Motorcycle Repair: no fire to the plug, point gap, plug cap


Question
I have recently restored a mini trail 50 that my neighbor gave to my son..the problem I'm having is I cannot get the plug to fire? I have replaced condenser,points , primary and 2nd coils in the magneto area and ignition switch. my question is could I be missing a ground on the newly painted ignition switch bracket? or is there a way to bypass or hotwire to see if i have faulty wiring, as I understand the bike does not need the battery to start even though that's new and putting out 6volts?
thanks for any help as he is dying to hear it run.
Dave

Answer
David,

-I believe the switch just grounds the ignition
to kill the engine. It should have spark with
the switch disconnected.

-You will have to double check all the ignition
components carefully.

-flywheel magnets should be clean and
have some magnetism.

-flywheel has a cam inside that opens
the points, see if it looks okay.

-make sure the flywheel key is not sheared.

-check that the points contacts are okay
and the points wire is insulated from
ground when the points are open.

-make sure point gap is not so
wide that the points never close.

-connect a test light to the black wire
and see if it lights when you kickstart it.
The lower coil should have some output there.

-make sure upper ignition coil is well grounded.

-check the plug cap and spark plug.

-set points to just break open with the flywheel "F" mark
aligned to the mark on engine case.
gap is around .014".

-check black wire for breaks.

-points contacts must be cleaned even if new.

-is flywheel side engine bearing loose causing
point bounce?