Hi everyone,
So some great news. I got the bike running!
https://youtu.be/92iLiky_ejsIn the end I found the problem to be the cheap aftermarket ignition coils that you can buy on eBay. These have a primary coil resistance of 1 to 1.5 ohms and they WILL BURN YOUR TRANSISTOR!!!
I managed to purchase a good condition used OEM suzuki ignition coil on eBay and it has a primary resistance of 4.5 ohms
I also soldered on a new D1071 resistor on the board, I then started the bike and it fired up within 1 second. Brilliant.
As mentioned earlier in the thread,
12v @ 4.5ohms = 2.6 Amps
12v @ 1 ohm = 12 Amps
The rating of the transistor in the black TCI module is 6amps. So it is quite clear to see that an ignition coil with low resistance will damage your transistor.
I hope this thread is able to help someone else out in the future as I know lots of people have trouble with these TCI boxes.
The moral of the story is. Check your primary coil resistance and only use a Suzuki OEM ignition coil!!
Cheers everyone,
Tom