I went through the carbs again...and again, all are clean.

Question: With a DVA, if I test high and low while running on muffs, can I accurately test the high speed voltage output at idle or do I need to push it to over 4K RPM? The voltage per CDI is 25-100V for high but it doesnt say at how many RPM's the motor needs to turn.

And finally, as I mentioned a few days ago, the rectifier is getting VERY hot when running. I checked the grounds several times and all checks out... could the stator be causing the rectifier to get hot, meaning too hot to touch?