How are you testing for spark? Are you just pulling it over listening for it to pop, pulling the plug and ground it on the case, or using an ignition tester?
Also, do you have an IPL? According to the parts diagram I"m looking at it looks like there are a total of 3 washers. Two for between the ignition module and case (stihl 4180 404 9300) and one that appears to go between the mounting screw and ignition "connector tag" (where the switch wires in) - this washer is called out as a separate part no. (9291 021 0100) and appears to be steel according to an online lookup. I'm not sure what the other two washers are made of but if you have an FS110 make sure all the washers are being installed identical to the working unit - as the fs110 uses the same washer configuration. As mentioned something may be screwy at this location.
I would definitely try it w/o the washers. According to the different parts diagrams the FS90, 110, and 130 all share the same coil and flywheels. Of course they all have different cylinders.
Have you tried the coil from your test unit in your bad unit? I know you have done it vice versa but it may be worth testing out the other way around to pinpoint something you may have overlooked.
If you still need the IPL PM me and I'll get it to you.
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