Volume 8, Issue 8, August – 2023 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Modification to Fuel Supply System of Honda CD125

Motorcycle Engine
I. D. Bandara K. P. P. Sanjeeva
Department of Mechanical and Manufacturing Technology Department of Mechanical and Manufacturing Technology
Wayamba University of Sri Lanka Wayamba University of Sri Lanka
Kuliyapitiya, Sri Lanka Kuliyapitiya, Sri Lanka

Abstract:- Fossil fuel which is a non-renewable energy limits, more attention has been paid to the fuel consumption
source is ubiquitous in automobiles. The present study and emission status of internal combustion engines.
aims to introduce a closed-loop electronic fuel injection Therefore, an electronic fuel injection (EFI) system was
(EFI) system for a 125 cm3 4-stroke gasoline engine, developed which is an efficient system for controlling and
which tends to efficiently utilize fuel. A compatible supplying the optimal amount of fuel to the combustion
prototype was developed and installed to the existing chamber [6] [8]. Here, delivering an accurate and equal mass
motorcycle engine with the aforementioned specifications of fuel to cylinder of the engine [4]. Although this EFI
in order to carry out experiments. Firstly, same volume of system has been used for automobile cars since bigining, it
fuel is supplied to the selected engine with three different has recently been used for motorcycles, then the number of
carburetors which are mechanical, EFI and the modified motorcycle using the EFI fuel systemis very few [10]. As
EFI and the engine was run at the speed of 6000 RPM. mentioned above, the benefits that are maintaining better fuel
Then, the time taken to burn the given fuel volume was efficiency, better cold start and emission of minimum exhaust
measured. Secondly, by using the three carburetors, an gas have become achieved as a result of including EFI for
emission test was carried out and analyzed the gases motor cars.
emitted by each case. The results of the first test showed
that the modified EFI system runs longer time compared The present study was carried out in order to achieve
to the mechanical system and shows that the system has the foregoing benefits of motor cars for motorcycles. A
better fuel economy. Also, the emission tests showed a closed-loop electronic fuel injection system (modified EFI)
significant reduction in CO and HC emitted by the was developed as a combination of electronic fuel injection
modified EFI system compared to mechanical carburetor. system and the existing traditional motorcycle carburetor. In
addition, this paper discusses different factors such as fuel
Keywords:- About—Electronic Fuel Injection (EFI), injection timing and inlet air flow controlling that are
Carburetor, Fuel Consumption, Engine. required to control the quantity of fuel in the airstream for
maximum fuel efficiency. The following sections will discuss
I. INTRODUCTION methodology, test results and discussion and conclusion.

Small gasoline motorcycle engines which have typical II. MATERIALS AND METHODS
capacities in the range of 50cc to 250cc are widely used in
many countries because of their convenience and good fuel Studies of previous literature helps nail down their
economy due to the high power-to-weight ratio [2]. A survey significant failures, analysis of obtained data and data
of the worldwide motorcycles has been performed in 2001. analysis regarding fuel saving methods that can be done for
According to the study, Asia stands 78% of the total number same motorcycles currently in use. Based on the
of motorcycle usage, Europe uses (14%) and Latin America recommendation from the literature survey, EFI method was
uses (5%) of motorcycle for transportation [1] [9]. The selected as the most fuel-efficient method and the most
reason of choosing motorcycles as a mode of transport has suitable method for this study. In this EFI method there are
been due to the continuous increase in fuel prices. As two types of fuel injection systems being used. Considering
motorcycle engines come with small engine capacity and the existing configuration of Honda CD125 engine, manifold
lower fuel consumption, the fuel efficiency has been utmost fuel injection system was used such that it was able to fit
interest to many manufacturing industries and research easily. Then fuel supply system was designed as shown in
organizations. In small motorcycle, fuel system comes with Fig. 1 and Fig. 5 which presents the fuel diagram of the
carburetor which mechanically controls the air fuel mixture. system. In an EFI system, fuel is needed to make high
However, this mechanical injection system has many pressured (300 kPa) [10]. Then pressurized fuel is supplied to
disadvantages such as poor control of air fuel ratio during the fuel injector and the fuel injector delivers fuel to the
sudden acceleration and deceleration, cold start problems, no combustion chamber as atomized fuel particles. This fuel
altitude compensations, and high emissions [2] [5]. pressure management is important in this study. Fuel pressure
Considering high usage of motorcycles on the road, this and butterfly valve are interconnected parts to maintain the
system has been the major contributor to air pollution air-fuel ratio. Then the air inlet system performance based on
especially in urban areas of developing countries [10]. the volume of air drawn into the system depends on air
Nowadays, due to the increase in fuel prices and emission

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Volume 8, Issue 8, August – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
pressure and density, throttle valve position, engine speed TABLE 1 Motorcycle engine specification
and the cleanliness of the air cleaner element [2]. Motorcycle Honda CD 125cc
Engine type 4 stroke Twin cylinder SOHC, Two
A motorcycle that consumes more fuel was used for valves per cylinder, air cooled engine.
testing in this study. Its engine specifications are shown in Bore × Stroke 43.2 mm × 43.2 mm
TABLE 1. When introduced EFI to mechanical fuel system, Compression ratio 9.4:1
fuel supply to the modified system was designed to provide Max power 12.4 KW
required fluel pressure since the exsiting mechanical system Max Torque 9.8Nm at 6500rpm
doesn’t buid up pressure. In the fuel system of EFI method, Number of valves 4 valve overhead cam
fuel is pumped by electronically driven turbine-style fuel Transition 4-speed constant mesh gear box
pump and fuel system consists of a filter, fuel injector and
presure regulator unit. The pressure in the fuel system is 300 TABLE 2 Fuel injector specification
KPa (43.5 Psi). Fuel is separated by a single-line fuel injector
Sector Specifications
which works from a solenoid actuator needle valve. There,
Working voltage 12v - 14v
pressurized fuel is sprayed by fuel injector. The charateristics
Temperature range 30ºc to 120ºc
of the fuel injector are shown in TABLE 2.
Working pressure 100Kpa – 450 Kpa
Drive current 1Amp at 12v
Flow rate 38 g/min
Closed time 0.65 ms
Max open time 1ms at 300Kpa

Fig 1:- 3D Design

Fig. 3. Testing arrangement

Fig. 2 shows 3D design of the throttle body and the final

throttle body was manufactured according to this design.
Then, the fuel supply system was changed in order to gain
the required pressure for the modified system and operation
of the fuel injector was based on crank position sensor signal.
The pulse from the sensor was amplified to the fuel injector’s
sensible voltage. The exact time when the fuel injector opens
is when the piston completes the first 900 degrees travelling
from TDC to BDC. At this point, the inlet valve is fully
opened. According to the electronic signals received by the
fuel injector, it releases the compressed fuel into the
combustion chamber as particles. The amount of fuel given
to the combustion chamber is determined by the signal given
Fig. 2 Throttle body design
by the throttle. Simultaneously, the pressure of fuel is
increased by the pump. Then more fuel is supplied as per
requirement. Here the RPM value of the engine depends on

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Volume 8, Issue 8, August – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
the amount of fuel supplied. According to the above TABLE 3 Time based test
description, it is clear that the engine RPM is indirectly Type Amount of Engine Time
influenced by the internal pressure of the fuel system. Fig. 3 fuel (Liter) RPM (min)
shows an experiment carried out for this study where the new Mechanical 0.25 6000 43
throttle body system was installed with the manifold and the carburetor
engine was started. Fig. 5 shows a flow diagram of all the EFI 0.25 6000 105
components from the fuel tank to injector. Modified EFI 0.25 6000 68

Fig. 5 Time with fuel consumption

According to the data, the motorcycle which uses the

EFI system showed more environmentally friendly results.
Secondly, the modified system showed a significant
improvement in terms emissions. The observations show a
pronounced reduction of harmful gases emitted by modified
EFI system since CO amount in the exhaust is considerably
lower than that of mechanical carburetor.
Fig. 4 Fuel system flow diagram
TABLE 4 Mechanical system emission results
III. RESULTS AND DISCUSSION RPM HC CO CO2 O2 λ
(ppm) (ppm) (ppm) (ppm)
TABLE 3 shows the results of an experiment using the
Idle 480 276 2.58 7.45 8.61 1.44
given fuel amount of 0.25 liters. All the engines used here
were maintained under the same conditions. This study has
2500 2480 300 2.60 6.80 9.33 1.49
proven that the new system provides a more effective
RPM
solution by maintaining a long run time. Further, it was
observed that the engine run time has an increase by 25
TABLE 5 Modified system emission results
minutes compared to mechanical carburetor. Fig. 4 shows
RPM HC CO CO2 O2 λ
fuel consumption in those three systems graphically.
(ppm) (ppm) (ppm) (ppm)
Furthermore, the fuel efficiency of the fully EFI
manufactured motorcycles was higher than that of the Idle 820 50 0.20 12.01 0.80 2.08
modified EFI system, thus indicating that this study has the
potential for further optimization. TABLE 4 shows the 2500 2480 100 0.09 13.05 0.50 2.00
emission test (or called eco test) results with mechanical RPM
carburetor system, TABLE 5 shows the emission test results
with modified EFI system and TABLE 6 shows the emission TABLE 6 EFI system emission results
test results with fully EFI system. λ represents the ratio RPM HC CO CO2 O2 λ
between the amounts of oxygen actually present in a (ppm) (ppm) (ppm) (ppm)
combustion chamber vs. the amount that should have been
present to obtain perfect combustion. Idle 820 3 0.09 15.18 0.50 1.02

2500 2480 5 0.01 14.54 0.20 1.01

RPM

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Volume 8, Issue 8, August – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
IV. CONCLUSION [7]. R. K. Kunjam, P. K. Sen and G. Sahu, "A Study on
Advance Electronic Fuel Injection System,"
In the present study, a standard mechanical carburetor in International Journal of Environmental Science and
Honda CD125 four-stroke motorcycle engine was replaced Development, Vols. 3-10, pp. 3608-3613, 2015.
with the modified EFI system to investigate fuel [8]. M. H. Mohsin, A. U. Khan, S. H. Mujtabat and M. B.
consumption. This includes new installation of an air Khan, "An Efficient Carburetor Design using Electronic
induction system, fuel supply system, and input signal Fuel," in Multi-Topic Conference (INMIC),, 2014.
system. The modified EFI method shows better results in [9]. M. F. Hushim, J. A. Alimin, H. Selamat and M. T.
different speed ranges. Muslim, "PFI system for retofitting small 4-stroke
gasoline engines," International Journal of
In the first test, the same amount of fuel was provided to Environmental Science and Devolopment, vol. 4, pp.
the all three fuel injection systems and running time of each 375-378, 2013.
system was measured. It was showed that modified EFI was [10]. T. B Raju and D. Hithaish, " A reviwe on gasoline
running long time period in comparison to mechanical direct injection system," IINTERNATIONAL
carburetor. The second test measured the composition of JOURNAL OF RESEARCH IN, vol. 08, no. 3, pp. 224-
gases emitted due to the three fuel systems. It was observed 231, 2014.
that the modified system has shown a significant reduction in
CO and HC emitted by the engine compared to mechanical
carburetor despite the fact that EFI system always shows the
best results. It is interesting that the modified system has
gained a positive impact on fuel economy and eco-
friendliness and it seems as a potential technology to further
improvements.

ACKNOWLEDGMENT

I am grateful to the Department of Mechanical and

Manufacturing Technology at Wayamba University of Sri
Lanka for providing the required resources to complete this
project.

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