Just wanted to say thanks for the help and advice but sometimes it's just better to buy new. I tried everything I could think of including what you posted but in the end ended up melting the plastic ignition clip and funny thing is it didn't pop the 15amp fuse. So I said screw this and bought a new Harness, CDI, Voltage regulator, solenoid & ignition. Hooked everything up and wouldn't you know it starts every time. No blown fuses, no melting, no headaches. My kid got to ride it a few times since then and couldn't be happier. So all in all if you have some problem that is giving you grief and $100 bucks can buy you happiness again spend the money and get back to riding.