Re: Please Help!!! Ive replaced the entire electrical system and it still wont start!
this is quite odd... you replaced the magnet coil? that square C-shaped thing with the fat coil that the black, white and blue wires come off of? And it still has no spark? The only thing I can really think of then is it's some kind of issue with the ground, the spark plug grounds against the motor (thats why the black wire goes under a bolt that mounts the coil). if you've swapped EVERYTHING (CDI, coil and magnet) from the other bike and the other bike still has a spark with your suspected dead electricals, it suggests to me that the issue is the ground path. only thing I can really suggest is clean off the head bolts and mounting surfaces. The jug is isolated from the case by the base gasket, but the ground still gets through the bolts, so if you used alot of loctite, it could be insulating the ground, but that wouldn't really explain why you were mid-ride when it died.
That is really an odd issue though. I wish I could help you more, but I'm out of ideas, the electrical system in these is pretty simple, consisting of 3 main components (4 if you count the spark plug itself). If you swapped everything from the working bike and have the same issue, I have no idea. Did you try the spark plug from your working bike as well? I know you tried several, but at this point I'm just grasping at straws here.