Hi guys, have tried all suggestions and a replacement CDI unit and coil, still nothing. very frustrating.
Cheers

Maybe try the logic of a fault finding flow chart?
Diagnosis Center - Helping you Find the Problem - ElectroSport

Fault Finding Guide - Motorcycle Electrical Fault Finding Chart - ElectroSport

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Dave

Check your CDI for a black/white cable.
This cable delivers the shut off signal to the CDI (coming from ign. switch,
kill switch etc).

With ignition off there will be ground/minus.
With ignition on, kill switch on, neutral gear there should be no ground/minus.

If you find always ground/minus disconnect the cable and check for spark again.

Keep us updated

Thanks for that but already tried it, no joy.
Cheers

There is an unconnected dark blue wire coming from the CDI unit, as far as I know it was like that when I bought it running??. Not shown on the diagrams I have.

I already replied via email but I just had a thought, try grounding that blue wire. This will signal the cdi that the bike is in neutral, won't hurt to try. Perhaps on your bike the neutral switch to CDI was bypassed and now goes directly to the neutral light from the switch.

For clarification for others reading this. The Side stand switch is an input to the CDI as well as the Neutral switch. Side stand wire is blue/yellow stripe. Neutral is dark blue (says sky blue on schematic) coming out of the CDI but is the SKY BLUE pigtail with bullet connector that goes on to the neutral light. Hooking the dark blue from the neutral switch to the sky blue directly will bypass the CDI. If you use the zeeltronic unit you will have to do this and ground the solid black wire. If your bike never had a side stand switch then the zeeltronic should plug directly in with no changes. With so many variations around the world and because the side stand switch is so temperamental and usually bypassed I suggested to Borut to just make the simple 8 wire CDI. Hyperpak make an 8 wire, 10 wire and 11 wire model. I think he builds the units as ordered and can make it any way you want. I ordered mine with the 8 wire and did the above bypass. Works great this way.

I hope this helps any who decide to go with the Zeeltronic or Hyperpak unit.

Steve

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'84 XT600 is now bored to 2nd oversize and new OEM pistons and rings installed. No more smoking.

@steve: