Very Weak Spark; 1980 KZ440A1 (with points)

F64: I set the gap to 0.015" first, then attempted to set the timing.

Scirocco: The contact breaker is brand new and the points came pre-installed on the points plate. The entire assembly was replaced as a unit (Genuine Kawasaki part# 21008-1014). So unless Kawi forgot to install the insulator, it is present. I also don't think that the bike would run without that insulator.

I had the same problem on my KZ-1000. Both advance plates were turned all the way to the right and I just barely timed it in. I was bugged by this so a while later I started from square 1 with both plates at center. Thinking back on it I probably should have gone over center and I may do that later. Anyway I went to work and set the points with a dwell meter and set the timing, but this time I didn't need to rotate the advance plates as far as the first time so I still had some adjustment left. Ironically while doing this is where I found out there is a substantial difference in point gap using a dwell meter versus a feeler gauge but that has been discussed previously. I would go back and start fresh with centered plates and see what happens when you are done. It only takes a few minutes to do this and see if it helps. Of course you have to be willing to accept the fact it may be worse this time around.
Rick H.