Well, I haven't been able to get this thing sorted out after a couple of angry thrash sessions I am ready to ask for help. The bike is getting supper erratic spark and I have had no luck at all getting it to even try to fire.
Motor is fresh rebuild. Sealed up nice and has great compression.
Here is a list of stuff that I have done. I'm hoping some one has one last suggestion I don't know about. I have also bought a new harness from Compulsive concepts and even tried swapping all components from another running bike. I'm out of ideas.
Trouble shooting list:
Flywheel and key (no rattles good magnetically)
Stator (ohmed and tried 4 known good stators)
Pick up and pick up gap (even filed nubs even)
Wiring harness Un wrapped and gone through
Plugs and connectors cleaned and greased
New spark plugs
Clipped plug wire ends where boots thread in
New plug boots
Ohmed and tried several known coils
Coil surface grounded and cleaned w/ dielectric Harness ground cleaned up
Tors/park brake/key/tps/ all deleted
Disconnected the tether switch
Test kill switchTrouble shooting
Swapped out 3 good running CDI's
At the CDI harness side connector, check for continuity between the red/black wire and the black wire. You should have continuity with the key on. (or bypassed) If no continuity, there's your problem. If that checks, check between the black/white wire and the black wire. That's your kill switch. It should be open circuit for it to run.
You got it. We noted and have posted many times, the typo that Clymer did in their manuals. Primary is from blade connector to blade connector and secondary is from plug wire to plug wire. Remember to remove the plug caps and test separately. They are known for failures . Remember also to unclip the wires completely from the coil and test "ONLY" the coil when you get a bad reading. Wires shit out commonly, the coil itself rarely fails.
your ignition has 4 wires. cut the ignition off. the black with white stripe and red with brown stripe need to be soldered . then solder the red and brown wires so you then have 2 wires. wrap them up in electrical tape (NOT TOUCHING) then your ignition will be eliminated.
the coil grounds where it mounts, and there is one on the back of the timing plate- it's the wire clamp. that is the whole engine ground. there is also one by the voltage regulator.