unit 8

ignition
systems

A n engine develops power when the heat o f a

b u r n i n g air-fuel m i x t u r e pushes the piston d o w n .
A n electric spark starts the air-fuel m i x t u r e b u r n -
ing. The spark comes f r o m a system on the engine
called the magneto.
A magneto needs several parts to make a spark.
The engine i n Figure 8-1 shows the basic parts o f a
magneto: a magnet, armature, c o i l , spark plug,
breaker points, and condenser. I n this unit we w i l l
study how a magneto i g n i t i o n system works.

LET'S FIND OUT When you finish reading and studying this unit, you should be able to:
1. Define the terms electricity and magnetism.
2. Identify the parts of a magneto ignition system.
3. Describe the operation of the magento breaker points and con-
denser.
4. Explain the operation of the magneto magnets and coil.
5. Describe the parts and operation of a spark plug.

use it. I n order to understand the electron theory,

ELECTRICITY
I n order to understand h o w a magneto w o r k s ,
you need to k n o w a little about electricity and
magnetism. The current theory or way o f t h i n k i n g
a b o u t electricity is called the electron theory. We
still do not k n o w everything about electricity.
U s i n g the electron theory we can, however,
understand h o w electricity behaves and h o w to
it is necessary to look briefly at what the scientists
call the c o m p o s i t i o n o f matter.
Everything in the universe except the complete
voids that exist between the sun, stars and planets
is called matter. A n y t h i n g that has weight and
takes up space is matter. Even things that cannot
be seen, such as air, are matter. M a t t e r may be i n
the f o r m o f a solid, a l i q u i d or a gas. A l l matter is

72

Figure 8-1. The basic parts o f a magneto. (Briggs &
Stratton Corp.)
composed o f very, very small particles called
atoms. A n a t o m is so small that it is not visible
except under the most powerful electron m i c r o -
scope. A t o m s are made up o f even smaller
particles.
SOLAR SYSTEM
Figure 8-2. A n a t o m is constructed like o u r solar system.
IGNITION S Y S T E M S 73
A n a t o m is constructed m u c h like o u r solar
system, Figure 8-2. T h i n k of the sun and the
various planets w h i c h revolve a r o u n d i t . A n a t o m
has a center or core composed o f particles called
protons and neutrons. This core is called a
nucleus. I n our example of the solar system, the
sun is like the nucleus. Other small particles called
electrons circle i n orbits a r o u n d the nucleus,
much as the planets circle the sun. Electrons
travel at a tremendous rate o f speed.
The particles w h i c h make up the a t o m have
positive and negative electrical charges. W h y
atoms have this q u a l i t y is not k n o w n but this is
where electricity comes f r o m . Positive and nega-
tive charges means simply that the t w o charges
are completely opposite. The s y m b o l + is used to
show a positively charged particle and the symbol
- to show one w i t h a negative charge. A l m o s t
everyone has experimented w i t h a set o f magnets
and observed that the magnets can be placed so
that they repel each other or so that they attract
each other. Electrical charges act i n much the
same way. T w o particles that are positively
charged w i l l repel each other; t w o negatively
charged particles w i l l repel each other. A posi-
tively charged particle and a negatively charged
particle attract each other. This positive-negative
a t t r a c t i o n is what holds the atoms together.
ELECTRON
ATOM
74 SMALL ENGINE SYSTEMS
The core, or nucleus, of an a t o m is made up o f
positively charged particles. The electrons that
orbit i n a fixed pattern around the nucleus are
negatively charged particles. The only difference
among the atoms o f different kinds o f matter is
the number o f particles i n the nucleus and the
number and spacing o f the electrons that orbit the
nucleus.
The nucleus o f the a t o m is composed of p r o t -
ons w i t h a positive charge and neutrons w i t h a
neutral charge. The electrons w i t h a negative
charge o r b i t a specific distance away f r o m the
nucleus. A n a t o m may have one, t w o or three
rings o f electrons depending on the number of
electrons it contains. Each of these rings requires
a specific number o f electrons.
The Flow of Electricity
I f we again compare the a t o m to our solar
system, the electrons orbit the nucleus as the
planets o r b i t the sun. The electrons remain in
their orbit a r o u n d the nucleus because of the elec-
trical a t t r a c t i o n the electrons have for the
nucleus. T h i s is similiar to the g r a v i t a t i o n a l p u l l
of the sun on the earth. The electrons that o r b i t
closest to the nucleus are strongly attracted to it.
These are called bound electrons. The electrons
that are farther away f r o m the p u l l o f the nucleus
can be forced out o f their orbits. These are called
free electrons. Free electrons can move f r o m one
a t o m to another. The movement o f the free elec-
Figure 8-3. Electricity is the movement o f electrons f r o m one a t o m to another.
trons f r o m one a t o m to another is k n o w n as elec-
tron flow.
A c c o r d i n g to the electron theory, electricity is
the movement or flow o f electrons f r o m one a t o m
to another, Figure 8-3. In order to have a move-
ment o f electrons, it is necessary to have a condi-
t i o n o f imbalance. I n a n o r m a l a t o m , the posi-
tively charged nucleus balances the negatively
charged electrons and holds them i n orbit. I f an
a t o m loses electrons, it w i l l become positive i n
charge. It w i l l attract more electrons in order to
regain its balance.
The flow o f electricity is made possible by caus-
ing electrons to leave their atoms and gather i n a
certain area, leaving behind atoms w i t h o u t their
n o r m a l number o f electrons. Science has discov-
ered a number o f ways to create an unbalanced
c o n d i t i o n to start an electron flow.
Language of Electricity
Electricity has a language a l l its o w n . A
mechanic must understand the meaning and rela-
tionship o f a number o f electrical terms i n order
to understand magnetos. The terms described
below are relatively simple but they are the foun-
d a t i o n for all electrical t r o u b l e s h o o t i n g and
servicing.
Voltage (volt) (E). I n order to have a flow o f
water i n a fire hose, pressure is necessary. I n order
to have an electron flow i n an electrical system,
pressure is necessary. I n electricity the force or
potential that pushes electrons is called voltage.

Water pressure is measured in pounds per square
inch; electrical pressure is measured in volts. The
letter s y m b o l for the volt is E (for electromotive
force) or V .
Voltage may be considered a source o f poten-
tial energy that exists when unequal numbers o f
electrons are present in a system. Voltage or volts
always describes a potential difference between
two parts o f an electrical system. The voltage o f
y o u r house w i r i n g may be 1 10. This voltage is
present even t h o u g h no household appliance is
turned on. The voltage "stands b y " u n t i l an
appliance is turned on. I t is i m p o r t a n t to under-
stand that voltage can exist w i t h o u t electron flow
although electron flow cannot exist w i t h o u t
voltage.
Current (ampere) (I). R e t u r n i n g to the example
of the fire hose, the rate o f water flow may be
measured in gallons per minute. I n an electrical
system, we are interested in the rate o f electron
flow. The flow o f electrons is called current. Cur-
rent is measured in amperes. The letter symbol for
current is I . The flow of current is measured by a
specific number of electrons passing a given point
in one second. One ampere is equal to 6.28 b i l l i o n
electrons per second. As was mentioned pre-
viously, current cannot flow unless there is pres-
sure or voltage.
Resistance (ohm) (R). The diameter of the fire
hose w i l l determine the a m o u n t o f water that w i l l
be able to flow t h r o u g h it in a given a m o u n t o f
time. A smaller hose w i l l provide more resistance
to the flow. There is also a resistance to electron
flow in an electrical system. Resistance is the
o p p o s i t i o n offered by a material to the free flow
of electrons. The unit o f resistance is called an
ohm. The letter symbol is R.
W h e n current runs into resistance, t w o things
occur: first, the electrons must w o r k harder to get
t h r o u g h , and this creates heat. Second, the rate o f
their flow is reduced because some o f the energy is
used up as heat. The heat built up by resistance is
sometimes used to do w o r k . F o r example, in an
ordinary household toaster, current is directed
t h r o u g h a strong resistance. The heat produced in
the resistance is used to toast the bread.
Conductor. A conductor is any material that
allows a good electron flow. I n a small-engine
IGNITION S Y S T E M S 75
electrical system, copper and a l u m i n u m wires are
used to conduct electricity because they a l l o w
good electron flow. T o be a good conductor, a
material must be made o f atoms that give off free
electrons easily. Also, the atoms must be close
enough to each other so that their free-electron
orbits overlap. O f a l l the metals, silver is the best
conductor but it is too expensive for general elec-
trical use.
Insulator. Insulators are materials whose atoms
w i l l not part with any of their free electrons. These
materials w i l l not conduct current. The copper
wire in a small-engine electrical system is covered
w i t h an insulator. The i n s u l a t i o n prevents the
current f r o m leaking out before it gets to its desti-
nation. Examples o f materials which make good
insulators are plastic and rubber.
Circuit. A circuit is a path or n e t w o r k o f paths
that w i l l allow current to flow to do some w o r k .
A n y circuit, no matter how complicated, is made
up o f several essential parts. A circuit is shown i n
Figure 8-4. There must always be a source o f
electrical pressure or voltage. I n this i l l u s t r a t i o n ,
the voltage source is a battery. I n this circuit the
current flow is used to light a light b u l b . The light
bulb w i l l offer resistance to the current flow. A
switch is necessary to t u r n the current flow on or
off in the circuit. Wires or conductors connect the
battery, switch and light b u l b . O u r circuit, then,
has a voltage source ( b a t t e r y ) , a resistance unit
(light bulb) and a switch connected by conductors
(wires). I n order for current to flow in a circuit,
the path must be u n b r o k e n . I n fact, the term
circuit means circle.
Ground Circuit. N o t only can electricity flow
t h r o u g h wires, it also can flow t h r o u g h metal
^
BATTERY
Figure 8-4. Parts o f a circuit.
76 SMALL ENGINE SYSTEMS
GROUND
Figure 8-5. Electrical parts can be connected to metal
instead o f to a wire to make a complete circuit.
parts on the engine. We can use these metal parts
in place o f one o f the wires i n a circuit. L o o k at the
example i n Figure 8-5. Instead o f a wire f r o m the
light b u l b to the battery, we could connect a short
wire f r o m the battery to a metal part on the
engine. We could connect a short wire f r o m the
light to the same metal part. Electricity w i l l flow
across the closed switch into the light. Current
w i l l flow t h r o u g h the light into the metal on the
engine and back to the battery. This completes the
circuit and the light lights up. The part of the
circuit connected to the metal is called ground or
grounded. We call this a grounded circuit or
g r o u n d circuit. M o s t electrical parts have one
connection grounded. This means we only need
one wire to have a complete circuit between t w o
electrical parts.
MAGNETISM
M a g n e t i s m is a force that is involved i n the
operation o f the magneto. The w o r d magneto, i n
fact, comes f r o m the w o r d magnet or magnetism.
Exactly what magnetism is and how it uses its
force is still not completely understood. One the-
ory is based u p o n the electron. T h i s theory says
that each electron has a circle o f magnetic force
a r o u n d it. I n an unmagnetized piece o f i r o n , the
electron orbits are not arranged i n any pattern. I n
a magnetized piece o f i r o n , the electron orbits are
lined up so that their circles o f magnetic force are
added together, Figure 8-6. W h e n a l l the mag-
netic forces w o r k together, the piece o f i r o n has a
strong magnetic field.
UNMAGNET1ZED MAGNETIZED
Figure 8-6. M a g n e t i s m is the a l i g n m e n t o f electron
orbits. ( C l i n t o n Engines C o r p . )
INDUCTION
I n d u c t i o n involves the transfer o f energy f r o m
one object to another w i t h o u t the objects t o u c h -
ing each other. I n d u c t i o n is used in the magneto
coil.
W h e n current flows t h r o u g h a coil, a magnetic
field is created i n the c o i l . I f the coil w i t h current
f l o w i n g i n it is placed near another coil w i t h o u t
current, the t w o coils w i l l influence each other. I f
two coils are placed next to each other as shown in
Figure 8-7, the b u l b connected to the second coil
w i l l not light. I f the switch is opened, the field
a r o u n d the first coil w i l l collapse and j u m p over to
the second c o i l . This collapsing magnetic field w i l l
cause current to flow in the second coil. The light
connected to the second coil w i l l light, but just for
a f r a c t i o n o f a second. I f the first coil is charged,
then collapsed again, the light w i l l light again.
The k i n d o f i n d u c t i o n is used i n magneto i g n i t i o n
coils.
MAGNETO MAGNETS
As we said earlier, the w o r d magneto comes
f r o m the w o r d magnet. A l l magnetos have
magnets. Magnetism may be used to help make
electricity. The magneto magnet is attached to the
engine's flywheel. The magnet may be attached to
the inside of the flywheel, as shown in Figure 8-8.
O n other engines it is attached to the outside o f
the flywheel. The magnet may be cast into the
 IGNITION S Y S T E M S 77

flywheel, or it may be m o u n t e d to the flywheel

w i t h bolts. The magnet goes a r o u n d w i t h the fly-
wheel. We use this revolving magnet to make
electricity.

Armature and Coil

We cannot make electricity w i t h just a magnet.

We need an armature and a coil. A n armature and
coil are shown i n Figure 8-9. The armature is
made f r o m several thin strips o f soft i r o n . The
strips are squeezed tightly together. The armature
is used to make a path for the magnetism.
The coil is attached to the armature. Inside the
coil is a fairly thick wire. This wire is wrapped, or
coiled, a r o u n d part o f the a r m a t u r e , as shown i n
Figure 8-10. I t is called the primary wire. One end
of the p r i m a r y wire is attached to the a r m a t u r e .
The other end goes to a switch called the breaker
points. We w i l l see how these w o r k later.

Figure 8-7. A collapse i n a magnetic field can cause

current to flow i n another coil.

Figure 8-9. A n a r m a t u r e and coil are part o f the

magneto.
78 S M A L L ENGINE SYSTEMS

engines, the magnet is mounted inside the fly-

wheel, and the coil and armature are mounted
under the flywheel.

Magnet and Coil Operation

Let's see how a magneto makes electricity. The

magnet goes around with the flywheel. As the
SPARK S E C O N D A R Y WIRE
PLUG
flywheel turns, the magnet goes under the arma-
ture, as shown i n Figure 8-13. M a g n e t i s m f r o m
Figure 8-11. There is a t h i n wire i n the c o i l , called the the magnet moves from one end o f the magnet
secondary wire. and into the armature. The magnetism travels
t h r o u g h the armature and back into the magnet.
The flywheel turns some more. The magnet
lines up under another part of the armature, as
shown in Figure 8-14. The magnetism now passes
t h r o u g h the armature in the opposite direction.
When magnetism changes direction next to a coil,
a small a m o u n t o f electricity builds up i n the coil's
p r i m a r y wire.
The a m o u n t o f electricity we get i n the p r i m a r y
wire is not enough to get the air-fuel m i x t u r e in
the cylinder b u r n i n g . To burn the air-fuel m i x t u r e
we need a lot o f electricity. We have to change the
small a m o u n t o f electricity in the p r i m a r y wire to

Figure 8-12. The a r m a t u r e and coil are m o u n t e d next

t o the flywheel and magnet. (Briggs & S t r a t t o n C o r p . )

There is another wire inside the coil. I t is called

the secondary wire. The secondary wire is
wrapped a r o u n d the p r i m a r y wire. The secondary
wire is m u c h thinner than the p r i m a r y , and is
wrapped a r o u n d the armature many more times.
One end of the secondary wire is hooked to the
armature. The other end is hooked to the thick
wire that goes to the spark plug, Figure 8-11.
The armature and coil are mounted next to the
flywheel. I n Figure 8-12 the magnet is attached to
the outside of the flywheel. The armature and coil Figure 8-13. As the magnet lines up under the arma-
are m o u n t e d right above the flywheel. O n some ture, magnetism goes i n one d i r e c t i o n .
 IGNITION SYSTEMS 79

Figure 8-15. T h e breaker points fit behind the fly-

wheel. (Briggs & S t r a t t o n C o r p . )

Figure 8-14. As the magnet turns, more magnetism

MOVING ARM
goes in the other d i r e c t i o n .

high-voltage electricity in the secondary wire. T o

do this we need some more parts. We w i l l con-
tinue our study of the magneto o p e r a t i o n in the Figure 8-16. T h e parts o f the breaker points.
next section.

B R E A K E R POINTS

The breaker points are a switch that is opened

and closed by the crankshaft or camshaft. The
breaker points are usually under the flywheel, as
shown in Figure 8-15.
The breaker points are t w o small, r o u n d points.
One o f the points is called the moving point. I t is
connected to a m o v i n g a r m . A small, r o u n d r o d is
used to move the a r m . This rod is called a plunger.
The other p o i n t does not move. I t is called the Figure 8-17. A flat spot on the crankshaft a l l o w s the
stationary point. Figure 8-16. breaker points to close.
The breaker points fit right next to the crank-
shaft. The crankshaft opens and closes the
breaker points. The plunger rides on the crank-
shaft. The crankshaft has a small, flat spot on it. As the crankshaft turns, the flat spot moves
W h e n the plunger is on the flat spot, the contact away f r o m the plunger. The plunger pushes up on
points are closed. A small spring helps hold the the m o v i n g point arm. The breaker points open,
points closed. Closed breaker points are shown in as shown in Figure 8-18.
Figure 8-17. Some engines have breaker points that are
 80 SMALL ENGINE SYSTEMS
Figure 8-18. T h e r o u n d part o f the crankshaft pushes
the plunger up and opens the breaker points.
Figure 8-19. A cam can be used to open the breaker
points.
opened by a cam. A cam lobe is attached to the
crankshaft. The cam turns w i t h the crankshaft.
W h e n the cam lobe hits the m o v i n g a r m , the
breaker points are opened. Figure 8-19.
Breaker Point Operation
N o w let's see how the breaker points w o r k to
help b u i l d high-voltage electricity. The magnet on
the flywheel generates a small a m o u n t o f electric-
ity as it goes by the armature. The electricity is
made in the p r i m a r y wire.
One end of the p r i m a r y wire is attached to the
armature. The other end is attached to the m o v i n g
point arm. Electricity can flow t h r o u g h the p r i m -
ary wire and into the m o v i n g a r m . The breaker
points are closed. Electricity can now flow across
Figure 8-20. W h e n the breaker points are closed, elec-
t r i c i t y flows in the p r i m a r y wire. ( M c C u l l o c h C o r p . )
Figure 8-21. W h e n the breaker points open, high-
voltage electricity flows i n the secondary wire. ( M c C u l -
loch C o r p . )
from the m o v i n g point to the stationary point,
Figure 8-20.
When the flywheel has turned a little more, the
breaker points open,Figure 8-2 1. Electricity can-
not flow t h r o u g h the open points. The electricity
f l o w i n g in the p r i m a r y wire stops q u i c k l y . This
causes a flow of magnetism to rush t h r o u g h the
secondary wire. The magnetic flow creates a very
high-voltage electricity in the secondary wire.
This voltage may be as high as 25,000 volts. This is
enough electricity to get our air-fuel m i x t u r e
burning.

THE CONDENSER
Electricity must stop flowing the instant the
breaker points open. I f it does not, we cannot
b u i l d up high-voltage electricity. Electricity w i l l
try to arc, or j u m p across the open breaker points,
as shown i n Figure 8-22. I f this happens, we do
not get a magnetic flow in the c o i l . We cannot
b u i l d up a high-voltage electricity.
Electricity j u m p i n g across the breaker points
causes another problem. The points w i l l be
burned and soon be destroyed. They w o u l d no
longer w o r k .
A condenser is used to stop electricity f r o m
j u m p i n g across open points. A condenser is a
small electrical part shaped like a tiny can. I t has a
small wire that comes out o f one end. A little
bracket allows it to be attached to the magneto.
Figure 8-22. W h e n the breaker points open, electricity
tries to j u m p across the points.
Figure 8-23. T h e condenser wire is hooked to the m o v -
ing p o i n t . ( M c C u l l o c h C o r p . )
IGNITION S Y S T E M S 81
The condenser is mounted next to the breaker
points. The condenser wire is hooked to the m o v -
ing p o i n t . A condenser and breaker points are
shown in Figure 8-23.
A condenser is shown in cross section in Figure
8-24. Inside, the condenser consists of t w o long
sheets o f conductor foil separated by several
sheets o f insulated paper. The foil and the insula-
t i o n are w o u n d i n t o a tight roll. The r o l l of insu-
lated and conductor paper is installed in a small
metal canister. A n insulated end-piece t h r o u g h
which a small insulated wire lead, or pigtail, is
routed, is placed on top of the canister. The end o f
the canister is crimped over the insulated end-
piece. A gasket is located between the end-piece
and the foil sheets. A spring sometimes is used at
the b o t t o m o f the canister to maintain pressure on
the end-piece gasket.
Very small amounts of moisture can have a
very bad effect on the paper insulation inside a
condenser. M o i s t u r e can lead to early condenser
failure. For this reason, air and moisture are
removed w i t h heat and vacuum in a process
k n o w n as hermetric sealing. The spring, gasket
and t i g h t - f i t t i n g end-piece are designed to m a i n -
tain the hermetic seal through the service life of
the condenser.
W A X E D PAPER
INSULATION
GASKET
^HERMETICALLY
SPRING TIN
SEALED
FOIL
W A X E D PAPER
INSULATION TIN
f FOIL
Figure 8-24. T h e parts of a condenser.
82 SMALL ENGINE SYSTEMS
Figure 8-25. W h e n the points open, electricity
i n t o the condenser. ( M c C u l l o c h C o r p . )
Figure 8-26. The condenser and s t a t i o n a r y p o i n t may
be one part. (Briggs & S t r a t t o n C o r p . )
The condenser works like a tiny storage tank.
The breaker points open. Electricity wants to
j u m p across the opening. The electricity has
another place to go. It goes t h r o u g h the condenser
wire and into the condenser, Figure 8-25.
The condenser stores electricity inside. Electric-
ity does not j u m p across the open points. The
points do not b u r n as q u i c k l y .
Some engines have a condenser w i t h o u t a wire.
The stationary point is hooked directly to the
condenser. A n engine w i t h this type of one-piece
condenser is shown in Figure 8-26.
IGNITION C A B L E S
The high voltage developed in the coil's secon-
dary wire must be sent to the spark plug. The wire
used for this j o b is called a secondary wire high-
voltage wire, spark plug wire, high tension wire or
i g n i t i o n cable. I g n i t i o n cables must be able to
handle high voltage w i t h o u t leakage. They must
also be able to withstand water, o i l , v i b r a t i o n and
abrasion. Usually the wire is soldered into the coil
at one end. It has a terminal connection.for the
spark plug at the other end, Figure 8-27.
flows
Figure 8-27. T h e high voltage f r o m the coil goes to the
spark plug t h r o u g h an i g n i t i o n cable.
SPARK PLUG
The spark plug gets the high-voltage electricity
f r o m the magneto. Its j o b is to make a spark to get
the air-fuel m i x t u r e b u r n i n g . The outside parts of
a spark p l u g are shown in Figure 8-28. The top o f
the spark plug has a t e r m i n a l . This is where the
spark plug wire is connected. The terminal is con-
nected to a wire that goes t h r o u g h the middle of
the spark plug. This is the wire that allows high-

Figure 8-28. The parts o f a spark plug. ( C h a m p i o n
Spark Plug Co.)
voltage electricity to get into the c o m b u s t i o n
chamber.
The high-voltage electricity must not be
allowed to leak away. A n insulator fits a r o u n d the
wire. The insulator makes sure the electricity goes
t h r o u g h the middle o f the spark plug. A metal
part called a shell makes up the b o t t o m o f the
spark plug. The shell has threads. The threads
a l l o w the spark plug to be screwed into the
cylinder head. The shell also gives us a place to f i t
a wrench. Hex shaped flats on the outside o f the
shell allow a wrench to be used on the spark plug
for installation and removal.
Basically, a spark plug is a wire w i t h an air gap
at the b o t t o m , that w i l l f i t i n t o the engine's c o m -
bustion chamber. A sectional view o f a spark plug
is shown in Figure 8-29. T h e wire which conducts
high voltage into the cylinder is called the center
electrode. There is terminal at the t o p o f the cen-
ter electrode to attach a connector f r o m an igni-
tion cable.
Since the center electrode must carry high v o l -
tage into the cylinder, it must be well insulated. A
IGNITION S Y S T E M S 83
Figure 8-29. Sectional view o f a spark p l u g . (General
Motors Corp.)
ceramic insulator surrounds the center electrode.
The ceramic insulator has ribs on its outside
diameter to increase the distance between the
terminal and the nearest g r o u n d . This helps elim-
inate current leakage, or flashover, especially
when the outside o f the ceramic is d i r t y or wet.
The center electrode and ceramic insulator
assembly are j o i n e d to a metal shell. The shell,
insulated f r o m the center electrode by the
ceramic, has threads rolled on it to a l l o w the
spark plug to be screwed into the c o m b u s t i o n
chamber. A side electrode is attached to the shell
and placed a small distance away f r o m the center
electrode. This distance is the air gap or spark
plug gap that the current j u m p s to create a spark.
The spark plug, mounted i n the c o m b u s t i o n
chamber, is subjected to extremely high pressure.
Seals are used between the shell and ceramic insu-
lator and between the center electrode and the
ceramic to prevent the leakage of c o m b u s t i o n
pressure. Either a copper gasket or a special taper
seat is used to prevent leakage o f c o m b u s t i o n
pressure a r o u n d the shell threads.
84 SMALL ENGINE SYSTEMS

Spark Plug Operation

Secondary high voltage flows f r o m the mag-

neto coil t h r o u g h the high-voltage i g n i t i o n cables.
The voltage enters the spark p l u g at the t e r m i n a l CHAMPION
CHAMPION
end o f the center electrode. Voltage flows d o w n
the center electrode to the air gap located i n the
engine's c o m b u s t i o n chamber. The current over-
comes the resistance o f the air-fuel m i x t u r e and
j u m p s the air gap to the side electrode. The spark
created as the current j u m p s the gap ignites the
combustible m i x t u r e o f air and fuel. ,
The voltage required to overcome the gap and
the resistance o f the air-fuel m i x t u r e is different
under different c o n d i t i o n s . The wider the air gap,
the higher the required voltage. The c o n d i t i o n o f
the spark p l u g electrodes also is very i m p o r t a n t .
M u c h less voltage is required to j u m p f r o m clean,
Figure 8-31. Spark plugs have different reaches.
sharp electrodes t h a n f r o m d i r t y , eroded ones. ( C h a m p i o n Spark P l u g C o . )
T h e higher the compression pressure, the higher
the voltage required to overcome the air gap.

Spark Plug Sizes

I f it is to w o r k p r o p e r l y , the spark plug must be
the right size for the c o m b u s t i o n chamber into
w h i c h it is installed. Different sizes o f spark plugs
are required for different engine designs. Spark
plugs are made w i t h different shell thread diame-
ters, Figure 8-30. The threads are made in metric
sizes measured i n millimeters. The metric thread
allows the plugs to be used i n b o t h i m p o r t e d and
A m e r i c a n engines.
The threaded section o f the shell is made in
different lengths. This dimension is called the
reach. There are several c o m m o n reach dimen-
sions manufactured. Figure 8-3 1 shows t w o . The

Figure 8-30. Spark plugs are made w i t h different

thread sizes. ( C h a m p i o n Spark Plug Co.)
'/////////, ymiitiih
 IGNITION S Y S T E M S 85

thickness o f the c o m b u s t i o n chamber determines

what reach is necessary.

Heat Range

The spark plug t i p , or electrode area, mounted

in the engine's c o m b u s t i o n chamber, is subjected
to temperatures that may exceed 2,000° F. The
f i r i n g end o f the spark plug is designed to remove
HOT COLD
this heat t h r o u g h the engine's cylinder head. The PLUG PLUG
path of heat flow away from the f i r i n g end is
shown i n Figure 8-32. Heat moves up the ceramic Figure 8-33. Heat flow i n a hot and cold spark plug.
insulator to the metal shell and then out into the (NGK.)
engine's cylinder head.
Spark plugs are designed to operate w i t h i n a
specific temperature range. The term heat range
describes the a b i l i t y o f a spark plug to conduct
heat away f r o m the firing end. The heat range o f a
spark plug is determined by the distance the heat
must flow f r o m the f i r i n g end to the shell. This is Electrode Design
determined by the length o f the insulator f i r i n g
end. I f the path is a long one, the f i r i n g end w i l l Several different kinds of electrode designs are
remain at a high temperature and it is referred to used w i t h small engines. The c o m m o n electrode
as a hot spark plug. I f the path for heat flow is designs are shown in Figure 8-34. The automotive-
short, heat is removed more easily f r o m the f i r i n g type electrodes are used i n many four-stroke lawn
end and the spark plug is cooler in operation. This mower and motorcycle engines. The dual gap
type of spark plug is referred to as a cold spark design is used i n many two-stroke-cycle engines
plug. T h e heat paths for a cold and a hot spark where fouling is a potential p r o b l e m . The
plug are shown in Figure 8-33. retracted gap also is popular i n two-stroke
engines. The surface gap is used w i t h many solid-
state magneto systems.

COOI-*— HEAT RANGE • HOT

\
RETRACTED DUAL AUTOMOTIVE SURFACE
GAP ELECTRODE ELECTRODE GAP
Figure 8-32. Heat flow away from a spark plug f i r i n g
end. Figure 8-34. Types o f spark plug electrodes.
86 S M A L L ENGINE SYSTEMS
Spark Plug Codes
I n order to be correctly matched to an engine, a
spark plug must have the correct thread diameter,
gasket or tapered seat, heat range, electrode type
and reach. Spark plug manufacturers identify
these items on their spark plugs w i t h a code sys-
tem. The code is printed on the ceramic insulator
of the spark plug, Figure 8-35.
M9X
Figure 8-35. Spark plugs are matched to the engine by
a code on the insulator.
STOP SWITCH
There must be a way to stop a r u n n i n g engine.
Engines are stopped by a stop switch. The stop
switch opens the c i r c u i t and grounds out the igni-
t i o n system. The g r o u n d i n g may be done at the
magneto p r i m a r y wire or at the spark plug wire.
O n many engines, a wire is connected to the m o v -
able contact point. This wire runs outside the
engine to a grounded switch. W h e n the switch is
closed, p r i m a r y magneto current cannot flow and
the engine stops.
A n o t h e r p o p u l a r stop switch consists o f a t h i n
metal strip attached to the top o f the engine,
STOP
SWITCH
Figure 8-36. W h e n the stop switch is pushed against
the spark plug t e r m i n a l , the secondary is g r o u n d e d .
(Briggs & S t r a t t o n C o r p . )
Figure 8-36. W h e n the engine is to be stopped, the
metal is pushed against the spark plug t e r m i n a l .
This grounds out the i g n i t i o n secondary current
and stops the engine.
C A P A C I T I V E D I S C H A R G E IGNITION
A n i g n i t i o n system that uses contact points has
some limitations. Contact points wear as the
engine runs. Eventually the contact points w i l l be
so w o r n that the engine w i l l be hard to start and
w i l l not r u n well. The contact points must be
changed to get the engine back into r u n n i n g
condition.
A new type o f i g n i t i o n system is now being used
on some small engines. This system, called the
capacitive discharge or CD system, does not use
contact points i n the magneto. The capacitive
discharge i g n i t i o n system uses the principle of
storing and discharging energy f r o m a condenser
or capacitor.
 IGNITION S Y S T E M S 87

As was described earlier under conventional capacitor is placed across the p r i m a r y w i n d i n g o f

i g n i t i o n systems, a condenser (or capacitor) is
made of t w o parallel plates separated by an insu-
lator. W h e n current enters the capacitor, elec-
trons b u i l d up on one plate, and their negative
charge repels a like number of electrons on the
other plate. 1 n this c o n d i t i o n , the capacitor is said
to be charged. Energy is stored in the capacitor;
when the current flow is stopped, the energy
remains in the capacitor. Only when a c o n d u c t o r
is connected across the two plates w i l l it dis-
charge, or regain electron balance. A small capac-
itor is capable o f storing a large electron charge
and p r o v i d i n g a big discharge.
In a capacitive discharge system, a charged
an ignition coil. As the capacitor discharges into
the p r i m a r y w i n d i n g , a strong magnetic field is
established and cuts the secondary w i n d i n g ,
inducing a high voltage. Energy is not stored i n
the coil; it is used only to step up the voltage f r o m
the capacitor. The energy developed in this way is
greater than that possible in a c o n v e n t i o n a l igni-
t i o n system. The capacitor is then disconnected
f r o m the coil and recharged, so that the discharge
into the p r i m a r y can occur again for the next
firing cycle.
The parts o f a C D magneto i g n i t i o n system are
shown in Figure 8-37. A simplified d i a g r a m o f the
system is shown i n Figure 8-38. Magnets on the

H I G H T E N S I O N LEAD

Figure 8-37. Parts o f a C D magneto system.

»-N

C H A R G E COIL INVERTER

RECTIFIER""

DIRECT C U R R E N T
(DC) M A X I M U M
4 0 0 VOLTS -
CAPACITOR
SPARK COIL
Figure 8-38. A C D i g n i t i o n system.

SPARK PLUG S 400 *

HIGH VOLTAGE
30.000 VOLTS
TRIGGER COIL
MAGNET — Hi

\
88 SMALL ENGINE SYSTEMS
flywheel are used just as i n a conventional system.
As they move under the armature, a small current
is developed i n a coil called the charge coil.
It is necessary to use a device called an inverter
to quickly build up a charge i n the energy storage
capacitor. The inverter changes the low-voltage
direct current available f r o m the charge coil into
alternating current. The alternating current trans-
formed by the inverter is changed back to direct
current by the bridge rectifier. The output o f the
inverter and rectifier needed to charge the energy
storage capacitor is a p p r o x i m a t e l y 400 volts.
The 400 volts stored in the capacitor must be
discharged into the coil p r i m a r y at just the right
time for i g n i t i o n . The flywheel magnets are used
to develop a small signal current i n a coil called
the trigger coil. The signal f r o m the trigger coil
goes to a switching device called a silicon con-
trolled rectifier ( S C R ) . The SCR gets the signal
f r o m the trigger coil and switches the circuit to
cause the capacitor to discharge into the spark
coil p r i m a r y . A high voltage induced in the spark
coil is directed to the spark plug. The SCR then
switches the c i r c u i t r y back, to a l l o w the capacitor
to charge, to get ready for the next discharge.
NEW T E R M S
atoms: Small particles which make up matter.
breaker points: The switch used i n the i g n i t i o n
p r i m a r y system to c o n t r o l coil operation.
capacitive discharge ignition system: A n igni-
tion system that uses the energy stored i n a
capacitor to develop high voltage.
capacitor: A n electrical device used to store or
soak up a surge of electricity.
circuit: A complete path for electrical current
flow.
coil: A n electrical device used to step up voltage
for i g n i t i o n .
condenser: The capacitor used i n the i g n i t i o n
p r i m a r y to prevent contact breaker point
arcing.
conductor: A material that allows electrical
current flow.
current: The flow o f electrons i n an electrical
circuit. Measured i n amperes. Abbreviated /.
electricity: The flow o f electrons f r o m one a t o m
to another.
ignition cables: High-voltage i g n i t i o n wires used
to carry secondary voltage.
ignition system: The electrical system that p r o -
vides the high-voltage spark to ignite the air-
fuel m i x t u r e in the cylinder.
induction: The transfer o f energy f r o m one
object to another w i t h o u t the objects touching.
insulator: A material that prevents the flow of
electricity.
magneto: Device used to develop the high volt-
age necessary for i g n i t i o n .
spark plug: Ignition-system part used to create a
spark i n the combustion chamber.
voltage: The source o f potential energy i n an
electrical system. Measured i n volts and
abbreviated E.
SELF CHECK
1. W r i t e a definition for electricity.
2. Where are the breaker points on an engine?
3. Where does electricity flow when the breaker
points are closed?
4. W h a t happens to the flow of electricity when
the breaker points open?
5. W h a t happens in the secondary wire when the
breaker points open?
6. Where does the spark plug fit?
7. W h a t wire is connected to the spark plug?
8. H o w does electricity go t h r o u g h the spark
plug?
9. H o w does a spark plug make a spark?
10. H o w is a C D i g n i t i o n system different f r o m
one w i t h breaker points?
D I S C U S S I O N T O P I C S AND A C T I V I T I E S
1. Use a small engine cutaway model to identify
the parts o f a magneto ignition system.
2. T u r n an engine's crankshaft and watch the
breaker points open and close. Can y o u de-
scribe the magneto operation?