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Want the scary news, one way for those parts to collide is the result of excess play in the crankshaft bearings. Grab the crank firmly and see if you can detect any play in the crankshaft bearings or in the taper shaft and and inspect the keyway on the armature to eliminate that as being a problem.

Just a few observations and suggestions; 1) your spark plug does not require or use rectified voltage to operate, AC works just fine to produce a spark. 2) that pickup coil needs to be cleaned and the proximity between the pickup and the spinning magnet needs to be as small as possible without ever physically touching. That is likely how you 'fixed' the bike when you removed and reinstalled it. None of those magnet to coil surface interfaces should include rust or metallic debris. 3) the head bolts should provide a solid sparkplug ground. 4) your diagram shows an ignition system with 2 coils, one coil dedicated to spark and the other to 12volt accessories such as LED lights and fan motor. Your photo appear to show a multi phase stator coil 🤔 you might not have the correct wiring diagram or the schematic displays the stator coils in a curious fashion. ... if the bike runs and you want to test the alternator outputs, best is to use an oscilloscope. add: my riding partner crushed a small capacitor that is wired up near the headlight and steering stops crushed it. You might want to check that part assuming his EVO is the same as your EVO add: the black box module almost certainly adjusts spark advance timing and that is likely where the biggest difference is between the various modules. ... timing of the spark is almost the only thing that can be adjusted.

I also ride mountain bike ( EMTB to be honest ) and when they became avalable I bought a MIPS rated helmet, mabe that's why I'm '' suffering '' so much with my trials helmet to the point that I'm looking at a new one with more ventilation.

Hmmm looking at closeups of the other connector and I noticed the water seal on the back of the high voltage wire (Red/White) to the coil looks less than perfect.

Is a bicycle helmet as safe as a motorcycle helmet? Probably not. But modern MIPS-rated helmets are pretty good. See: https://www.helmet.beam.vt.edu/bicycle-helmet-ratings.html It may partly depend on the ambient temperate at which you ride. I know that if my brain gets overheated I don't make good decisions, and am more likely to actually need a helmet. Assumption of personal risk is a very personal decision.

I’m not sure I agree with an MTB helmet so I’m putting this out there for consideration. There’s an old saying that goes like this, “Buy the best helmet you can afford!”. The reason being is that you’re playing Russian roulette with your brain. MTB helmets aren’t subject to the same testing standards as DOT helmets are. Yes, trials riding isn’t as fast as street or MX but what happens if you go down and the bike lands on your head that’s next to a tree, rock or hard pack. The shells on MTB helmets aren’t as strong as a rated helmet because MTB bikes weigh a fraction of what a motorcycle weighs.

Back with learndings about the electrical system on my EVO after it glitched and cracked some ribs. Thought it was carb but seems it was electric. One interesting insight was how the electrical system finds ground for the spark plug. The other was the revelation that the 300 Ohms called out in the owners manual for the trigger coil might be a wrong value so if you're diagnosing your Stator and the trigger reads 185 Ohms you're probably OK. EDIT, fixed some typos Beta debug.pdf

Probably the best-ventilated helmets are for mountain biking (MTB). Might be worth a look if your club does not require a motorcycle-specific helmet. Probably easier to find a vendor to try something on as well. My wife wears a full-face MTB helmet all season for trials.

I agree with you Konrad, I need to try it on before buying, the problem I have here in Quebec, is there is not a lot off trials gear retailer and they are quite far apart, so any info will probably save me a lot of traveling.

If there is any way for you to try on a prospective helmet before buying, I strongly suggest you do so. I bought a GasGas-branded Hebo Z4 Carbotech by mail because it was a fabulous price. The Carbotech is a top-of-the-line helmet with two annoying (to me) "features". 1. The cheek pads were far too tight, despite the helmet otherwise fitting perfectly. I figured they would eventually "pack out", but did not. I ended up removing them completely. 2. The buckle hit my Adam's apple, which was most uncomfortable. I eventually improved that somewhat, but it's far from perfect.