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April 14th, 2018, 06:03 AM   #1
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Engine change 650

Hi!

I was going to change the engine in my Husaberg 650 06 to an 03 engine. (do not ask why)
Everything went great until I discovered that the ignition was quite different ...
I have a ignition coil for both engines but can not figure out how to connect the wires to make it work. Do I need a new CDI box, or is it it's just plug and play if you connect everything correctly?

I hope you guys can help me, I really miss riding this bike!
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April 14th, 2018, 06:59 AM   #2
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totally different. you need an sem coil/cdi.
i don't know or think the kokusan flywheel will fit the '03 crank, but worth trying?
Thanks from F70X
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April 14th, 2018, 01:18 PM   #3
ede
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Hi BigJalle,

of course for both kind of engines you'll need the correct type of ignition/generator system.

For the old engines (before 2004) there is the SEM-Ignition. Since 2004 there is the Kokusan one. I don't know what you mean with you have both ignition coils - do you mean you have both CDI's or do you mean you have both stators? The CDI - Capacity Discharge Ignition - comes with a capacitive element already.

If you would like to do a conversion, read this post from Bushmechanic first!
SEM KOKUSAN Conversion

If you decide to go with the SEM system, you'll need the following:
  • Rotor
  • Stator
  • Ignition Coil / CDI Unit (the black box that states ICU in big letters)

Original SEM-CDI's are hard to find. They're powered by the generator. If it's also o.k. for you to go with a battery-powered alternative, Ignitech could be a solution. You can also go for a Vortex (more expensive) or maybe other solutions that I don't have in mind...

Regards,
EDE
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April 15th, 2018, 11:10 AM   #4
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Ok I feel that my english is not good enough so I will take some pictures tomorrow and you guys can tell me what they are called and what I need to get.

I have big faith in you!
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April 16th, 2018, 11:28 AM   #5
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https://imgur.com/a/1R21w

Here are some immages of the stuff I have and also having some problems to name ^^
I have given each pic a name so maby someone can help me name them correct.

And of course help me get this bike started

Thanks,
Jalle
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April 17th, 2018, 02:54 AM   #6
ede
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Hi BigJalle,

let's get things sorted - I'll start with your pics first:
  • 03 NR1: 2003 SEM CDI
  • CDI 06: CDI for Kokusan stator
  • 06 NR1: 2006 ignition coil
  • 03 NR: 2003 SEM rotor & stator
  • 06 NR2: Kokusan rotor & stator
  • 06 NR3: Kokusan rotor & stator

When you'll swap engines from 2006 to 2003, you better replace all units - that will save you lot's of machining work, making an 06 rotor/stator fit an 03 engine. So put the 2003 engine and the 2003 SEM CDI in your bike.

Remove the typical 2006 parts:
  • 2006 Ignition coil
  • 2006 CDI
  • 2006 TPS from your carburettor, the 2003 one comes with a Dellorto Carb and the 2003 CDI doesn't work with TPS modules...

When you put the 2003 engine in your 2006 frame you need to connect the 2003 SEM stator to 2003 CDI:
  • [stator] red --> [CDI] red
  • [stator] green --> [CDI] green
  • [stator] black --> [CDI] black

So far, 3 cables sorted. On your SEM stator there should be 3 cables left: 2 yellow and one blue.
  • [stator] blue (ground, mass) --> put it were the other ground wires go (e.g. bike frame)
  • [stator] yellow --> yellow cable on your 2006 harness, which connects the light switch with the headlight and the rear light
  • [stator] yellow --> white cable on your 2006 harness, which connects the regulator-rectifier to load the batterie etc.

The stator cable are all connected now. From your 2003 CDI there are a few cables left to connect:
  • [cdi] gray --> you can leave that one open. On a 2003 it connects to your "High/Low Ignition Curve" switch, which I guess is not available for 2004/older models. If you like, you can add on (closing circuit to ground)... but it doesn't change a lot....
  • [cdi] orange --> yellow/blue wire (stop/kill switch), connected with your key switch (your 2006 harness)
  • [cdi] white --> yellow/red from your 2006 start button (connects to regulator/rectifier, fan, flasher system/blink relay, speedometer)
  • [cdi] black --> ground wire connection point, e.g. frame

Since I did this in my lunch break and never mixed a 2006 and a 2003 wiring harness before, take all information carefully! No liabilities on those tips
Anymay: Always work carefully, cross check everything, voltage, amps... Check your connections and switch functions with a multimeter.

I don't know if the 2006 regulator/rectifier will work with SEM output. I guess it does, but it's not for sure. Also check your SEM stator first, before you swap anything. You measure the resistance in Ohm with your multimeter between the following wires:
  • [SEM stator] black - red: 2900...3000 Ohms
  • [SEM stator] black-green: 160...170 Ohm

If your measurements are out of range, your SEM is already fried. You can buy an aftermarket replacement at electrex (Electrex World - Motorcycle electrical parts for Japanese, European & British bikes)

I attached a few pics, a 2005 workshop manual (wiring diagrams at page 127), and a 2003 wiring diagram. I hope I could help you a bit. Maybe somebody from this forum also has some input and knows better,

regards,
EDE
Attached Thumbnails
Engine change 650-sem-ignition-chart.jpg  
Attached Files
File Type: pdf 2003-Wiring-Diagram-FE-FS-Electrical-Starter-Models-with-Turn-Signals.pdf (35.7 KB, 8 views)
File Type: pdf 2006_WORKSHOP_en.pdf (7.11 MB, 5 views)
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April 22nd, 2018, 10:13 AM   #7
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Thanks!

I will print this and start working on it as soon as I get the time and tell you how it went.
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June 13th, 2018, 11:48 AM   #8
ede
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Hi BigJalle,
can you give us a feedback if the wiring is working now?

Regards,
EDE
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