INSTALLING THE CDI

CONNECTION: The CDI has four wires, two which connect to the blue and black wires from the magneto, and two which connect to the motorcycle ignition coil. Its input wires need to be soldered to their mating wire and then the heat shrink tubing shrunk over the exposed metal for good insulation. You can connect it to your bicycle frame just using the double sided foam tape already stuck to its underside and also use black electrical tape. The newest model is reverse wired from CDI to h.v. coil for stronger spark and longer plug life. (read more) With it you need to make sure the metal frame of the high voltage coil does not touch the bicycle frame or any metal of the motor in order to prevent the CDI output shorting to ground. Also it's best to coat it with silicone sealant to prevent people from getting lightly shocked with the pulses of voltage from the CDI if they touch it and the engine at the same time. The ignition coil should be held in place with a hose clamp. To connect the CDI ground wire to the ignition coil you'll need a 1/4" diameter bolt, nut, and washer. Here you can see how to connect the wires:

Questions & Answers

Does my spark plug need the screw-on nipple that was taken off to work with the spark cap supplied with the CDI? Yes, you will need that to match the new spark cap. If you don't have one then splurge and buy a iridium or platinum tipped spark plug to give you the best performance.

How can I test it to see that it produces a hotter spark? Just take out the spark plug, connect it to the spark plug cap, hold the spark plug onto the cylinder head so that it is grounded, and with dim lighting (best at night) push the motorbike and you will see the actual spark. Do this same routine with the standard ignition system before changing to this new system so you will have a point of comparison.

Does it come waterproof? Mostly. Just position the box onto the frame so that the box lid is the low side. That way no water can rise and contact the electronics within. Then it will be waterproof.