this... Quote:


the power goes from the run/stop switch to the clutch safety to the kickstand safety to the decomp controller to the cdi.

try disconnecting the clutch safety shorting the 2 wires together.
then do the same with the kickstand safety, but 1 at a time.

Here are some videos and directions I put together for testing a couple parts of the ignition system.

How to test the pickup coil with two LEDs shoved in the connector.

• Get two different color LEDs. 5mm size are fine. Blue and green are better choices but I used blue and red.
• Disconnect your pickup coil connector.
• Shove the LEDs into the connector coming off of the pickup coil.
  
  • The LEDs should be inserted with polarity opposite of each other.
• While making certain you have the leads from the LEDs making good contact inside the connector, try starting the engine.
  
  • This will cause the rotor to spin around the pickup coil. Each time it passes the pickup coil it will cause the coil's magnetic field to collapse and shoot voltage through the LEDs. One LED will light up when it approaches the pickup coil, and the other will light up after it passes it.
• If you are getting blinky lights, your pickup coil is working correctly.

Here is a really poor video of me talking about the theory behind this test and stimulating an old pickup coil with a wrench. The video was made as a series talking about something else so it isn't a great substitute for the instructions listed above.
https://youtu.be/EpfbL_aCoNA


How to test the ignition coil by forcing it to spark without the CDI

https://youtu.be/PWDGqB-hW3w

How to test the CDI box by forcing it to spark

NOTE: This test assumes you already know your ignition coil and pickup coil are both good.

First verify power to the CDI box. I am using the diagrams for a 1996 Savage.

• Remove CDI box from wire harness
• Remove spark plug from engine but keep in socket
• Turn on key switch
• Turn engine run/stop switch to run
• Check voltages on the CDI wiring harness
  
  • Put a voltage meter on the Orange wire with a white stripe, and the black wire with a white stripe. You should have battery level voltage. This means your CDI box is getting power to actually think and make operations. If it isn't, you have a issue with power getting to your CDI box.
    
    • Check your you safety/bypass switches.
  • This same orange/white wire supplies positive power to the ignition coil.
    
    • If no power on this line, no power for your coil to make a spark

Second, verify power can make it through your ignition coil to the CDI box

• Put a voltage meter between the blue wire with yellow strip, and black wire with white stripe. You should have pretty close to battery voltage.

Third, disconnect the pickup coil wires and halfway bypass it.

• After the plug is disconnected, jump the orange wires together. Leave the green wire disconnected.

Fourth, reconnect your CDI wiring harness.



Fifth, ground your spark plug.

• Use an alligator clip and ground the plug to a clean part on the engine case.

Sixth, force the CDI to spark by dumping the pickup coil's magnetic field - look at the spark plug for a spark or listen for it

• On the pickup coil's harness plug, tap the green wires together.
  
  • This sends a pulse to the CDI that is normally only made while the rotor is spinning around.
• You should have gotten a spark out of this action. If you didn't your CDI is likely bad. (Or your rotor is currently sitting over the pickup coil. Move your engine a bit more ahead so it is past the timing mark).

Video kind'a outlining this test
https://youtu.be/KdEjrKjbUYM

that is why this place is great the last 2 posts mjs great info and versa adding to tsg .i have said this before i was on the fence about buying a s40 till i found this place. a lot of great advise given in a friendly manor