I got my used CDI and coil and now I have good spark but I still can't get it to start or run. These are the things I have checked:
Timing- the mark on the stator and the flywheel both line up perfectly with the mark on the case at TDC. I haven't hooked up a timing light but I think this should be a good starting point. Removed both coils on the stator, cleaned the mounting surfaces, and used a little dielectric grease to prevent future corrosion.
Fuel supply- I'm getting good flow through the petcock and can see the fuel moving when I go to Prime to fill the bowl. All of the fuel supply lines are new.
Air- I have the stock air filter setup with all new parts. There is no change with filter installed or removed.
Compression- I have a new 60cc kit from treats. Ring gap and orientation are good, head and cylinder gaskets are new, head nuts are torqued to 90 inch/lbs. I used my regular automotive compression tester and only got 40 psi, but it has a 14 inch rubber hose so I don't think that really tells me anything.
Spark plug- It is sparking and I occasionally get a pop when I'm kicking it. It is a new NGK BP4H plug with FSM gap. It smells of fuel when I pull it out but doesn't have any obvious signs of combustion going on.
Carb- New 12mm clone carb from treats. I disassembled and cleaned out a few flakes of metal that were in there. Set float height to spec and installed a new 82 main jet and 20 idle jet. Also set the mixture screw to 1.75 turns out per the book. Throttle and choke both operate smoothly.
Crankcase- I got a new conn rod and bearings pressed on and have new viton crank bearing seals (along with all the other seals on the bike). I sealed the 2 halves of the crankcase with HondaBond.
Exhaust- New MLM next level stock pipe with new gasket.
Intake- I looked at the reeds and they seem to be working as they should. As far as I can tell they close tightly and don't have any chips or anything. The molded rubber gasket where the intake joins to the crankcase looks fine. Should this have sealant?
I tried squirting some fuel into the spark plug hole and then cranking but it still didn't fire at all. I've been through Fred's guide several times and I think I have considered all of the options. I really don't know where to go from here. Anyone have any ideas? Thanks!