Kokusan in Husaberg

Hi!
my last modification
https://picasaweb.google.com/1015717759 ... nHusaberg#

spark is very nice

Cover was made by me, ignition coil, flywheel, ignition module, pulse generator is from KTM 525, stator is from chinese scooter )))))))) it cost less than 8 Euro . It have 4mm biger outer diameter than oryginal Kokusan stator, I turned it ........and it works It fits into flywheel very nice.

All cost me less than new stator (Electrex) and I have old parts.
Damian

That is very impressive. Nice job!

yes well done Damien, tremendous job! let's hope the chinese stator doesn't let you down either!

regards

Taffy

Taffy this chinese stator is manufactured by......Kokusan Lanfang:
http://www.lfkokusan.com/english/gsjj.asp

it is "part" of Kokusan Denki Japan.
Plese see on ebay stator for chinese scoters and eg. Honda CFR 250-450, it is very similar. Scooter has two holes for screw Honda has three, rest is almoust same.

It is very similar. Another adventage is that this stator has 3 phases for battery charging and regulator is also cheap Japan, Swedish, Chinese 12V is always the same

After measurement I know that coil for charging module during kicking gave between 50-80VAC (it depends on kick strenght) it is enought for spark.


Stator need only to turn a litle from o.d. and change connection for module charging coil.
Costs:
-module, ign. coil pulse generator I have bought in Poland for ca 120Euros
-flywheel from German ebay auction for 38Euros
-stator 8Euros
-aluminium for cover about 5 Euros

It gave around 180Euro so it is cheaper than Electrex.
I don't know if someone remember my post about e-starting problems (electric starter was spining engine very very nice but there was no spark, it was only on kick starter, I even tried to replace sem for Electrex-my younger brother has bought one for his 501 berg- it was the same, problem was in SEM ignition module, I have replece from my brother bike and my berg starts every time from kickstarter)...........

After all that problems I decide "never again SEM"

Regards Damian

Very impressive DAmian

I've been searching for this solution for a long time, for those of that uses old bergs this SEM thing is always a big and expensive problem.

Please tell me one thing, could this work with the original CDI ?

I don't understand what you bought used and new, please explain.

Could you make one detailed paper about this ? If you want I can help. This is big, and should be available to every poor baster that uses old bergs.

:cheers:
ZAGA

Hi!
It is very interesting to check it with orginal SEM CDI........
Oryginal stator is borrowed from my friend just for measurements and fittings to engine block I have bought one from chinese scooter because it is very similar in shape and almoust all dimmensions are same (and new one is around 10x cheaper than used original )

I think the best way is to do good "photo story" in Husaberg.org gallery.

I have to check one thing- max. voltage from module charging coil, Zaga I have seen Yours solution with Zener diode it is very good and simple thing to do.

Regards Damian

hi
this a great thread i really like wot u have done and u seem to have done it very well but my first thoughts about this being a cure for sem are is it a practical solution i mean if 1 hasnt got use of lathes or milling machines how much would sumthing like that casing cost to b fabricated by an engineering company?
another thing i thought of is when people hear that ktm electrical systems are highly valued to husaberg owners for converting there bergs do u think the value of the parts would then increase as there more valued ?
im in no way at all trying to mock ur work as it looks fantastic and would of took alot of thoughts and effort its just them 2 thoughts that came to mind

cheers kris

Hi!

My berg was starting from first kick on SEM, (I was starting it from seat by left foot) but there was something wrong with ignition module because it won't gave spark on E-starter (engine was spining like a crazy even twice faster than my friend KTM520 EXC) what is wrong I don't know till today.

I had two ways
1) Replace my ignition module and hope that stator will work for a long time )))
2)try to replace whole ignition system for kokusan.

I have lathe and miling machine in my workshop aluminium is quite cheap, my friend have striped engine so I borrowed parts to fit when I saw that all is possible I started to search cheaper solution than original KTM parts.

I think that new cover made from aluminium by special workshop (on CNC) should cost less than 60Euro.
Maybe in the future I will try to connect cheap ignition module instead of KTM CDI and try the bike.

I don't know maybe there is possibility to use cheaper flywheel (chinese scooter? who knows).

I want to have good enduro bike with e-starter that was my target, at first Hribman inspired my to fit Kokusan to my berg.

Regards Damian

hi
yea im with u on that 1 iv thought about it alot myself but i havnt yet found a cheap flywheel with the same taper as the crank or many cheap ones that face away from the motor but i have got a flywheel in my garage that iv had sum ideas about. the flywheel iv been looking at is meant to go on the crank facing the motor ( like the old bergs were the stator goes on first) but in the middle where its tapered there is enough and more metal to turn it around and lathe the bigger taper that the husabergs crank have into the flywheel allowing the stator plate to still bolt into the outer cover. but i was thinking if ya lathe the middle of the flywheel and re mill the lacating key slot u would probly have to get it rebalanced as all this might un balance it (coz i wouldnt like to put an unbalanced flywheel on my bike lol ). the only problem with that is i dnt know were to get a flywheel balanced. also by changing the flywheel that could open more options to make husabergs more user friendly or more suited to different terrains by allowing space for flywheel wheights. iv researched how flywheel weights can change the way a bike rides lots of enduro riders prefer them as they give u more torque and traction low down also the factory motorcross yamaha yzf's have them from what iv read there very needed on the factory yzf's as the full on factory ones squeeze 10+ bhp extra out of there engines and the flywheel wheights are a big part of this as without them there bikes would not b quite as usable with all that extra power. on other bikes there is actualy kits to bolt onto ur existing flywheel but on the bergs everythings a tight squeeze with standard setup.

cheers kris

Hi,
http://allegro.pl/magneto-kolo-magnesow ... 43375.html

this is very cheap flywheel, You can drill through the rivet, and made new cone which will fit from one side to flywheel and inside it will fit on the crank journal.

This is same idea made for other bike:
https://picasaweb.google.com/1015717759 ... 3701803170
(it was made for my old Polish 350ccm bike, to fit 12V alternator).

I would prefer to check flywheel balance (it should be perfecly balanced) if not just balanced it for "0".
Channel for woodrof key I would leave at the same place but cut of and replaced metal strip for pick up coil (pick up send signal to CDI unit when strip pass the coil). I will weld it by TIG, is is only strip of metal.

If the flywheel is "0" balanced it won't change cranckshaft balance % it is only added weight.

Regards Damian

hi
im a little unsure y u need to cut the pick up strip off and reweld on a new 1 maybe its because ignition timing wont line up but by the looks of ur housing u have made up it looks very adjustable with the washers sitting on a lip to keep it on couldnt u just simply loosen the screws and rotate the cover to compensate?
another thing the 1 i was looking at in my garage is near enough the same as the 1 on the picture that u have been looking at and instead of remaking a cone for the middle could u not use the exhisting 1. i know ur thinking its not right but the exhisting taper at is largest end is near enough the same size as the smallest end of the crank taper and if u look at how much meat that original cone in the cheep flywheel has got u could easily put the berg taper in the original cone and make a spacer to compensate the threaded hole that would then be at the back also the original cone would need to be threaded on the oposite side so u can get it back off the crank

cheers kris

I have to replace and reweld strip not only because of the timing but also because it is on wrong height on flywheel.
It has to go under metal part of pick up coil and oryginal kokusan has it on wrong height......
There was no possibility to fit pick-up coil in other way.......I don't worry about it, it is very simple operation.

If there is enought "meet" it is simple we can use it and make new taper for crank (even without replacing the rivets).

All parts and dimmensions can be made with big tolerances, it is very big adventage of that solution.
High precision is demanded only with few dimmensions (places):
-taper (taper angle must be same as on crank journal it is hardest thing to do)
-cover centering diamater must be made with +/- 0,1mm tolerance (it is not much)

Rest of dimmensions are not so important. You can even left the taper without chanell for key, if cone is well made and perfecly fit to crank journal it will work without problems.

Regards Damian

iv had quick look on ebay and searched ktm 525 flywheel and it brought up flywheels off a polaris outlaw stating ktm 525 in the description maybe this could be a good step if dimensions are the same as they would have the same taper and there only 20 gb pounds used and theres a few of them on there

cheers kris

Hhahahaha great job!!!!

http://www.ebay.co.uk/itm/Polaris-Outla ... 483e98e53e

look very similar...........

World is crazy people pay for KTM parts 3 or even 4x but noone knows that there is cheap substitute for it with good quality and the funniest thing is almost whole word is connected to internet

Damian

Another layout:

ha ha ha u like haha
also check out the polaris 525 cdi units very cheap
these polaris could be a great source for ur project with them being riddled with ktm 525 parts at a fraction of the price

cheers kris

This layout was made by Hribman.
I have only one problem with polaris parts........ all those are offered in USA and I'm from Poland, shiping cost plus parts cost I think it could equal cost of same parts in Poland but for a higher price.
But for riders from USA it is very good information.

With best Regards Damian

Hi guys

You just talk about the 525 CDI, do you think that that would be good for a 400 ?? Don't know about the advance curves.

Keep up the good work :!:

:cheers:
ZAGA

I think that those engines are so similar that would be no problems.

Regards Damian