I have tested the spark again with very different results, first I tried disconnecting the white wire from the CDI (which gets 12V + when you hit the button) and cranked it off the button = no spark at all, then I kicked it = good spark to 10mm or more, then I hooked up the white wire again that goes to 12V + when you hit the button and spark was there but only good to about 5mm which is better than I had last week. It started second kick off the kickstarter but not off the button.
My conclusions are (please correct me if wrong) that when using the kickstarter it turns the motor a lot faster and generates enough power to make a good spark. When using the electric start with the white CDI wire disconnected there is no spark which to me says that the motor is not cranking fast enough to generate a spark on its own but when the white wire is connected it gets 12V + from the battery to generate spark but it is still weak. My conclusion would be that the engine needs to turn faster off the electric starter to make a good spak on it own or it needs more power going down the white wire when cranking but the starter motor is taking most of it.
Over to you Sparks.
Regards Dan
