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Kokusan upgrade survey

Hi Husabutt,
Those pictured are mower units with the rotor fins being used to circulate air across the engine. Such a design has been in use on small industrial engines for several decades.

Respectfully,
Dale
 
ignition?

Dale L,
Well after changing to an FCR, replacing the decomp mechanism, replacing kick & gear seals, bearings for the clutch & k/start,purchasing larger volume battery, repairing kick starter & gear selector mechanisms, replacing starter motor,replace sprag clutch, etc etc etc why not spend another $1000 + bucks???? I know its not your fault but come on these single cylinder, no plastics and not much technology are WAY over priced compared to road bikes! We pay $12000 Aust for a bike that needs a new stator within 12 months?
The very least they could do is make the stator & rotor available seperately.
No I think it is to expensive.
ps, what are the symtoms of a stator failure, and is it true that they can appear ok on a multi metre and still be stuffed?
pss, good work for the bloke that retro fitted the unit, a job well done!
Scully
 
Bergerboy

Bergerboy,
There is a dealer in S/Aust Betta Bikes that will rewire a berg stator for $300 and give it 20% more power.
R U saying that an LC4 stator will fit & work on all post 2000 Bergs no probs except for sussing out the wiring?
Was it you that sent your stator to Betta Bikes? As they have just done a 650 Berg?
What shop do you work at? I just got a sprag clutch from Bendigo Dirt Bikes and found them really good, as my local dealer just couldnt be bothered and they wont trade Bergs back??
You can PM me if you feel more comfortable.
Scully
 
bergerboy

Rob, does that also mean that the LC4 rotor is the same deal to??
 
Thank You Dale for your time & effort! I feel that a $1000 would be a bit to expensive to be cost effective. $1000 for a $4000 bike is a bit over the edge! Most likely if and when, I have to deal with a stator failure. I will buy a sems unit. Or Replace the bike, with a brand that is either reliable or the company is willing to stand behind there product!
"Just for the record Husaberg and my dealer Euro motors has stood behind me" for now I'll just won't rev the old girl out so far.

Bergerboy: I'd like to have more info on your retro fit of the FC4 parts
 
i still don't get why they fail?

i have MX gearing so it's very easy to hit the redline. i've even tuliped the valves so i definately rev it. however i don't think that that many MX and enduro folk get through them.

now dale's FT bikes will have many laps of high speed, high frequeny vibration. they also withdraw the engine balancers often. the lads doing high speed road work and trail riding are the other group more than likely to suffer these failures surely?

so surely this is a high frequency/long duration problem that we enduro and MX lads often avoid?

any of this make sense?

Taffy
 
Taffy said:
so surely this is a high frequency/long duration problem that we enduro and MX lads often avoid?
Click to expand...

Sorry Taffy but the mx and enduro guys don't get to avoid these problems either.

Personally I have been lucky in that both stators in my bikes have held together OK for 4 years and 18 months respectively so it doesn't happen to everyone.

Cheers,
Simon
 
Hi All. It sounds to me like the problems with the SEM are based on a variable quality, versus an inherent design problem. Sure, the output may not be optimal for a large disp. 4-stroke, but mine has failed once due to moisture and so-far-so -good on my second unit. Perhaps we need to ask SEM to address the vibration issue directly and provide us a unit with same design, (no retooling necessary), with better connections for the aftermarket? Anyone have connections with SEM? Are they willing to talk about a solution? Perhaps they will be open to discussion since they apparently lost the bid at KTM, who went to Kokusan. BD
 
BD said:
Perhaps we need to ask SEM to address the vibration issue directly and provide us a unit with same design, (no retooling necessary), with better connections for the aftermarket?

Anyone have connections with SEM? Yes.
Are they willing to talk about a solution? No.

Perhaps they will be open to discussion since they apparently lost the bid at KTM, who went to Kokusan. So far they have proven less than receptive. BD
Click to expand...

Hi BD,
See reply in Bold.
My first attempt regarding SEM direct was in 2001.

Kind Regards,
Dale
 
Hi Dale,

I'm on my second stator, 98 FE501. The first failed, possibly, at about 250 hrs. It may not have failed, but the bike died just before Christmas in 40c deg heat near the end of a long ride. When it cooled, it went again. I suspected the stator and went looking for a replacement. I was able to get a replacement from Suttos for $180OZ so I just did it as I had a big ride planned and didn't want to have a problem. The original sits in the shed as a spare. I'm now up to 460 hrs, 210 hrs on the replacement. If/when it fails I'd look at a new or rewind replacement SEM rather than spend $1000us on a Kokusan. I may also consider the hribman alternative as I don't mind a fiddle from time to time.

Steve
 
Been Lurking for a while guys and I have to say the stator was one of the few things that did not fail on my 01 501. I could not justify spending another 1,000 on a bike that has a totally new motor, gearing, chain, tires, and brakes that I cant even get one offer to buy or even part out. I loved the bike but the parts price and availability was what drove me to something different. I don't like my new ride as much but I've put 5,000 miles and only changed the tires brakes and oil.
 
I have not had any failures.Knock on wood but I wonder if there would be a cost effective way to isolate the sem so the vibration will not be a problem.A upgrade would be nice but why just the ktm unit?I would look at other setups and good with the best all round unit.Example:I have a streetbike that has the pickup at the end of the crank and the box is under the seat.The bike is a 78 Yammie xs11 the ign. is transittorized with pickups which does away with points.Couldn`t something like that work?It would mean relocating wires and adding 2 at crank end{for the pickup}finding a suitable place to mount the box which then could be rubber mounted.Sounds good I just don`t know if it would work. :?:
 
bboy

Come on Bergerboy where are you? You cant just lob here and sprout some info and piss off we are waiting to hear from you?
 
Guys,
Just a note. Bergerboy (as known on this site) is not a well man at the moment. A busted shoulder and a wrecked back have slowed him down considerably, so please give him a go.

In the case of the LC4 stator I will follow up with him but I understand that the stator from the early 400/540/620 LC4 KTM engine is the same unit, less the connectors as the Husaberg SEM units. I have not done any research on the Berg stators but i understand that the variance in the part numbers relates to the differences in the flywheels rather than the stator and again less the connectors. The other item to remember is that the SEM stator that is used in the FC models is completly different to the FE/FX/FS models and cannot be fitted with a lighting coil type flywheel. This is due to a completly different placement of the magnets in the flywheel.

Rod
 
Hi,

I also made some investigation.
I phoned up a mate who is a Husaberg veteran who owns 4 or 5 Bergs.
He collects them. :wink:
And as I thought, he told me that the LC4 stator cannot work on a post 1999 model.
The reason is to be found in the so called "Dynamic Force Control".
The new stators work on the old models but it´s not possible to do it the other way round.
We tested it already. But when Bergerboy made his statement, I wasn´t 100% sure.

greetings

hribman
 
Most SEM stator assemblies are of the same basic design albeit with different phasing (winding orientation).

Early and late SEM stator assemblies will work with most any flywheel combination providing the rotor is properly positioned on the crankshaft.

I have successfully interchanged SEM units between KTM, Husqvarna and Husaberg.

As for DFI:
No load sensing is provided. Said feature is simply a catch phrase used to describe the dual map option.

Kind Regards,
Dale
 
?

Rod, thanks for that info. I was only takin the piss out of Bergerboy, please pass on my good wishes and hope he recovers ok!
 
Two cents,

I have a 2001 FE501E as well as my 2004 FE550E.

I would definitely convert to the Koukosan (sp?) should my SEM fail. I'm still on my original SEM, but have had a couple of interesting flame outs while riding, motor just shuts off and I grind to a halt. Then the bike will restart almost immediately. The only time it happens is when the ignition switch is in the HIGH postion. The flame out doesn't happen immediately with it in HIGH, nor is the flame out consistent, that is, it doesn't flame out ie quit everytime I put the switch in HIGH. IT's weird, and am not sure that it is just electrical. But, in the event it doesn't finally sign off due to electrical I'll be contacting Dale for the conversion.
 
Dale,

The flame out in high sounds more like the high low switch or the wiring. Put an ohm meter on each end of the harness when in high position and wiggle everything around to simulate vibrations.

I don't think the bike would fire up right away if you have a stator problem.

Good luck,

Hakan
 

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