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Originally Posted by TallGuy
...The power supply voltage to the CDI, measured when cranking, is around 46 volts, could be more if the battery is fully charged. Timing trigger registers 5.3 volts, and a resistance test on this pin is 0.5 ohms. Ground pin checks ok, kill switch checks ok, and the ignition coil pin shows no voltage....
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Two problems:
1) 0.5 ohms on the timing trigger pin is way too low. It should be more like 150 ohms.
2) 5.3 volts AC on the trigger pin is way too high. It should be more like 0.3 to 0.5 volts AC
Down around your stator there is a group of wires that come out of the engine (from the stator) and tie into the wiring harness. Is there any possibility that these may have been miswired recently?
Measure the resistance of all the wires to ground at the stator output connector(s). Do any of them read around 150 ohms?
What I'm wondering is if the battery charge winding in the stator is wired to the trigger input of the CDI. It's resistance and output voltage at cranking speeds is a lot closer to what you measured for the trigger pin then the expected trigger voltage and resistance.
You may want to measure the trigger voltage and resistances again just to be sure you get the same values. And remember that the picture of the CDI pins is mirror imaged from the mating pins in the wiring harness since you have to flip the connector over to look into the pins.