still not starting

[Barnsey]

Yes the pawl is on order from Draganfly.  I'll just pray that they can send one out during the week. 

And yes, the most annoying and frustrating part of this hobby is the poor quality of parts available. They are either worn out originals or badly made copies.  And I can't believe some of the mistakes which they make in the manufacture. 

  I might investigate turning the points assembly around , while the engine is open, so that the connection is at the back.

[rhyatt]

  I might investigate turning the points assembly around , while the engine is open, so that the connection is at the back.
[/quote]

May I ask why you wish to turn the distributor around , my Son's distributor screw connection points outwards , I sent you pics of a satisfactory distributor.

[DAVE BRADY]

Hi,

I recently bought a pawl from C&D Autos.  They do not have website but if you ring earl enough they get things in the post the same day.
Call 01564 795000 or email canddautos@gmx.co.uk

Dave.

[JulianS]

There are still new old stock parts out there, including the kickstart pawl

https://www.ebay.co.uk/itm/196423262542

[Barnsey]

DOH!   I've ordered the pawl from Draganfly now.  The new-old stock would have been better. 

Having tweeked the timing ,to get it right, the connection to the distributor was pointing in completely in the wrong direction and I had to extend the wire to reach the connection. Not that this is important right now. 

[Barnsey]

The kick start pawl is here but I have spotted a crack in the inner side cover where the spring attaches.  Annoying as this is already a replacement for the original which was itself cracked. Anyway I am shopping for a replacement on Ebay.

[Daz]

DOH!  I've ordered the pawl from Draganfly now.  The new-old stock would have been better. 

Having tweeked the timing ,to get it right, the connection to the distributor was pointing in completely in the wrong direction and I had to extend the wire to reach the connection. Not that this is important right now. 

Sounds like you may have timed it (distributor) 180 degrees out?

[cornishbob]

i think by now i'd be considering cutting my losses and dob it in for a bus pass

[iansoady]

Counsel of despair! If you have compression - you don't actually need that much, somewhere close to correct mixture, and a spark at approximately the right time it should at least try. If you're sure about the ignition timing I'd try a squirt of asy start in the carb inlet. If it fires then the problem is fuel. If no sign of firing then ignition.

I may have suggested this before.......

[ducati2242]

Counsel of despair! If you have compression - you don't actually need that much, somewhere close to correct mixture, and a spark at approximately the right time it should at least try. If you're sure about the ignition timing I'd try a squirt of asy start in the carb inlet. If it fires then the problem is fuel. If no sign of firing then ignition.

I may have suggested this before.......

I usually use brake cleaner . it will fire anything that sparks at the right time .

[Barnsey]

I found a nice side cover on EBay for around £20 with p&p so that is on its way to me now. 

Yes, I am definitely on the right stroke. Both valves are closed.

Yes, I have tried Easy start, but no joy. We had already concluded that it was electrical before the kickstart broke for the second time.   

I was just at the point of testing it out with the new ignition switch when I broke the kick start. 

 It has had a new loom, coil and I tried jury rigging a new condenser.

  I can get a spark of around 10mm on the bench but not on the bike.

 I haven't tried new points, but the existing ones look to be in good condition.

  Le me reassemble the engine with the new side panel and then we will go from there.

  And, maybe not a bus pass....  but sticking with my Toyota Aygo seems a serious good idea right now. 

[rhyatt]

If you've aged a 10mm spark (just under 1/2" then the coil is fine on a rig .
Now duplicate that rig on the bike - battery neg to coil neg , battery positive to engine(do it to engine 1st , frame later) and coil neg to points.
Plug out , kick it over should give you your fat spark as on the bench rig.
If it sparks , then move the battery pos to the frame earth , still spark ? Good leave it there and proceed to start the bike.

Worry about the battery neg going via loom and switches later

[Barnsey]

The new cover arrived today, and bead blasted too.  As a bonus it already has the bronze bushes fitted.
I'm hoping to fit it this weekend, but we have hedges which need cutting, so it might get pushed back.

[V500]

Nah, you don't want to push it back, you really need to cut it for a proper job...

[Steve.S]

Rhyatt is absolutely correct, but you don't seem keen to take his advice, offered more than once.
I think I might also run a separate earth cable from the distributor to battery earth, just to make sure. If you have a spark, I would also recommend confirming that it will jump 10mm as on the bench.
If it's still a weak spark, then disconnect the wire at the points, and just jab the wire to earth. This should give you your 10mm spark each time you jab. If you get a good spark, this will indicate that the points are the problem, perhaps assembled incorrectly?
Please make sure you disconnect all the loom wires from the battery, coil and points. If the loom is faulty (and it ran before you replaced the loom), leaving it connected could affect the results. Check the battery is still reading 6.4 Volts.
Regarding kickstart wear, bear in mind you have probably given it 10 years of wear over the last few weeks.
I'm surprised your knee is still working, but that is why you have 2 knees.