Method 1) Unplug the CDI and remove the kill switch pin in the CDI connector on the wiring harness. The pin is held in with a spring tab on the pin itself. You'll have to probe into the connector and push this tab in order to extract the pin. Plug the CDI back in (kill switch wire dangling) and see if you have spark. - I used this method and still no spark

1) Unplug the CDI. In the wiring connector measure the resistance of the AC Ignition Power pin to the Ground pin. You should see 400 ohms or so. What do you measure? - 355 ohms

2) Measure the resistance of the Timing/trigger pin to the ground pin. You should measure 150 ohms or so. What do you measure? - 131 ohms

3) Leave the CDI unplugged. Set your meter to measure AC volts on the 100 volt scale. Measure the voltage on the AC Ignition Power pin to the ground pin while cranking the engine. You should see 40 to 80 volts AC while the engine is cranking. What do you measure? - -.8 volts

4) Set your meter to measure AC volts on the lowest scale you have. Ideally this would be 2 volts but many meters don't go down this low. In that case use the lowest scale you have. Measure the voltage on the Timing Trigger pin to the Ground pin while cranking the engine. You should 0.2 t0 0.4 volts AC. What do you measure? - -.006 v

A) Leave the CDI unplugged. In the CDI wiring connector measure the resistance of the Ignition Coil pin to the ground pin. You should measure less than 1 ohm (but not zero ohms). What do you measure? - 1 ohm

B) Plug the CDI back in. Set your meter to measure AC volts on the 20 volt scale. Set all kill switches to the run position. Crank the engine while measuring the voltage on the Igntition Coil pin to ground. Poke through the insulation of the wire if you can't probe the connector. 0


Can anyone point me in the right direction to producing spark? Been working on this thing for months...new wiring harness, and all electrics, new starter also.

 

From your tests, you have a bad stator. It should be producing more than 0.8v. Check that the wire from stator to the CDI is OK. There is another point, some CDIs are wired so that when you earth the kill wire, the CDI stops producing a spark, some are wired so that when you connect the kill wire to earth, it produces a spark. Whoever designed Method 1 is making an assumption that the system is earth to kill, which may not be right.