Restoration of CDI system using a Signal Light Relay for educational purposes

1.1 Background of the Project

The Capacitor discharge ignition (CDI) system is an electronic ignition system

commonly used in small engines like motorcycles, chainsaws, and some turbine-powered
aircraft. It works by storing electrical energy in a capacitor and then discharging it rapidly to the
spark plugs, creating a hot and powerful spark. This is more efficient and reliable than older
magneto ignition systems. At present, many things have been changed because of technology.
The researchers invented the CDI (Capacitive Discharge Ignition) system for SI (Spark Ignition)
Engine using electronic ignition & contact point ignition. This system includes a pulse control
circuit, spark plug, pulse generation circuit, main charge & discharge capacitor coil, etc.

Through the study of aviation electrical, AMT students had been exposed to the actual
CDI system unit with all the pieces. Due to a prolonged period of inactivity, the CDI box which
is the brain of the system lost its functionality. The instructor suggested that it’s better to restore
the CDI system rather than wasting it. AMT students are commissioned to fix it and make it
functional once more. This is the rationale behind the start of this project. This will serve as a
challenge to the students to come up with better ideas on how to use the signal light relay as an
alternative replacement for the CDI box.
1.2 Objectives:

 To restore the CDI system using a signal light relay to full functionality and accuracy.

 To improve performance and reliability of the signal light relay for the sparkplug to ignite
continuously.

 To extend the lifespan of the CDI system and reduce waste instead of disposing of it
which is harmful to the environment.

 To be cost effective alternative replacement instead of purchasing a whole new CDI

system unit.
1.3 Project Period:

Day 1 and 2: Disassemble - Carefully disassembling the CDI system. Assure all the
screws, nuts, and bolts are stored in one place. (2:30-4:00 pm)

Day 3: Inspect the parts - Carefully inspect all the parts for damage. Looking for
cracked or broken plastic, frayed wires, corroded electrodes, and any other signs of wear and
tear. (2:30-4:00 pm)

Day 4 and 5: Gathering supplies – Necessity of variety of tools and materials,

depending on the condition of the CDI system. Upon inspection, a signal light relay is purchased
for alternative replacement in the CDI box. (2:30-4:00 pm)

Day 6 and 7: Clean the parts - Clean all the parts of the CDI system using degreaser or
solvent to remove stubborn dirt and grime. Dry all the parts thoroughly before reassembling.
(2:30-4:00 pm)

Day 8 and 9: Test the components - Replace any damaged parts with new ones. Use a
battery supply to test the electrical components of the CDI system. Make sure that all the
components are working properly. (2:30-4:00 pm)

Day 10: Reassemble – Reassembling the CDI system and securing to tighten all the
screws, nuts, and bolts securely. (2:30-4:00 pm)

Day 11: Final testing - The CDI system is now reassembled, test it with a well-good
spark plug to make sure that it is working and operating within safe and efficient parameters.
(2:30-4:00 pm)
1.4 Target Outcome:

The target outcome of the project should be well presentable enough by showing the
continuous ignition of the sparkplug. The wires must be tucked in accordingly and the color must
represent its purpose. For example, the ground should be the color black, while the positive color
is red. The components of the CDI system using a signal light relay should be placed neatly;
Ignition key switch, signal light relay, high tension wire and sparkplug. The ignition key switch
must be the one who starts the system, and all supported by the supply which is the main charge
or battery. As soon as the spark ignition is continuous, it indicates that the sparkplug is already
charged through a signal light relay’s function.
1.5 Project Activity Flow:

Inspection Analyzing the damage parts

Purchasing replacement
Planning and budgetting
parts

Applying replacement parts Testing and Troubleshoot

Final testing