I will double check that all the earth wires are where their meant to be,
Well i have turned the mixture screws 1.75 turns out and set the float heights and it still wont start, last time I tryed to balance the carb's the bike flooded so i took the them off and set the float heights and it wont start now so i'm a-bit dumb-founded. I think it's a mix between unbalanced carbs, with some sort of electrical issue,
Im starting to think that its the CDI because i downloaded the Jap manual for the gk73a and it had a chart to measure the resistance on different points on the CDI and some of the points were showing nothing and others nothing near the specs stated in the manual. But the problem is I wont be able to find another CDI for an SP model as i think their not the same as the normal gk73a CDI and as rare as hens teeth apparently!
Dose anyone know of any aftermarket CDI's are available that would work on my SP model?
Also chris how on earth did you get the case off your CDI??!
Jake

This is the dodgie trigger wiring, going into the nearside cover.




The braided wire with the red connceter clips was the dogie one that was corroded and loose, any ideas what it is for?it turned the neutral light off when i deconnected it.

Well it looks like a complete mess to me, from a quick search it looks like your version has a throttle position sensor which i am assuming is cut out to make a standard cdi work. If it was me i would spend some time on google to see if it is possible to get a standard cdi to work, i would also take all the insulation tape off and see what mess is hiding under it! Re-do all the connections with solder instead of crimps.... or get a standard harness and fit that instead to swap to a standard cdi (about £30 on e-bay) assuming that whatever makes it an SP can be removed, which i would guess it could.
Wouldn't pay too much attention to suzuki resistance values, my experience with them on an EFE was that no unit ever came close to what the manual said!
I would go at sorting all the wiring first and then sort the float heights, did it work before you change the float heights and not after?
To get to the circuit board i had to cut the cdi box along the length of it then get the board out, not exactly text book but it works, glued it all back together with araldite and covered in duct tape

Good luck!
Chris

Harness on ebay now: 110667892871

Chris