Cross Ref KTM/BERG - KOKUSAN

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zaga

zaga

Joined
Mar 22, 2009
Messages
1,386
Location
Portugal
Hi

I was comparing some ref. from KTM and noticed something similar, can anyone tell me if this are the same:

STATOR
BERG - 800.39.004.000 KTM - 583.39.004.000

CDI
BERG - 800.39.031.000 KTM - 583.39.031.000

Thanks for the help

:cheers:
ZAGA
 
Hi Zaga!
In my opinion YES :)
I see that You are not sure about ignition advance curve:)

Regards Damian
 
Hi Damian

Great to hear from you again.
This post was from when I was searching on ebay and the numbers are very similar, I can't remember now but this was from a much older bike, I think it was from the last LC4's, super competition, that were converted from SEM to KOKUSAN.???
Any way, I bought one complete system from one 400 2003, stator, flywheel, CDI, reg/rect, wiring...it was a very good deal.
One question to you, the flywheel that you bought was the forged one or the one with the rivets ?
I think I'm going to have problems with that.
:cheers:
ZAGA
 
I'm not sure now.......but I think it was forged.

But it doesn't matter. If it fitt on crank journal it will be ok!!!

You have to only weld on the metal strip on it.

Regards Damian
 
But in the ktm the engine case its not so close, and the rivets go 2mm more.

I'm afraid that with the crank flotation it might touch the engine cases.

If you chech the ones that were used in Berg 2003 + they are the forged, they don't have rivets, like the SEM one.

:cheers:
ZAGA
 
This is a picture on the original engine.

[attachment=0:1erbs0or]Ktm_timing.jpg[/attachment:1erbs0or]

:cheers:
 

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  • Ktm_timing.jpg
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Hi!
Zaga I have very good news for You. Yesterday I checked timing on my new kokusan in 501 motor.
After replace SEM ignition I have to set static ignition advance but I didn't have any data about it. So the last thing to do was set the static advance preliminary then start the bike and test. After few tests..........I have exactly same static advance as on Your picture....... :)

So You are on good way :)

Thanks for confirmation my measurements :)

With best Regards Damian
 
Hi
ElSonoro, this is a long term project sice I recently broke my clavicle so I can't do much right now, but will do it some time. Wich me luck.

Damian, this should be the stetup, its like the 04 berg, but on the other side, I'm sending you one image from the 04 manual for you to check.
[attachment=0:2wh2r1uz]Berg_04_ignit_set.jpg[/attachment:2wh2r1uz]
Personaly I don't understand this set up because there is very few deg after the strip end, and if the CDI would wait to the end of the strip to make some calculations about the engine speed and the advance it would need, it could only determine the advance for the next cycle, not the one of that moment. Don't know if I explained myself correctly ?
But aparently this is the correct setup.
Did you checked your flywheel about the rivets ?

:cheers:
ZAGA
 

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  • Berg_04_ignit_set.jpg
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Hi,
Zaga mine is forged (so without rivets). But I don't think that those rivet would be a problem.
I'm not sure but it is posible that CDI is counting:
-first "contact" with flywheel strip
-second "contact" with strip (end of strip)

This will be counted and after calculations it very short time there is spark for same cycle (not for next).
This short time is equal turn angle from center to end of pulse generator housing.

I know that in chinese scooter change of strip lenght change also the ignition timing, so as I mentioned it is important to weld same lenght as oryginal strip for Your conversion.

Regards Damian
 
Hi
I still have some doubts about the rivets because of crank flotation, will see.
About the timing, how could with just a few deg after second contact, if the cdi waits for it, how could it give 30 deg of advance ??
I'm sending you picts of the stator of one of my pits:
[attachment=1:2ktw6dlc]Pit_igni_1.jpg[/attachment:2ktw6dlc]
[attachment=0:2ktw6dlc]Pit_igni_2.jpg[/attachment:2ktw6dlc]
See how similar they are
:cheers:
ZAGA
 

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    Pit_igni_1.jpg
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  • Pit_igni_2.jpg
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Those (stator and flywheel) are also kokusan? :)

Yes Zaga You are right it can't be on same cycle but for next it is impossible to advence 30 degree in this layout.
But it doesn't matter if it works correctly in other bikes like KTM.

Damian
 
No, the ones on the pictures are chinese from one of my pitbikes, but they are very similar from the original kokusan.
If you want to search, its from the pitbikes with electric start, the one without electric start are with the flywheel outside and the stator inside, like the pre99 bergs. But this last ones the stator is different with only 2 big coils.
:cheers:
 
If You have any skils in turning (lathe) I'm 100% sure that there is possibility to fitt that flywheel on husaberg journall.

Rest is piece of cake :)

Damian
 

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