Motorcycle Repair: please help!!, honda xl 250, feeler gauge

Question
Hi Bill. I need to know how to get my 1975 Honda XL-250 running. the engine is fine, i just bought a new coil, and 2 new spark plugs. The bike is generating enough to where the neutral light dims a little when i kick the bike, but there is no spark coming from the spark plug. the coil is fine, my guess would be the points assembly, i just need word from the expert!!!

Answer
Mike, Honda coils seldom fail, but always nice to start with a new one, I guess.
XL250s with points require some maintenance and adjustment to make the sparks happen, though.
I would start by removing the point plate, checking the mechanical spark advancer first, so you know that there are no problems there.
Once that is been cleaned, lubed and checked for proper function, reinstall it, put a little lube on the point cam and the check the point contacts for clean, shiny contact surfaces.
Next, rotate the motor over until you see the points open to the widest gap possible. Check with a feeler gauge and set the gap so it is about .014"-.016" wide. Be sure not to contaminate the point contacts with any oil or substances transferred from the feeler gauge.
Next step will be to observe WHEN the points just open, which should be when the "F" rotor mark and stator indicator are aligned. You can use a thin strip of cellophane between the contacts and you should just be able to pull it gently between the contacts, when the timing marks are aligned. Again check the points for any remaining debris and you should be good to go. If you crank it over, with the plug out and connected to the plug wire, grounded to the head, you should get a good spark. If there is evidence of a lot of arcing across the points, as they open and close, then the condenser is bad and needs replacing. That should solve the lack of spark issues, as long as the plug cap isn't excessively high in resistance values. Should be around 5k ohms.

I would put a fully charged battery in the bike so you have lights. Running with a dead battery will cause an overvoltage to the light filaments when the engine is running and blow them out!

Bill Silver