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80s Suzuki DS80 rebuild has begun!

  1. #51
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!


    Quote Originally Posted by Kurlon View Post
    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.

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  2. #52
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by breakdirt916 View Post
    bummer...grounds?
    I don't think so? It's a 1 wire system so there isnt much to go bad...

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  3. #53
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    Re: 80s Suzuki DS80 rebuild has begun!

    80s Suzuki DS80 rebuild has begun!-20200721_071750-jpg

    80s Suzuki DS80 rebuild has begun!-20200721_071834-jpg

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  4. #54
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    Re: 80s Suzuki DS80 rebuild has begun!

    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.

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  5. #55
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!


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  6. #56
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    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.

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  7. #57
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    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.

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  8. #58
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    Re: 80s Suzuki DS80 rebuild has begun!

    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.

    80s Suzuki DS80 rebuild has begun!-20200724_192937-jpg

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  9. #59
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    Re: 80s Suzuki DS80 rebuild has begun!

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

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  10. #60
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

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

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  11. #61
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    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

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  12. #62
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    Re: 80s Suzuki DS80 rebuild has begun!

    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.

    80s Suzuki DS80 rebuild has begun!-20200726_173127-jpg

    80s Suzuki DS80 rebuild has begun!-20200726_173132-jpg

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    Last edited by xrocket21; 07-27-20 at 06:35 AM.

  13. #63
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    Re: 80s Suzuki DS80 rebuild has begun!

    New points came in and I installed them!!!


    Still no spark.

    Damnit.

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  14. #64
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    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?

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  15. #65

    Re: 80s Suzuki DS80 rebuild has begun!

    Woodruff key in the flywheel?

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  16. #66
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    Re: 80s Suzuki DS80 rebuild has begun!

    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.

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  17. #67
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    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?

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    Last edited by Kurlon; 07-29-20 at 04:53 PM.
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  18. #68
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    Re: 80s Suzuki DS80 rebuild has begun!

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

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

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    I went to MMI I know what Im doing here chief

  19. #69
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by loudbeard View Post
    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

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    Last edited by xrocket21; 07-29-20 at 06:29 PM.

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