Questioni have a 91 honda xr80. i did a tear down of the bike(not motor) and the spark is blue but weak. we checked the grounds and wiring. not many wires on a 91 honda. it will spark a little against the bike but it wont spark on the new spark plug. i also tried the old plug. i replaced the coil with a new one. im just getting frustrated any help would be great. its getting fuel, and compression so im concerned about the spark.
AnswerKeith, you got the last of the points/condenser ignition systems.
http://www.cmsnl.com/honda-xr80r-91-us_model860/partslist/E++07.html
With a magneto ignition system, the contact breaker faces have to be clean and shiny first and foremost. Next they need to be adjusted so that the points just OPEN at the F mark alignment on the flywheel/rotor and case marker.
If the points are clean and set to open properly and there is still no strong spark, then the other options are that the condenser has failed. You mentioned replacing the coil, but it is a separate part mounted next to it.
http://www.cmsnl.com/honda-xr80r-91-us_model860/partslist/F++16.html #1
If you replace the condenser and the spark is still weak, you will have to remove the flywheel/rotor and check the insides for any rust that builds up on the rotor magnet. You will have to buy a special rotor removal tool, but it is fairly common and can be ordered/bought through most m/c shops or a Honda dealer.
If the breaker points are damaged or worn down so they won't open properly, you will have the chance to check their condition and that of the low tension coil when the rotor is removed.
Don't forget to adjust the valves to .002" cold intake/exhaust, just to ensure that you have good compression all the time.
Bill Silver
