bountyhunter wrote: I have yet to see any evidence that forcing the spark plug voltage higher by widening the gap does anything good for performance. If there was even a single HP to be gained, bike makers would have been doing it for decades but they don't. The energy delivered in the spark is 1/2 L (I) squared which has absolutely nothing to do with the voltage that the spark jumps at. Same energy, slightly longer spark but gas burns the same.
It's not about spark energy. It's about the amount of air-fuel being initially ignited. With a larger gap, the initial flame kernel is bigger, and thus the entire mix will take less time to burn. This allows you to use less advance, and still get the burn completed for best power. But there is diminishing returns to this. If it were to burn too fast, it would just hammer the piston and more would be lost as blow-by and heat. You want the burn be a smooth increase, then decrease in pressure.
And of course, as you said, it is really hard on the ignition system.
My only evidence is seat-of-the-pants. I had neglected my plugs for a long time. In the city I don't get a lot of full-throttle opportunities so it was not an issue until one day, I went wide-open-throttle at higher RPMS, and it was as if someone turned off the kill switch. I could also hear loud ticking... the sound of spark discharge under the tank as the sparks were finding an alternate path of less resistance. As soon as I let off the throttle, it resumed firing.
So I checked the plugs and the gaps were about 50% larger than spec. This might also explain why the bike was knocking slightly more, when giving too much throttle on a hot day, on the highway.
The only thing I did was replace the plugs with new ones. Now I could go full throttle with no problem. But I definitely felt the bike was not as lively as it had been, even just the day before.
I've also found a few articles, many years ago, about enlarging the spark gap, but I didn't make copies of it. I think John DeArmond might have written them.
To get the longest life out of the coils and igniters, I run standard gaps.