coil is nearly aligned with the drain plug. if you were to punch a mark on the centre of the drain plug it will be only out by approx 1.5 deg advanced. FWIW if you wanted to rectify that just make another punch mark 2.8mm higher up on the plug.

more pics when bit of metal start flying around
Attached Files
File Type: pdf 550 layout for kokusan ignition.pdf (119.1 KB, 70 views)
Thanks from zaga, makazica and rectoret

Last edited by bushmechanic; June 1st, 2014 at 04:12 AM.
bushmechanic is offline  
June 1st, 2014, 11:27 AM   #3
Senior Member
 
Joined: Mar 2012
From: South Australia

Posts: 235
Thanks: 5

I Ride:
I like how you spend your time playing with the important stuff and dont bother wasting time with stuff like cleaning, ha ha! Always good to see somebody having a go at solving problems like this. Will be very handy when parts are non existant and mixing and matching will keep these beasts alive!
akshun is offline  
June 1st, 2014, 08:16 PM   #4
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
Thanks Akshun

the pics are not mine, the bike is way too clean to be mine

the mod in the pictures was done by

Berg_501 http://husaberg.org/users/berg_501/
bushmechanic is offline  
June 2nd, 2014, 12:57 AM   #5
Senior Member
 
zaga's Avatar
 
Joined: Mar 2009
From: Portugal

Posts: 1,385
Thanks: 247

I Ride: KTM 300 XC
Hi Bushie

You starting this job, has gave me the momentum to start my !

Last time I've put my hand in to this, I had come to the conclusion that I had to change the position of the metal strip of the flywheel more out, so if I had to changed it, why not putting it in the position that I wanted ? Not to the front of the bike, but to the sprocket side (back) ?

What do you think about that ?

Also can you change the colour of the drawing ? It's very hard to read the green. Thanks


ZAGA
zaga is offline  
June 2nd, 2014, 09:40 PM   #6
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
that's a good idea actually to relocate the strip Zaga

to put the pulse coil in the same location as for the new cases is a bit tricky as it interferes with one of the cover bolts and one of the case bolts on the 02 cases.

one cover mount hole is covered by the pulse coil and one case bolt is hidden under the cover so I will weld a 1/2 nut to the head of the case bolt and use this for the third bolt thread

I have one model done with the pulse coil mounted upside down in the cover

now trying to decide weather to order a big chunk of aluminum and turn it into swarf pillow stuffing for Dr_C or make a mold and try a carbon cover.

im going to be running the coils in oil so i prefer aluminum ATM.

OK Zaga no more green lines



Thanks from Dr_C
bushmechanic is offline  
June 3rd, 2014, 12:49 AM   #7
Senior Member
 
zaga's Avatar
 
Joined: Mar 2009
From: Portugal

Posts: 1,385
Thanks: 247

I Ride: KTM 300 XC
Hi Bushie

I can see your CAD master, I should, but I don't have a clue how to use it

The dimensions of your cover might be bit different that I want, because you will be using ne FC flywheel, but anyway, could you post another pdf without the lines in green ? Thanks

Just 2 more ideas that I previously had, first I don't know if I can get the timing exactly right, so I thought of using one back plate for the stator and pulser coil that can be adjusted, something like the 2 stroke KTM. I don't know how the my CDI will behave, so before I do something rigid and be sorry after, I think I should do something that can be a bit tuned. Another member Paul, that knows a lot about ignitions, told me to stay bellow 40 advance, to be safe maybe between 32 - 36, so a tuneable solution would be wise.
Other idea is to make one hole in the cover so you can check timing with a strobe.

Why are you going to use oil, they seem to last on the KTM's dry, why are you going for that trouble ?

Cheers
ZAGA
zaga is offline  
June 3rd, 2014, 12:58 AM   #8
Senior Member
 
zaga's Avatar
 
Joined: Mar 2009
From: Portugal

Posts: 1,385
Thanks: 247

I Ride: KTM 300 XC
When I'm talking about a back plate, here are some examples
Attached Thumbnails
SEM KOKUSAN Conversion-ktm200002-1.jpg   SEM KOKUSAN Conversion-dscf5040.jpg  
zaga is offline  
June 3rd, 2014, 02:16 AM   #9
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
Hi Zaga

the oil will be in there because I am boring out the main bearing tunnel to take a sleeve for a 20mm wide spherical roller and there is not much room for the seal.

Im using the FE flywheel not the FC so the models dimensions should be usable for you, when its working i'll create some ISO drawings for you to go off, and yes I can redo the first one.

I like your ideas about having a means for altering the timing, this build for me is just a cheap trailbike to ride around in the bush with some old mates of mine I know with big beer guts so i'll be happy with replicating the oem kokusan timing.

this shows where the half nut goes



Last edited by bushmechanic; June 3rd, 2014 at 02:58 AM.
bushmechanic is offline  
June 3rd, 2014, 02:56 AM   #10
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,826
Thanks: 1150

I Ride: 2008 700FK, 2002 628FST
here you go Zaga

layout without green

not sure which dimensions you are interested in, let me know.

the top of the cases at the head gasket is setup parallel to the X axis

bushmechanic is offline  
Reply

  Husaberg Forum > Mechanical and Technical > Electrical

Tags
conversion, kokusan, sem



Search tags for this page
Click on a term to search for related topics.
Thread Tools
Display Modes


Similar Threads
Thread Thread Starter Forum Replies Last Post
SEM conversion to kokusan? Teodor1 Electrical 9 July 12th, 2010 11:29 PM
Sem/kokusan (new question) BelgiqueBasterd Electrical 14 April 15th, 2010 04:16 AM
Sparks Kokusan stator rewind, DC conversion,wiring upgrade DaleEO Electrical 5 August 10th, 2008 07:52 AM
Kokusan KTM & Husaberg JBSracing Electrical 8 November 7th, 2005 11:54 PM
Kokusan stators doug1 Electrical 2 August 15th, 2004 07:52 AM


Facebook Twitter Google+ RSS Feed