So my battery light came on but i figured because I'm on a small average I start and shut unit off a lot so battery wasn't charging enough I decided to take it for a good long ride to charge battery up. Got about a half kilometer from home and I heard a load pop and she quit. Main fuse had a large hole burnt through it and after I installed a new one I had no spark! Like you I tested every thing but the manual is sketchy. So I replaced the coil and wire and theCDI unit. Fired up and quit again.
I read somewhere on the web you have to replace four units together cdi, coil, rectifier and stator.
I'm dealing with a company here in Alberta and when I find something out I'll let ya know as I need this unit running