167 FMM weak spark issue

[sofaking]

o7 Wildfire 250 acquired with damaged wiring harness and a new rotor/stator that was partially installed because of fitment issues. Once I removed the rotor I discovered mismatched keyways 3mm rotor/4mm shaft, made a custom woodruff key. Then saw pulse coil was about 6-7mm out of align with rotor pulse pad. Milled down the mount posts about 6mm. Done-right? Wrong. With my Fluke set on AC upon cranking stator(red/black)wire reads 40V and pulse coil reads 0.50V. when I connect CDI my coil signal is 4V. IDK what it is at the plug but spark is very very small and blue. Does anyone have any suggestions that could get me running?

[sofaking]

if AC cdi power is 40V and pulse is 500mV then what shoild cdi be sending to the coil in order for the coil to fire a hot spark? trying to determine the weak link here. please help.

[sofaking]

replaced old CDI with new "high performance" AC CDI (it was advertised as specifically for the CRF230 clone) supposedly had little better advance curve but idk. replaced pos and neg battery cables with 2-00 replaced stock battery with a 275CCA lawn garden battery. and fit a CRF230R carb on it. has a new 8 pole stator and rotor/magneto. coil has 7.5 Ohms resistance. cranks good. BUT WEAK SPARK AND NOT ONE TIME DID IT FIRE WHEN I DRUG IT AROUND THE BLOCK WITH MY TRUCK.

[J4Fun]

I have heard that the “high performance “ CDI might not be as good as you think. Also just curious about your spark plug and wire. I’m just thinking out loud here but could it be your plug is wrong for the spark plug wire? Maybe others will chime in on resistor in the spark plug cap and the plug also…