It has to be an easy fix, but I can't figure it out. I bought this thing knowing it had a bunch of issues. I've replaced the voltage regulator, CDI, starter, stator, and ultimately the whole harness. Timing marks are accurate. The issue I have is that the ignition coil keeps shorting out.
- If the coil is not mounted, meaning it is not bolted to the frame, the engine will turn over but here is no spark to the plug.
- If the coil is mounted, meaning the stud is bolted to the frame or it's touching metal, the engine will not turn over and the coil will short out (still no spark). The coil casing splits, melts, and will eventually catch fire...
I've now gone through 3 ignition coils.
Ladies and Gentlemen, what do I need to do to fix this?
Thanks for any advice!

 

Seems like everything is earthing through the coil, so check your earth leads to engine, frame and battery. You will also get problems if you have tried to replace a DC ignition system with an AC one, or vice-versa.

 

Sorry for the bump but after searching for hours and going through a few coils myself I have finally decided it best to try to refresh the only thread I saw that mimicked my issue. I have checked the grounds and even added an additional ground from motor to frame. Entire harness and all electrical components are new. Same exact issue through multiples of each component and still can't figure it out.