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2003 650 lost key and spark

Joined Aug 2005
23 Posts | 0+
Ontario Canada
Hi guys
I have been blessed with a real nice 2003 650 fe sitting in my shop. The owner lost the ignition key and ordered a new ignition for it. When it arrived he took it to a dealer who subbed out the job. Now 8 months later the job is not finished and the bike was brought to me. There is no spark.
Is there a type of key switch that is not compatatble with certian models or could the stator be dead from all that sitting.
I have only spent about 10 minutes on it so far and thought I would ask to see if there are any people out thee who might shed some light on this before I dig too deep into the wiring.
Thanks for the input JIM
 
Well, you may need to order him a new stator.

There are a lot of threads here on how to test the stator with a multimeter.

Check "The Doc!" and also the hard start guide in the download section.
 
Thanks for the reply.
You were right. The readings are all wonkey. The plastics around the windings are all warped and cracked. Does not look good.
What do you recommend for the replacement?????
I have heard of useing a KTM unit and I have read the Kukosan unit is the best. But will it fit this bike????
What is the best option. Thanks JIM
 
Sorry, but Kukosan does not fit the 2003. They fit the 2004 onward.

Search for "stator" on this forum and you should be able to find out which one.

The older LC4 stator is supposed to fit but I am not sure. Better buy the stator + flywheel package specific for this model.
 
Under the tank, disconnect the orange wire on the iginition module.
Give a kick and see if there is some spark on the spark plug.

If there is, the stator is ok. And the problem is on the ignition switch.
If there isn't, is better think on a new stator.

regards,
 
Well Guys
I think I have tried everything, The readings on the stator is
Black to red 2700 ohms recommended 3000 + or - 300
Black to green 147 ohms recommended 260 plus or - 26
Spark plug cap restistance is 5K ohms ( NGK cap)
I unplugged the orange wire and kicked it over......nothing.
I notice the high tension wire has been replaced with an automotive wire cut to length. It is a wire core type so I assume it is OK.
Is there a way to test the coil without ordering a new stator? Or am I best to start with the stator and work uphill from there.
I am at a loss. With one reading in the ballpark and one out in left field I can only assume the stator is cooked
Thanks to everyone for the help. It is nice to associate with such a great bunch. JIM
 
Did this bike really sit for 8 months for the sake of an ignition switch???? An hour or two with a file & you could make a key.
 
Yes it did sit for 8 months.
The owner does only basic repairs such as plugs and oil changes. He figured it would be best to have a new ignition installed. For what reasons I am uncertian.
The shop he took it to was a ex KTM dealership. The guys that own this place only do repairs, no sales. The owner of the Husaberg tells us there are approx 200 bikes at this shop. A big warehouse full of bikes needing repairs and they are from dealerships who have work subbed out. I was not aware there was a lot of this going on but they tell me in the big cities it is common.
Because it took so long for them to get to installing the switch I guess what happened was all the moisture in the stator area corroded the parts enough to cause all the problems I have encountered. There are marks on the rotor where the stator looks like it touched. The rotor is white with oxidation as is the inside of the motor cavity. I could not get the stator off the cover and had to make a puller to fit down inside the stator and remove it that way. The black plastic is warped and even has small cracks from either the heat or moisture getting inside the plates.
I have read that a KTM stator will replace this unit. I hope this is the case as the KTM dealer has told me there is no return on electrical parts.
I have not ordered the stator as of yet. I will wait until the first of the week as I have to go away to work for a couple of days. If anyone out there has any doubts about the stator not working please let me know before I order a new one. Thanks again JIM
 
I do not know of a KTM stator that will be a correct match for the 2003 Husaberg. The older KTM stators were made by SEMS also and fit the 89-98 Husabergs. The 2003 Husaberg stator is a SEMS but is not the same design as the KTM version.

The newer KTMs have Kokusan stators.

The 03 Husaberg SEMs stator is going to be very expensive, so run some more tests first.

With the stator pigtail separated from the CDI pigtail measure the AC voltage across the Red to Black and the Green to Black wires on the stator pigtail.while kicking the motor over with the kick starter just as if you were trying to start it.

I use 2 straightened paper clips inserted into the pigtail sockets to make contact for the multimeter.

Red to black should be 30-35 VAC. Anything less than 25 VAC will not start.

Green to Black should be ~ 3.0 VAC. Less than 2.5 VAC may not run correctly even if it starts.

Let us know what you find out.

Regards,

Joe
 

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