Electrical Gremlins....

I've found the little metal crimps inside the harness will fail where a wire will "Y" off. They'll look absolutely fine on the outside, nice, clean and tight, no corrosion or other mechanical defect but it will still fail to make good electrical contact. Bend the harness 10 degrees one way it's fine, 10 the other and no go.. A test light where the power is supposed to be (your case, the ignition power lead or power to the RH handle bar switch) and run up and down harness bending it and moving the handlebars until you can pin down the general area. Once you have a good idea where the issue is, slit the harness and remove the offending crimp, Solder and shrink wrap the wire.

I had one last year that took over an hour to find, but I did find the little bastard causing the issue. In my case it was a "Y" crimp in the harness for the power to the RH switch in the general vicinity of the steering head. The dead giveaway was the headlight would go off as well as the ignition. On the 70's jap bikes, the power for the headlight still went up to the RH switch even though there was no on/off switch anymore (as mandated by the DOT). It was a "vestigal" connection that was really no longer needed, like an appendix. The starter still worked though as the japanese are big on "grounding" with switches, rather than applying power, so that was a seperate circuit.

I will be stripping the harness over the weekend. I know it is not in the handlebar switch wiring, I have the kill switch by passed......Got a feeling it is in the disaster by the battery. Was going to rewire over next winter, might not be able to wait. Sometimes when it craps out, even with the kill switch jumped, the starter will not engage so I am thinking it very well might be in the kill switch wiring that is in the harness. Thing that is interesting is on the schematic the only place there is a grey wire is at the kill switch. Does not show it any where else....

Connector at coils? Not plugged it all the way? I always get them plugged in tight make sure it starts and then put a small dab of silicone on them. Bikes vibrate alot, the silicone is invisible and holds the connector in place.

No connector at the coils, other than the ring terminals that are connected to the coils. But I know they are tight, 2 star washers and a dab of LocTite on each screw....

Coil wires are on as well.

This thing has been plagued with electrical troubles since day one. Coil wires coming off, power to the circuit breaker fell off, short in the handlebar switch housing just to name a few. Vibration caused the HID headlight to break, have lost a mirror or two. Vibrated one of the bolts that holds the rear fender on.