Weak spark...no start

I have a brand new plug gapped to .025" and mixed up some fresh 40:1 mix with no air box installed. 47cc cag is all stock. A month ago i fouled the spark plug(25:1 mix), so i replaced it with a new one and flushed the gas out. Got it started once for about 5 minutes and tried to adjust the idle lower and she died out on me. I have the idle screw exactly where it was when it ran fine(6 hours ride time total since new). The spark plug wire(cheap coil piece came out of the wire, so i stripped some of the wire back and put the metal connector from a car spark plug wire on the end and crimped it on. I still can't get it started and the spark seems weak. It doesn't seem like it sparks everytime i pull the pullstart either. Possible for timing to be off?? What could be wrong? (cleaned float bowl and main jet when installed new plug)

What about the coil being bad? how can i check this? Could the stock "key" come out of place? Whats involved to pull the flywheel off? What should i look for? Really wanna get this thing running again.

Well both problems are possible. I have had a bad coil. the plug sparked weakly outside of the cylinder but when installed the spark did not have enough energy to ignite the fuel air mixture. Swapped coil packs with my sons bike and the problem followed the coil.In another post a fella had a problem with spark. He found that his magneto had loosened and the key had vibrated out. he had spark but bad timing. Search on spark AND key. you may find the thread. If I remeber right it was a long thread that started with my cag wont start. Or serch on my posts I remember posting in the thread.

Check to make sure the coil is close enough to the magneto, also if your flywheel is loose or wobbly it can give you inconsistent spark so it won't run. Take the pull start off with the 3 allen heads and you will get a clear picture of all of this and yes coils go bad for no apparent reason sometimes but if it is intermittent like that check everything else first. The gap from the magneto to the coil should be very small, a piece of paper is about the length so slide one in there as a measuring device.

I'm the "spark problem" fella that Geezer was talking about...
Check the following:

• Remove starter assy and check orientation of "magnet portion" of flywheel when turning motor. "Magnet portion" of flywheel should match up with magneto at same time piston is at TDC. If it is not, pull flywheel and check for abscence of woodruff key.
• Check gap between flywheel and magneto. It is supposed to be between .008" and .010"

Original Thread...

Good luck!

ALright, so your saying that when i take the pull start assembly off, the magnet part of the ignition coil should match up with the mark on the flywheel? I don't think mine is. Is the mark on the flywheel like a shiny metal that looks like the shape of the magnet?

Sounds right, mine was shiny and was much darker than the rest of the flywheel's metal.

Pull the starter assy and pull the spark plug. Stick a screwdriver into the spark plug hole. Turn the motor over by hand with the flywheel. When you start to feel the piston get to the top of it's stroke, stop turning. Get the piston it to TDC(top dead center). Check the flywheel. There is a square "marked" section on the flywheel. It should match up pretty well even with the magneto. If it does not, then your ignition timing is off, and you must pull the flywheel to inspect for the abscence of the woodruff key.

If the key is missing, now would probably be a prime opportunity to install a rocket key if you've been wanting one.

I pulled the spark plug and the pull starter off and put a screwdriver in the plug hole. Seems that the magneto does line up with the ignition coil when its at TDC. Hmmm, now what.

YESSSSS, i figured it out. Swapped the coil with another bike and the problem follows the coil. So, she's running again. However i'm not sure if how i had the coil wire "rigged" to the end of a plug wire for a car was part of the reason for the weak spark. I would like to solder it together. What type of plug wire(for cars) has metal core that can be soldered?