I have a 2002 LT80 that I disasembled painted frame and put a new top end on. After I reasembled the quad I now have now spark. I check the grounds one in front of motor by the starter the other by the CDI box and coil both those are good. I took the coil to Suzuki and had it test and it tested good. I don't have my volt meter it broke and have not replaced with a new one so only thing I had was a test light. I checked the back of the coil and the test light is bright as can be. Grounded and put test light on the end of the plug wire and the light is weak. When Suzuki test the coil do they also test the plug wire. Im thinging the plug wire is weak but needing some help my boys are about to drive me to the nut house begging me to get their bike running again.

 

I think the plug wire is high voltage and low current.

 

I'm not an expert on LT80 ignition systems. They are quite a bit diffferent than the typical chinese quad. I have an LT80 service manual, and so my only expertise comes from reading that, and general electronics knowledge.

I assume that when you say in your post that "I now have now spark", that you meant to say that you now have "no spark". Right?

Test lights are not going to give you any useful info here. Buy a meter and throw the test light away. I'm serious - test lights are total garbage. I'm actually surprised you got any indication at all on the plug wire. It's really low current through a very high resistance (as cesar110 already alluded too).

Do you have the integrated CDI/ignition coil where the integrated module is fed from the stator through two wires (not counting the plug wire)? Or do you have a separate CDI and ignition coil. I have wiring diagrams for both on 2001 models - but I have no diagram for 2002 so I don't know.

How many wires come out of your stator and what are the colors? How any wires go to yur ignition coil and what are the colors? If you have a separate CDI then how many wires, and what are the colors?

 

Here is a manual for it 9751222-Suzuki_Lt80_Service_Manual_Repair_1987-2006_Lt_80.pdf
Im no expert one these as I have not even seen the one my wife just bought, but I fly home tomorrow. It runs, but I'm sure it will need something at some point, So I got a manual to read up on in my spare time.
Enjoy
Ken