Well, not much has changed since my last post. I've been busy getting my KLR650 on the road, so now that's finally done, I'm going to focus on the XS and get that running again. After some research, I think I may pull off the LH rotor cover and ensure the gap is correct for the pickup and timing tab.
Here's the symptoms:
With the spark tester, I'm getting an orange glow for every spark.
I'm the dark, I can't see the spark from the plug to the ground.
I've verified the kill switch works as it should.
I've run direct ground to the battery from the coil just to eliminate any bad ground possibilities.
The coil is getting power to it, but I just realized I never tested the voltage amount until I wrote this.
The relay clicks on and off like it should when I turn the key.
My thought is that the gap between the timing tab and pickup had increased, thus reducing spark. But I'm not sure if the pickup is just a signal or actually picks up the electrical current to make the spark. If it's just a signal, then the gap wouldn't be as significant, but if it does pick up the current to make spark, then it would matter quite a bit. It would make sense if it slowly vibrated away from the pickup only to make a weak spark. But that's just a theory.
I've replaced the coil and that didn't change anything. Same results.
I've tried different spark plugs, no different.
Let's hear what you got.