electrics, electrics, electrics grrrrrrrr
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@sward That doesn't make sense to me, are you saying that with no battery connected you get a spark, but when the battery is connected you get no spark? How would your electrics work with nothing to power them? If that's the case then you have a short somewhere and most likely its somewhere along the battery cables.
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There is two parts to the generator on a dt and most bikes. There is charging coils that produce Ac current that the regulator/rectifier converts to 12v dc, to charge the battery. The 2nd is ignition coils which are used to produce a spark at the coil. Most bikes will run fine with out a battery, but with out the battery there to 'buffer' the voltage from the reg/rec you run the risk of voltage spikes so not recommended.
I presume the ignition switch interrupts the main power feed ( red and brown wires) and a feed to the ignition system, through the other two wires. I would see if the bike sparks with these other two wires (blue I think) disconnected at the ignition switch, but with the ignition on. -
I tracked down the issue to a broken wire in the loom, so all fixed and great to hear the bike running, I'm not going to identify the individual wire that was causing this as if people know they could just cut one wire and steal the bike, though in addition as many people talked about bad earths I also made sure they were all spot too, could have been a combination of two things. lol.
Thanks for all the suggestions and help,
Simon