Is there anyway someone can help me out. I was putting my bike back together tonight and got to the wiring. I hooked everything up like it should and went to test the fire out to see what it looked like. When I rolled it over it seemed to have a weak spark, almost orange looking. So I figured it was a ground issue. I than scraped away the fresh pd'c to get to bare metal. I already did this once and did it again for safe measure. I than checked my ground wire. Did the same thing. I checked the spark again and it seemed to get blue'r but not as heavy as a spark as one would like. So I pulled the multimeter and manual out and went to checking things. The stator checked out fine, the Primary side on the coil was within limits but when I checked the secondary it was way out there. So I grabbed another coil and it checked the same way. So I than thought it was my meter, but I went ahead checking things anyway. I went to the CDI and that where everything got screwed up. Everything I checked was not anywhere near where it needed to be. So, I grabbed my extra CDI, and what do you know, same exact thing. There is no possible way, well I guess there is, but I would not think that two components that weren't being used could be reading the same as the ones that were on the bike before rebuild, could they?

Anyone that can dicipher this let me know what I should do.

Well Ii thought it was a ground so I removed one of the front motor mounts and removed the powdercoat from the frame where they meet and bolted it back up. NOTHING. So Im starting to think its a pickup gap issue. I may just put the remote starter on it and see what happens.

Try electric grease on all your connections.  Also is it a new plug

Thought I'd let you figure that one out on your own :p