Very Weak Spark; 1980 KZ440A1 (with points)

Well, I test-fit the coil and set it up a bit. With the gap reset to 0.030", I am getting a loud spark that I can see (albeit barely) in broad daylight (tank removed). That's a huge improvement over the case before, so I think we're probably good. I still need to trim the wires up and take it for a test ride, but I think it's good.

I went for a test-ride, and while it definitely seems to be running better, it's still missing under high load. Curiously, it doesn't miss at all under low-load, even at high RPM. If I don't roll on hard, it runs great at any RPM.

I have yet to trim the wires to the correct length. I want to save that for when I'll be confident that this setup will work. Should I gap the plugs down a hair, reduce the points gap, or just trim the ignition wires to the correct length?

The resistance across the coil secondary through the plug caps is right where I'd expect for this coil and my caps (27 kOhm), so I'm pretty sure I have a good connection between the plug caps and the wires.

Sweeeeet!!!!
Sure, close in the spark plug gap a bit.
The high load misfire could be a fueling issue.
I think your ignition is definitely much better!!!

Ehhhh, I'm suddenly not so sure. I'm still getting tons of arcing across the points, especially at higher RPMs.

I'm not sure at all what might be causing that. I have a good connection to the condenser, and the condenser itself was just replaced a couple weeks ago so I don't think it's faulty. There's certainly no continuity through it.

Is the points wire touching the condenser wire electrically?
There is still a possibility the condenser is bad.
Is the condenser a Kawasaki part?

I couldn't find a genuine part when I looked, but they were advertised as fitting a KZ440. Although I know that doesn't mean much.

There is good continuity between the clip on the condenser wire and the points spring.

As a possible clue, it seems to be worse when the air is cooler, although it's hard to tell if that's just me or if it's an actual trend.

The cooler temperatures do affect spark plug voltages.
They're talking about magnetos but the spark plug info is relavent.
www.themagnetoguys.co.uk/voltage-at-the-spark-plug

I've been reading up on condensers for the last hour. It seems there has been issues in quality control everywhere.
So even if you have a new one, it may still be faulty.
See if you can find an NOS Kawasaki condenser.
part # 21013-1004

There are a couple on ebay

www.google.com/search?client=firefox-b-1-e&q=21013-1004

It seems many have a lack of contact pressure inside the can and arcing is taking place.
The condenser is pretty simple. It's basically two strips of aluminum foil with a two layers of plastic. Roll it up and put it in a can---it's a capacitor.
nonlintec.com/sprite/cap_failure/
www.physicsforums.com/threads/death-of-a...with-autopsy.877969/

I managed to find a whole NOS contact breaker assembly (Plate, points, condenser, coil lead) part 21008-1014. It wasn't too expensive, so we'll see if that helps. This set of points didn't seem to fit quite right anyway, and I'm very strongly leaning towards that being the problem.

What is the proper points cam lubricant?

I did a 30 minute search.
Probably just a couple drops of 10 weight engine oil on the felt.

gavroyer wrote: .................What is the proper points cam lubricant?

Either of these.........





Ed

Good news! I put my old set of point and the old condenser back in the bike and the misfiring is totally gone. It's running like it's supposed to (probably better, given the new ignition coil). So it sounds like my condenser was probably bad. The points were highly suspect too, so the new breaker assembly should get the bike totally good (which it should be given that I'll have replaced nearly the entire ignition system with brand new components).

I also removed and disassembled the advancer to give it a good cleaning. It was still moving fine, but there was lots of old dried out grease that needed to be removed. I regreased it and everything is looking good there (confirmed with my timing light).

Very good!!
Glad we figured it out.