I'm starting to reassemble my 500 and I had the frame powder coated. I was wondering what areas of the electrical system you guys would recommend sanding the powder down to bare metal? Under the regulator mount? Under the coil mounts? Between the frame and one or two of the engine mounts? Anything else you guys would recommend while reassembling the electrical system would be appreciated.

I fought a grounding / electrical issue for about 6 months on my build back in 2010.  Make sure you have a solid connection at the regulator frame mount, coil mount, head stay mount plates - engine to frame.

I wanted to make sure I had a good ground on my build and ran a 8-10 gauge wire bolted to the frame to one of the head bolts.

for future reference, pick out areas and install bolts with washers in them before powder coating.  I did the same thing last time.  I have another frame ill be getting powdered and will be doing this.

Yes, my symptoms were ok start and idle, but it would cut out under mid/top power.  When I removed the head I found blackened bolts and head stay plates from the arching that was going on.  It was an a-ha moment.  I had a partial ground thru the bolt to frame connection but it is just not enough.

I also used 'throw-away' bolts to protect the threads.  Didn't think about the washers, but that is a good idea.  I will use this for future powder coating.