Now it's time to test the resistance readings from the ignition coil, stator, and pickup coil. If you don't have a digital multimeter, buy one. With the engine cold, test for the proper resistance values specified in the TW200 Service Manual. The service manual is available for download in the Zong Sticky. ;)

Spud :)

Hey spud. I don't have a tester but I had all of the parts so I changed them one at a time and checked to see if the bike would start. So far I have changed the firing coil (that connects to spark plug) then I changed the Cdi again. Then I changed the rectifier (black box under seat). none of this worked so i'm about to change the stator (magneto) to see if that's the problem. If it still doesn't start, where should I go from there?

The stator and pickup coil (sold as a pair) and the only two components you haven't changed. The regulator/rectifier won't cause the problems you have observed. ;) You might have a loose connection somewhere. Check to see if the connectors from the stator and pickup coil are secure. These connections are located in the small rubber boot near the carburetor. Examine these connections and check all the wiring for abrasions before you change the stator/pickup coil. Also, make sure you have a good ground connection for the motorcycle. Did you check the connections in the spark plug boot?

Spud :)

I changed the stator as well but still not starting. I'll get another spark plug ASAP and try that also. I don't know what else to check. Guess ill be doing some reading over the holidays.
MERRY CHRISTMAS TO ALL AND PLEASE EVERYONE.... REMEMBER THE REASON FOR THE SEASON.
ENJOY.

Did you install a new pickup coil? If so, you replaced everything which sends electricity to the spark plug.

Spud :)

Yes a new pickup coil came with the new stator so I changed that as well. The plug boot is also new.
Whatever the problem is or maybe was now, it might have fouled the plug again so I'll get another plug and check to see if this corrects the problem.

I will be sure to go over the whole wire harness tomorrow to see if there is anything lose or frayed.
Thanks and I'll be sure to update as I go along. This is a great learning g experience for me.

Check to make sure the large ground wire is securely bolted to the engine frame behind the cylinder. If you want to do your own electrical work, you really do need to acquire a digital multimeter; it doesn't have to be an expensive one. Can you get someone to loan you a digital multimeter? Even a test light would help you confirm your bike's electrical grounding system is in good shape. ;)

Spud :)

I had a similar problem and it wasn't the ground behind the engine mount it was the ground at the battery box. Tightened it up and ran like a champ...until the tire went flat. I still need to loctite that bolt down so that it doesn't work loose again.

I do have a test light and I ordered a multimeter as well. I didn't get a chance to do any work on it today, all my time was taken up with the 7 kids. Had the best day ever. I'll check all of these things starting first thing tomorrow morning and will post results ASAP. Thanks for all the great suggestions and help guys. Sometimes the simplest things we don't think of. I really did t check the ground to the frame or to the battery and I should have checked these before anything g else.
Thanks again guys. Have a great evening. And on e again MERRY CHRISTMAS.

Have you tryed bypassing your killswitches? I highly doubt that they are the problem though. I'm almost postive it is the stator and pick coil. Its about the only thing that can produce a intermittent problem like you are describe.

The Zong's kill switch operates by grounding the output from the CDI unit. Therefore, a defective kill switch won't cause ignition problems for the Zong; it will only cause a problem when trying to kill the engine. ;)

Spud :)

I changed everything g I could think of including the spark plug and still not starting. I check all of the connections of the harness and can't seem to find any problems. I will ask a friend to check it for me he's a machenic. I can't think of anything else to do.

You said you had a weak spark. Is that still the case? You might have additional problems with either fuel, air, or compression. Have you checked the valve lash recently? Please do let us know what your mechanic friend discovers.

Spud :)

The valves were checked again today and they are fine. I'll keep posting
Thanks