Sem to kokosan rebuild possible?

P-son · Feb 15, 2014

Have a spare egine for my 650, but its an 03 with SEM ingition, i have kokusan on my 06.

Is there any way to convert the SEM to kokosan?
There is no place for all the kokosan sensors behind/left of the flywheel with everything oem.
But has anyone tried buuilding some kind of bracket and new cover and making it work?

// Andreas/P-son
using Tapatalk 2

ned37 · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

Is there any way to convert the SEM to kokosan?

no. why would you want to ?

bushmechanic · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

P-son said:
Have a spare egine for my 650, but its an 03 with SEM ingition, i have kokusan on my 06.

Is there any way to convert the SEM to kokosan?
There is no place for all the kokosan sensors behind/left of the flywheel with everything oem.
But has anyone tried buuilding some kind of bracket and new cover and making it work?

// Andreas/P-son
using Tapatalk 2

Hi P son

I'm doing this to some 02 cases soon .. . mostly because I only have kokusan components but also because not much seems to go wrong with the kokusan stuff

my first thoughts are to cut out a portion of the round protrusion on the cases weld some bits on to fit a kokusan cover and make an adjustable bracket for the signal coil

or machine the cases nicely and make a new cover to fit

alignment/timing would need some fiddling FWIW on the 80mm crank there is a locating hole for the crank locking bolt and the signal coil is located directly above that hole

but none of that stuff is difficult and a few people have done it already in different ways

viewtopic.php?f=6&t=15611

https://www.google.com.au/search?q=sem+ ... 8Qfb_ICYDw

this is just one

some more results to browse through

https://www.google.com.au/search?q=sem+ ... 8Qfb_ICYDw

bushmechanic · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

I like this this one by hirbman

depending on where your kokusan components come from the signal coil either goes at the front or the back.

Dave1867 · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

are these conversions using the kokusan running dry like the SEM? appears that way. would it last longer if it were wet, or is that even an issue? If someone had thought of this when I had my 01 550 it would have saved me a pile of money on stators!

bushmechanic · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

could be wrong but it appears that they are dry

that makes it easier to keep the oil inside the engine

I will also be putting a 20mm wide 22206 spherical roller on the ignition side of the crank which doesn't leave much room for a seal so Im going to be running the stator in oil.

the kokusan igns are run in oil on other bikes so it should be OK

Dave1867 · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

Are the bergs that came with kokusan dry also? I didnt think of that, never owned one of that era. No doubt having an adapter in there will make sealing a challenge.

bushmechanic · Feb 15, 2014

Re: Sem to kokosan rebuild possible?

yes the oem husaberg kokusan is dry

P-son · Feb 16, 2014

Re: Sem to kokosan rebuild possible?

ned37 said:
Is there any way to convert the SEM to kokosan?

Click to expand...

no. why would you want to ?

Why ?
Because I rely on the kokusan, but not on the SEM.
It it possible to replace the kokusan with a trailtech stator, if the oem should be discontinued
Not the same for SEM if I am not wrong... is it still possible to get new oem ?

Im quite new to Husaberg, but everyone Italk to agrees that the SEM could just stop working at any time.....

P-son · Feb 16, 2014

Re: Sem to kokosan rebuild possible?

bushmechanic said:
alot of good stuff

Hi Buschie !

Thanks, did not know that the KTM´s had the sensors "backwards", that helps some !

Whell, I now know that it is doable !
Please let me know when you are done with your convertion and running.

Would be nice to have the same harness for both engines !

zaga · Feb 16, 2014

Re: Sem to kokosan rebuild possible?

Hi

Doable but not easy :mrgreen:

Don't know where the strip metal of the berg flywheel is, but probably to do it correctly when you use it for the 03 engine you will ruin it for the 06 one, because you probably will need to change the place of it.

The main thing is that you understand completely how the system work.

For this project has been a stand by one for 2 years :mrgreen:

:cheers:

ned37 · Feb 17, 2014

Re: Sem to kokosan rebuild possible?

but everyone Italk to agrees that the SEM could just stop working at any time

seems like a lot of work for something you just don't trust. i've been using "Sparks" rewound stators in my sem bergs for the last five years or so with no trouble at all.

P-son · Feb 17, 2014

Re: Sv: Sem to kokosan rebuild possible?

ned37 said:
but everyone Italk to agrees that the SEM could just stop working at any time

Click to expand...

seems like a lot of work for something you just don't trust. i've been using "Sparks" rewound stators in my sem bergs for the last five years or so with no trouble at all.

The trust thing is the second.
The first would be thatvI would like to switch engine without changing all electrics.
I know its not mutch electrics, but still.
Feels like the kokosan stuff have more spares and so on.
Will see if I get to it.
I have the 03 on the bench, so its quite easy to do a mockup.
And I have the kokosan running on 2 engines.
Promise to update if I get to it

Now I atleast know that it has been done before

Just haveto do a solution that works on both stock and modified.

Is the TDC mark on the same place on the Sem flywheel as the kokosan?
If I get a KTM stator, then Inhavo get a KTM flywheel aswell to match?
Looks like SEM flywheel on the pics, or does the KTM look the same?

// Andreas/P-son
using Tapatalk 2

Kayeffess · Feb 17, 2014

Re: Sem to kokosan rebuild possible?

I think it is easier to just carry a spare sems in your kit. That's my plan. Found a used one, it will go out for rework and then ride as a passenger.

HeimirBardason · Feb 21, 2014

Re: Sem to kokosan rebuild possible?

To start with I have had the original SEM ignition since 2001 in my 550. No problem whatsoever for 13 years. Bulletproof.
As it is a dry ignition you need to open the ignition cover after a wet ride to let moisture dry and spray with wd 40 from time to time. Case closed.
So I have never understood this "reliability issue" with the stock SEM ignition, unless you never open the ignition cover to let water and dirt out.
Seems to be quite some work switching to a Kokusan.

What is the real benefit with the Kokusan ignition ? Someone ?

Best,
Heimir Bardason

bushmechanic · Feb 21, 2014

Re: Sem to kokosan rebuild possible?

not sure there is an advantage ?

If I had an SEM im pretty sure I would be using it ..

I have 2 kokusan setups and 2 engines so for me I just have to make my spare kokusan ign fit in my 02 cases then I have 2 bikes

the kokusan has an input for the TPS = good if you run the FCR carb

and there are a few platforms of programmable ignitions to choose from that can plug straight in to the kokusan platform

zaga · Feb 24, 2014

Re: Sem to kokosan rebuild possible?

HeimirBardason said:
To start with I have had the original SEM ignition since 2001 in my 550. No problem whatsoever for 13 years. Bulletproof.
As it is a dry ignition you need to open the ignition cover after a wet ride to let moisture dry and spray with wd 40 from time to time. Case closed.
So I have never understood this "reliability issue" with the stock SEM ignition, unless you never open the ignition cover to let water and dirt out.
Seems to be quite some work switching to a Kokusan.

What is the real benefit with the Kokusan ignition ? Someone ?

Best,
Heimir Bardason

Hi

You must be one exception, I've never eared of one SEM stator lasting that long, I mean if you used the bike all those years

I open and clean the stator every ride, and even doing that I've had problems. With the old MKI I've had new stators lasting just a couple of hours !!

The benefits of making that change are the obvious reliability issue, also the more advanced ignition specially if you are using the FCR carb with the TPS sensor, because your CDI will have another information input and it will change the advance accordingly to that.

All that said, it is a lot of work to change from one system to another (machining, testing, etc) , that is why my kokusan is still in the box

and there is also the cost thing, if you try to buy one new system it will cost you a fortune !! so you will have to be lucky to find one used on. And it will have to be complete, even the regulator/rectifier, you can't change just a few parts, it's all different.

Hope this helps

:cheers:
ZAGA

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