Cleaned completely,Good strong pilot, New Pilot generator.
adjusted generator for max flame exposure.
With heater switch off - generator leads read 454 mV
With heater switch on - reading drops to 330 mV
When problem first occurred I could flip the on off switch a few times and it would finally turn on. Then that quit working.
By the end of last season I could jumper between generator red lead and coil and get the burners to turn on if I tried enough times.
Now with the new generator if I jumper red lead to coil, I hear the valve click then the pilot goes off.
Last year I tried bypassing all the switches and would have success and failures with each combination. This is what lead me to suspect the pilot generator. I thought that the success was a momentary spark with enough voltage to kick open the coil, but not enough to consistantly get it going.
I really doubt that a brand new 750 mV generator would be bad out of the box but it is possible.
I tried a bench test with a cigarette lighter and also maxed at about 450mV.
Desperate for Ideas.....