Hello all,
I've been hanging around this site for a year. I have never been much of a joiner, very much a loner but figured it was time to get involved if I wanted to ask questions. You folks seem like a great bunch. The patience that has been extended with some of the silly questions is incredible! Hopefully I can be the recipient of some of that patience.
I have an '85 Honda ATC 200S that I have put WAY too much money into restoring it. Powder coated everything, new plastic, new tires, new seat, new bearings, fresh cylinder, new to me cylinder head and valve work. I have always been able to fix things or figure them out but this one has the best of me. After assembly and checking my handywork I rotated the engine checking for spark. The spark is very weak, barely visible in a lighted garage. I started on diagnostics: cleaned every connection on the wire harness with contact cleaner and small wire brushes then checked for continuity at all connections. Checked specific ohms readings at every pin on the CDI unit verifying readings to the Honda service manual. New coil and wire even though the old coil's resistance checked out via the service manual (primary and secondary sides). Checked the resistance at the pulse generator... within service manual spec. Removed the handlebar kill switch so that it was not part of the equation. Added an auxiliary ground from the frame to the engine (bad grounds can cause you to pull your hair out!) Verified proper continuity at the exciter coil, resistance was 200 ohms. Every harness and frame connection was installed with dielectric grease. Replaced the original rotor with a known good unit (not sure that the old had lost any magnetism??) And yes, a new spark plug.
After all of that, I have the same very weak spark. What the heck am I missing? Thanks for your helps!
PD