ORIGINAL: gkamysz
If you are using the spring loaded battery boxes, those can be flaky.
I am, but as you can see from the photo, I am keeping the batteries from bouncing around, or vibrating out with the foam cover, held down under pressure by the dowel. Also, on this box, the springs are very tight. This morning, I removed the plug from the motor and stuffed it into shroud out where I can see it while it's sparking. most of the time, I hear that clicking from the ign box each time I pass a magnet by the sensor. Sometimes, I DON'T hear that from the box. When that happens, the plug fires. Otherwise, there is no spark from the plug.
Based on the above, I still think I ruined this ignition box by running it when the hot wire wasn't making contact with the plug. At this point, I'm pretty sure the clicking from the box is the coil arcing, bypassing the plug. Sometimes, for whatever reason, when the coil doesn't arc internally, it happens to deliver a spark to the plug. Statically, that happens about once in every 15 magnet passes. I'm calling CH for a new one.