So an update from the garage:
I broke open the manual and followed the instructions:
When dealing with ignition problems, the following items should be verified in this order:
1. Spark occurrence/ spark plug condition- (
This is why we are checking aren't we...(plugs replaced)
2. Battery condition-
Yea, interesting findings here.
3. Electrical connections-
Checked all connections, seemed OK. Removed 2 fuses from MPEM that had some slight corrosion on them, replaced with fresh ones. No other problems found.
4. Engine start/stop switch -
Not checked
5. Safety lanyard switch-
Not checked
6. Timer-
Not Checked
7. Multi-Purpose Electronic Module (MPEM)
Not Checked
8. Magneto output (717 enines)
N/A
9. Ignition coil output
Not Checked
OK Back to the battery:
Original Battery:
Voltage no load ~12.8 Voltage while starting ~9.8.
Took the battery off and put it on the charger.
Put on my AGM battery
Voltage no load~12.6 Voltage while starting ~10.5 turned over much faster. About that time, Original battery is charged.
Swapped AGM for Original.
Voltage no load ~13.0 Voltage while starting ~5.8??
Apparently something is drawing a huge amount of current all of a sudden that wasn't before. Think this might be something of interest. I am waiting for the AGM to get a fresh charge and I will check again to rule out the battery he gave me with the ski (original)
Yeah...I got a feeling you have a bad mpem.
The fact you have checked the pickup (which should have the updated pickup already) and it was fine, and the back ebox was clean...running that extra ground is a step you want to use on an XP....it doesnt help much on a GSX, and it usually gets run from the back ebox or ground on the battery to the front Ebox to rule out a ground wire issue on XPs.
Check to make sure it isnt the coil pack by unhooking the white wire off the coil and put a test light on that wire and ground. Crank the motor....it should flash. If it doesnt....
Since you know the MPEM is getting power and ground, and you know the pickup is ok, then theres two things it can be....Wiring/pin corrosion, or MPEM.
It isnt very normal for a panel MPEM work operate but have no spark...but it is possible. The CDI is built into the MPEM and like any machine, a CDI can die.
I really hope you aren't right but I would like to find the culprit here.
-On 07-02-13 of the 97 service manual there is a chart for testing the MPEM, I know it isn't a full check but perhaps it can lend some insight as to what might be the problem. Do you have experience checking using the resistance checks show there? Is it a worth while check?
Also regarding checking the coil. I don't own a test light....I assume I could look for voltage using a multi-meter?
[MENTION=41828]Minnetonka4me[/MENTION] go ahead and send me a PM on what you sell good MPEM's for/ what it would cost to check mine.
Thanks all for the help! Keep the suggestions coming!