my final thought on this problem is since its intermittent , i really think it's a loose wire or connector or a connector pin has back out of one of the connector, if a compont failed then usally its dead completly,

 

take the cdi box from the one that is running and swap it with the other-this is the only ignition related part that I have seen fail-its a small 1 1/2 in x 3 in black box that has one plug-it is above the right front wheel mounted to the frame

 

I swapped the CDI boxes between bikes and the good CDI from the broken frame bike is smaller but when connected, it produced spark but not consistently. Put the old bigger CDI back on, no spark. Swap out, minimal spark. Spoke w/ the SUNL dealer and he said the two sizes have different circuitry which creates different timing for the spark. He is sending a new big CDI so hopefully that will indeed solve the problem. He said teh CDI is sensitive to shock which is why it has a rubber mount to the frame. But that may explain things since this one was hanging when we got the bike and always fell off.

Thanks to all for your great input and troubleshooting.

 

you have to connect the two wires when you disconect the tether to close the circut other wise you have an open circut which is the same as a pulled tether