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If the unit is brand new, then there shouldn't be an issue with a weak spark. Typically you would shine up the spar tip with fine sand paper if it corroded, but if it's brand new then that likely won't help. I would call warranty as it sounds like the spark module may just be bad and producing a weak spark. Warranty's number is *****
Not really, but not every spark will be exactly the same strength either, it will vary a bit from each spark.