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Ok, got my new CDI, Ignition coil, and plug wire in and the first thing I did was to try the ignition coil and plug wire to determine if it was the CDI or not and I had the same symptoms (weak erratic spark). Next I installed the new CDI. I had to rewire it as discussed with tvanacman and all of that went well. I double checked everything to make sure I made no mistakes. My red/black wire has 0vdc on it with the kill switch and key off and 12.7vdc with it on, the green/white wire ohmed out to ground, the black/yellow wire runs stright to the ignition coil (I ohmed it out to be sure), and the blue/yellow wire runs to the stator harness and has ~0.5vac when I'm trying to crank the engine and 0vac when its just sitting there. So I put the sparkplug in the boot and held the metal to the frame and turned on the key and kill switch and I'm getting a weak spark without even trying to crank. When I do crank the spark looks awesome (just like the video in my other post). I measured the feed from the CDI to the ignition coil and I get about 5vac with just the key and kill switch on and something like 17-30vac when I'm cranking. I would think it should be zero vac without the trigger but I'm not sure.

My questions are why would I be getting 5vac without a trigger from the pickup coil (I verified it isnt present) and why is 5vac enough to cause a spark? I've read where less than 15vac or so shouldn't be enough to fire the plug.

I havent tried turning the engine over with it like this as I wanted to resolve this issue first. The spark I'm seeing with just the kill switch and the key on is very similar to what it looked like before when i was trying to crank (erratic and weak).

Any help here would be appreciated.