80s Suzuki DS80 rebuild has begun!

[xrocket21]

Remove the condenser if you don't already have a replacement, that'll tell you if it's the culprit. All it does is slow the rate of points wear, it's not required to run.

ahh bummer, I didnt know that, it was only like $8 for a condenser though.

I have a read that a bad condenser can toast the points. The points do look black, can I hit them with the little fine sand paper? They don't look super worn, thickness-wise.

I unfortunately dont know shit about points / condenser systems, it is before my time. I have it apart though and it looks pretty friggen simple so I am optimistic I can win this battle.

[xrocket21]

bummer...grounds?

I don't think so? It's a 1 wire system so there isnt much to go bad...

[xrocket21]

[xrocket21]

New condenser in, still doesnt start. I learned the coil wire was wired directly to the points, skipping the condenser, because I could see the old broken wire.

I sanded the points a bit.

Spinning it with my impact I get like 300 mvac which clearly isnt enough.

Trying to watch youtube vids on points to try to figure this out.

this says .019 gap

https://answers.yahoo.com/question/i...tjN2yJB8byBkN3

but where? At TDC? i dont friggen know.

[Kurlon]

https://www.youtube.com/watch?v=F0WtBOapvhM

[xrocket21]

https://www.youtube.com/watch?v=F0WtBOapvhM

thanks man

My feeler gauges dont fit through the hole.

Is it true if the points are slightly off it wont get spark?

I sanded the points, I think they got burned up from the condenser being bypassed.

I can get a new set, but its more money and im not sure if that is even the problem.

[Kurlon]

Eyeball it to start, your timing will be off but as long as they open enough and fully close you should at least get spark.

[xrocket21]

Still no spark, even after cleaning the points, replacing the coil, and replacing the condenser. I think its time to cut my losses.

I just noticed the case is cracked. I guess Ill try to ebay what I can to get what money back I can.

[xrocket21]

In hindsight, I really should have got spark and noticed the crack in the block BEFORE I ordered $400 in parts....

[Kurlon]

That chunk missing won't bother anything, you could always JB Weld putty it. Is there an actual crack that I'm not seeing?

[xrocket21]

That chunk missing won't bother anything, you could always JB Weld putty it. Is there an actual crack that I'm not seeing?

Just the chunk. I was super frustrated last night

[xrocket21]

Well, I did the JB weld putty and I think it worked pretty great! I also got the sprocket and chain, rear brake, front brake, airbox, and cleaned carb installed. Literally all that is left now is to get spark and put fluids in.

I ordered a set of points on ebay, hopefully that will do it.

[xrocket21]

New points came in and I installed them!!!


Still no spark.

Damnit.

[Kurlon]

Sucks that the cam for the points is on the flywheel and not the crank, makes it harder to tone it out with a meter. Something is either grounded where it shouldn't be, points aren't closing or opening, or that ignition coil is shot? How's the magnet in the flywheel, good and strong?

[breakdirt916]

Woodruff key in the flywheel?

[xrocket21]

When I kick it over, I get voltage on the low side of the ignition coil. Points are definitely opening and closing. Magnet feels and looks good. Maybe its the friggen spark plug? It looks new, but I feel like ive changed just a bout everything else, and I can confirm im getting voltage to the low side of a brand new ignition coil...


I guess if the gap was too big it wouldn't have the voltage to jump the gap.

edit: just checked another plug, no dice.

[Kurlon]

On the points, check continuity through them closed and verify they're giving a solid connection. How much AC voltage were you seeing out of the ignition coil?

[loudbeard]

Do you have an inline spark tester? Pretty handy $10 tool.

Sorry this one is giving you fits bud, I'm pulling for ya.

[xrocket21]

Do you have an inline spark tester? Pretty handy $10 tool.

Sorry this one is giving you fits bud, I'm pulling for ya.

No worries at all man!

I have no professional training and it's a 1982.

It's frustrating, but Ill get it

I dont have an inline spark tester though

[xrocket21]

Got the shop manual, re-set the points, still no spark.

I've taken it to two shops now, they hear "1982", "points", and "condenser" and it's a pretty quick "thanks but no thanks" that come out of their mouths.

[xrocket21]

Good news!!! a local old timer (ive been told he is like 80), agreed to look at it on monday! "I don't usually work on that kinda stuff, but if it is simple, Ill take a look at it!"

FINGERS CROSSED.

This is the end of the line probably, next step for sale, then if thats a fail, its getting parted out.

[xrocket21]

Dropped the bike off this morning.

My guy thinks the condenser is bad so I have ordered another one.

[xrocket21]

another condenser and still no. the only think I cant find is the stator coil. 21049-1009 is the part number. no luck on ebay, speedzilla, amazon, bikebandit, etc.

any suggestions?

its literally the only part of the ignition system I havent replaced

maybe somewhere to rewind the stock stator coil?

this is NOT the ignition coil, its the coil in the stator.

[Kurlon]

I did some digging around and couldn't find an aftermarket option. Give Rick's Motorsports Electronics a call and see if they'll do a repair/rewind if you don't want to try tackling the job yourself?

[breakdirt916]

Custom Rewind in Alabama (guy had a stroke, so call and get his number than text him) or Baja designs but their customer service kinda sucks