Planning it to get it done by Asghar. Hopefully next Saturday.

After many days of scheduling and postponing, finally got it installed today.


My curiousty with the CDI began sometime around May 2009. My biggest worry was the installation. Apart from riding, filling petrol and what I've studied about internal combustion engines in Std 9, I know nothing about bikes Besides, I had only RX100 those days and from what I could gather on an RX100 install is not as easy as RX 135.

With this bike, I had no emotional attachment like RX100 and so was willing to experiment a bit.

Bike is 2002 model RX 135 4 Speed with fat cat-con. Magnet & Coil plate assy are stock that came from the factory.

Bought Mico W5BC & Activa plug cap.

Plug cap reading: 5.05
Source Coil reading: 0.8 (presume 80 Ohms??)
Battery: 13 (Measured when bike was NOT started)

Wiring harness looks like this:-



Coil Plate:



Grounding 1



Grounding 2



Final Mounting



Please let me know if there has been any mistake while installing. There was no old cycle tube handy so wrapped it in polythene cover and taped it. It is NOT touching/rubbing against tank or anything.

Bike revvs much better now. This bike is now, where my RX100 is already is in terms of free revving. Earlier do 40kmph in 3rd gear and you would feel resistance. But now it revvs upto 60kmph easily. On stock CDI, RX 135 4 Speed is like having intense foreplay and then a severe anti-climax. With digital CDI, you don't bother yourself with the foreplay at all

I am not too sure the bike is running any cooler though. Let me commute next week and update this comment but this is the biggest expectation I had from the CDI. That even after 20-25kms of commuting in rush hour traffic, I should be able to touch the head. My initial impression is it is not runnning any cooler.

Like Arvind said, if I change to cat-con I should see even better revvs. But I will take sometime to make that decision. As of now I am happy with the additional revvs.

Long-term durablity and reliablity-only time will tell that. Going by many people's experiences it should be good. If you are running on cat-con this product is a worthy investment assuming long term durablity & reliablity of bore-piston is unaffected.
OT: Got to ride pillion on Arvind's RD today. They need to put on a seat belt to that bike DO NOT TAKE A GIRL ON AN RD EVER.

Seems like a good job Nitin; hope you scarped off some paint when grounding; also ensure you've routed through a fuse which is the best approach as the fuse takes the brunt even if there's a short circuit protecting the CDI.

Nice n clean install Nitin. Good to see you have atleast 2 grounds. One thing i'd like to tell you is, always connect the brown +12v. wire the last [after double checking the rest of the connections] and its a good idea to have a fuse box between the brown wire and the bikes wiring harness counterpart. Pulsar fusebox is a direct fit there.

Thank You Ganesh & Nitesh for your feedback. Yes, fuse box is used. Infact bought a fuse box while installing and the installer (Asgar) was particular about NOT running it without fuse. He has clearly instructed that if fuse blows, replace fuse immediately and NEVER try it to run w/o one as I might damage CDI.

And yes, paint was scraped off and then sandpaper used for preparing space for grounding.

IMO, never do that; find out the cause for the blown fuse & then replace...even if it takes a lot of time to find out the cause. For the very reason, the replaced new fuse might be strong enough for sometime, but not the RDD CDI (heard the newer ones are quite resistant), causing them to blow off. Just my experience though.

Like Aargee said, find the cause of the blown fuse before replacing it. So now the bike has two fuse boxes rt.?

Bike has only one fuse box with two fuses in it. Earlier there was just one fuse installed (no box). Asgar didn't like it. He said "This thing is too complicated" No idea what he meant by that. So, per his suggestion I bought a fuse box and got it installed. There was nothing that got blown yesterday

I will keep your advice in mind . But I hope nothing gets blown

Yup, this time Ron has made it resistant upto 35V. The unit can withstand input upto 35V.

What i meant was to install as additional fuse between the brown CDI wire and the harness. the brown wire powers the CDI so if in case there is any fluctuation in power, the fuse will blow rather than harming the CDI.

Understood finally I am going there this Saturday for clutch bell replacement and will get additional fuse also installed. Thank You once again for that advice

Headlight has gone completely dim today. It glows like park light Horns & indicators are working fine. Any pointers would be very helpful.

Also there is a noise when I rev past 1/2 throttle. Sort of a metal vibrating noise. Will post audio clip shortly.

EDIT: http://youtu.be/W02NGDxgr_c at 0:30 to 0:31 the sound is prominent.

possibly a lose headlamp wiring. Change the bulb and see. the sound could be anything .. a lose bolt, headlight dome, meters. try to pinpoint where its originating from.

Opened the headlight assy. The bulb looks like this:-



Replaced with a local bulb (but functional) I had and only one filament is glowing.

Has the first bulb blown? Filament (or whatever else that string kinda thing is called) hasn't come off Even after replacement only one filament is glowing

You might want to check the wiring to the holder now. Check if the wires are where they should be attached .

I have owned a brand new RX135 4-speed straight out of showroom. A stock 4-speed with big-catcon will not do beyond 90Kmph (speedo indicated), unless you have a 5-speed GB with sprketing of 16/34 or porting.


A stock 135 4-speed with factory setting is easily able to do 60Kmph in 3rd gear, no issues at all. It is the most free running 2-stroke motor i have come across in stock trim.

No foreplay at all? Looks like you have a RX135 4-stroke now. Foreplay & then climax is what differentiates 2-strokes from 4-strokes.


Enough said, get your RX135 & i will get couple of absolutely stock 135s & lets see which one revs better. I don't believe in theory & you know it very well. I will be comparing apple to apple only. PM me if you like to meet up. Otherwise i will feel this is yet another heavily biased RDD writeup. Lets do it the gentlemen way, rather than bragging over internet as to whose balls are bigger.

Keep revving.