Hi guys
Sorry, I've been meaning to reply. I've parked it up since my last post, can't bring myself to replace yet another component and not have it solve the problem...
The answer is somewhere in this thread and that drives me nuts. I know its something simple. I've been trying to think along the lines of what someone mentioned last page, go back to when the problem started. It started the ride after I fitted an ADA head and had the pipe re powder coated. I can't believe its the pipe, I've had it off half a dozen times and its physically fine.
Since that ride (now five months ago) I've checked and changed virtually everything. To address the more recent posts, it has had a new pair of known good carbs swapped on, blocks been pressure tested, crank in block looks and spins perfect bearings are mint, fuel supply side flows free (I will check return at dirtsons suggestion).
Jimu, your suggestion gives me hope. I disconnected the thermal sensor when fitting the ADA naturally. First I just chopped the leads and since have unplugged and taped them up inside the box. I thought the switch was just a basic circuit that opened or closed with heat however? Is the cdi really smart enough to have limp modes?