So far everything has been going reasonably well after starting the pull down of the machine and assessing the work to do.

I removed the head and checked the valves and the Exhaust port needed some work. I ended up doing both and reassembled the engine.
Cranking now gives a reading of approx 150psi.

New parts for the carb are still on their way (overflowing) so I hope to have that sorted soon.

As for the spark issue.
Previously I’d noticed that the Neutral and Reverse switch wires were around the wrong way and when I reconnected then I had a spark. hmm, now I don’t.
I went though the manual and checked everything as best I could.

I couple of questions…

So the primary coil voltage should be at least 100v minimum. I’m assuming that this is testing at the two wires going into the coil? I’m getting no voltage reading here. The coil itself tests within spec.

I’d love someone to explain the "primary and secondary sides" to me please?
ref: 95-00 TRX300 Service Manual page 17-6

I’m guessing it’s coming down to the pulser coil now?