[Sharksawyer]

Check your main switch(key) for continuity. The plug is under the left fake carbon piece. Unplug it, turn your key on and check the resistance on the two small wires. Bet it will be high. The two small wires run through your starting circuit cut off relay to your CDI(ignition unit). If you have an intermittent connection on your main switch, you will have an intermittent spark. Check it several times. Turn the key off and then back on before checking again.

Mark

 

[Sharksawyer]

Uhh...it happened to me and I went through the same thing minus Yamaha techs. After a couple of weeks with the bike cutting out, I finally found my main switch bad. What I did was wired a toggle switch and use the key for steering lock only. Napa auto part #TG6145. About 10-12 bucks. I mounted it up front on the center fairing bracket. I was the only one who knew how it worked so I wasn't too worried about theft.

Mark