BTW, I really appreciate you chiming in on this. It's been a real ball buster. I'm just an amateur but, usually, I can stick with it, think it through, ask questions and follow directions and figure it out, be it mechanical or electrical.
This one completely stumped me and my Dad. Took it to my buddy who runs a thriving shop and is no slouch, and he doesn't get it either.
EVERYTHING tests good. Per the manual, per Rex's troubleshooting, per hints and suggestions we've gotten. EVERYTHING is in spec.
The switch and controls are tested at the rear of the bike, which means you're testing the main loom at the same time. All the tests are good. But THEN...we tested each component separately; ignition switch and RH control up at the headlight, then the loom from headlight back to rear of bike. All good.
Rigged up extra grounds. Tried UNgrounding the CDI. At one point, he had a temporary loom set up that completely bypassed the key and RH switch. Nothing. Power straight to coil. Nothing.
Over and over and over.....