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Thread: The SEM to Kokusan ignition retrofit thread

  1. #151

    Default Re: The SEM to Kokusan ignition retrofit thread

    Quote Originally Posted by malibu406 View Post
    I found some parts from a 2017 ktm 250, here is where i am unsure. As you so in the picture this looks like the correct weight 2k-2 flywheel. But the part number is different than any i have seen used. P/n 5543905100. The p/n used by most is 54739005144 and this number went on for years. So im concerned the new one is different, maybe shaft taper or whatever? Anyone know?




    Lastly, while the stator too is for sale i cant see how it would fit the 96 360 because it doesn't appear to have a stator plate mounting like the older one. Its pn is 5543904000.

    Any help is appreciated


    The flywheel looks correct so try it.
    CDI:
    You have two choices here.
    Try the newer one and see if you like the power.
    Or get an older one and see if you like the power.
    All I KNOW is that they were mellower/more abrupt over the years depending on model/designation.
    There's really no way to tell short of trying them and their map switching,
    or to contact KTM directly and request a detailed load out of their designs,
    or at least a quick rundown of the "spread" over the years/models.
    (Good luck)
    In other words:
    Most of these will work, just don't use the ones designated for 4 stroke.
    Don't overthink this, its not an EFI/Current tech race machine.

    Just make sure your harnesses match-up, and your stator plate.
    The newer stator plates WILL NOT fit older bikes.
    2-k3 is shaped different, and honestly I haven't kept up with design revisions.
    so they could have something even diff for 2017.
    Please read the old guide, and the whole thread here and you should be fine.

    I lost my youtube vid.
    My apologies on that one, my bad.


    I never thought this thread would amount to anything but hey, here we are!
    Keep the rubber side down folks!
    Have a good one!

    Oh and that chart...bumped for convenience:
    http://ktmtalk.com/attachment.php?at...0&d=1457163312
    Last edited by RenixJeep; 03-19-2019 at 10:55 PM.
    1992 300 EXC....The battle never ends, UPDATE She's a runner!:
    http://ktmtalk.com/showthread.php?t=488234

    Got an older bike with a bad ignition?
    Got a bad case of the SEM blues?
    Click below for my Ignition Retrofit Thread!:

    The-SEM-to-Kokusan-ignition-retrofit-thread



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  3. #152

    Default Re: The SEM to Kokusan ignition retrofit thread

    Oh and that chart...bumped for convenience:
    http://ktmtalk.com/attachment.php?at...0&d=1457163312
    1992 300 EXC....The battle never ends, UPDATE She's a runner!:
    http://ktmtalk.com/showthread.php?t=488234

    Got an older bike with a bad ignition?
    Got a bad case of the SEM blues?
    Click below for my Ignition Retrofit Thread!:

    The-SEM-to-Kokusan-ignition-retrofit-thread



  4. #153

    Default Re: The SEM to Kokusan ignition retrofit thread

    Thanks for all the help. As long aspeople are still running old turds, you never know what thread will take off. 😂

  5. #154

    Default Re: The SEM to Kokusan ignition retrofit thread

    Quote Originally Posted by malibu406 View Post
    Thinking i should try this upgrade on my 360. But, I am so confused about all the different years versus whats available Im frozen like a deer in the headlights afraid to buy anything. The pdf i looked at stopped at 2005 on cdiís.

    Will the newer 2k-2 flywheels (2014-2018) from ktms and huskies work?
    For the same years i assume if you get a 250 or 300 cdi, stator and harness they too should be ok?
    Is that all or is voltage regulator needed too.
    What does map switch do?
    Thx
    Quote Originally Posted by malibu406 View Post
    Thanks for all the help. As long aspeople are still running old turds, you never know what thread will take off. 
    Well look at that, you were scared shitless, and then you got a sense of humor about it!
    My work here is done.
    You are welcome, and glad I could be of help if at all.
    Don't give up on your older bike, once the electrical is ironed out, they tend to pay for themselves.
    Good day!
    1992 300 EXC....The battle never ends, UPDATE She's a runner!:
    http://ktmtalk.com/showthread.php?t=488234

    Got an older bike with a bad ignition?
    Got a bad case of the SEM blues?
    Click below for my Ignition Retrofit Thread!:

    The-SEM-to-Kokusan-ignition-retrofit-thread



  6. #155

    Default Re: The SEM to Kokusan ignition retrofit thread

    Has anyone tried one of these kits?
    https://www.regulatorrectifier.com/c...tator-flywheel

  7. #156

    Default Re: The SEM to Kokusan ignition retrofit thread

    Update:

    2018 wiring from an 250 XC , 2009 CDI from a 300, 2007 flywheel & stator from a 250 and a 530/450 coil (turns out its the same as a 300) all fit great and work!
    PS Seems the coil did need to have both grounds attached to the frame for a reliable spark.

  8. #157

    Default Re: The SEM to Kokusan ignition retrofit thread

    Hey I used this thread to upgrade a no-spark 1994 300EXC with a Kokusan Stator, flywheel, CDI & coil from a 1997 360 MXC. The bike started 2nd kick, runs great. I will post the details after I fix my remaining issue, the lights. I am only looking for basic lighting like the original.

    My issue is the donor bike did not have a voltage regulator (it was a MXC w/o lights) so I used the original SEM voltage regulator. I did not plug in the headlight but I measure 20 volts AC at idle and 40 volts when I rev it up (yellow wire). I assume this will blow the bulb.

    1) Do both SEM & Kokusan output AC voltage?
    2) Why won't the SEM voltage regulator bring the voltage down? The SEM has higher output so I would not think it is undersized
    3) I assume the Kokusan voltage regulator would make it work, they are hard to find (54711034000), is there a cheaper alternative?

    Thanks in advance...

  9. #158

    Default Re: The SEM to Kokusan ignition retrofit thread

    I am by no means an expert with electrical but this AC regulator from Bajadesigns came to mind.
    https://www.bajadesigns.com/products...ac-unwired.asp

    I am sure others will chim in shortly with better options.
    -basi

  10. #159

    Default Re: The SEM to Kokusan ignition retrofit thread

    Update - I realize I did NOT have the voltage regulator plugged in when I was testing the voltage (too many liquid refreshments that night?). Once I had that in the circuit I measured ~11 volts at idle and ~12+ volts when revved up.

    So yes the original SEM voltage regulator works fine with the Kokusan 2k-2 ignition, lights are working.

  11. #160

    Default Re: The SEM to Kokusan ignition retrofit thread

    Just installed a 2002 complete ignition on my 96 300mxc. I have no timing mark on the case. When you time this with a dial indicator what part of the bump on the flywheel should be centered on the stator. Front? Center? Back?
    Sorry I'm just a little confused.

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