I've also included the cad files for the case, for anyone who needs to make this cdi box themselves or make it better! Added a parts list since someone mentioned it, includes part numbers for every component.

Thought I would add the gerber and schematic files, the gerber files should be in the zip file, and should be everything needed to get a pcb made. The engine seems to be doing fine so far, but I will continue to test it and see how it goes. (C4 on schematic) Thyristor, (Q2), Part number VS-30TPS12LHM3 SCR, (Q1), Part number BT169D,116 Zener, (D3), Part number TZX10C-TR Diodes are part number 1N5623GP-E3/54 My particular bike is a 74, but this should work on most TS185/250s. This Suzuki 36618-30610 WIRE HARNESS fits the following models and components: Aftermarket Parts ELECTRICAL Wiring Suzuki Motorcycle 1972 SAVAGE - TS250. For the discharge capacitor, I used a Panasonic metallized polyester, the part number for which is ECQ-E6225JF. I wanted all components to be easily available from Mouser (although I’m sure they would be just as easy to find anywhere else) In the schematic below, you will find manufacturer part numbers for all components to avoid confusion. My main goal was crack one open, figure a circuit diagram, find modern replacements for all components, and arrange them according to the circuit. (I tried 4 different readily available 5 pin AC CDI boxes from ebay, and all were way off timing) Basically, I have successfully “replicated” a CDI box for Suzuki TS185/TS250 motorcycles. I feel this is important because for these models of bikes, no replacements are currently made, and owners are depending on 40 year old brain boxes to keep their bikes running. Suzuki Ts250 1979 N Usa E03 Parts Lists And Schematics. VAT 6 Volt 25/25W PR30 Headlamp Bulb P15d. You may also like Suzuki TS185 TS250 Rectifier 6 Volt 1973 to 1978 12.50 Incl. This kit has a ‘Pro’ skill rating meaning you must have good mechanic’s experience and understand wiring. I know you guys aren’t “bikers” but I feel as though posting here is my best bet at making this info “visible” on the net for those who need it. Motorcycle Wiring Diagrams Evan Fell Works. It does not make the lights brighter or convert the electrics to 12 volts.

Suzuki ts250 wiring