The Coil was bad and fried the CDI. This made perfect sense as the CDI I replaced lasted for 1 start and then was toast. With the new coil and CDI it literally starts in 5 seconds on first button push.
That aside – HUGE PROPS to Art and Rod at RLV (http://www.rlv.com/). These guys were nothing but pros all the way. Lots of same day emails, extremely responsive and even brought in a test kart to confirm what the readings should have been. In the end I shipped them our entire Easystart system that they diagnosed the same day it arrived in cali. I cant say enough about the service I received and how happy I am to have these guys backing us up.
Concerning the technicals – here it is.
FACTORY = Known good easystart system
ME = the readings from our kart before the repair. You can see readings off the relay were definitely not right and our CDI was .11V off.
FACTORY: 12.7v / 10.4v on crank
ME: 12.58v / 10.55v on crank
RELAY GREEN WIRE
RELAY WHITE WIRE
BLACK & YELLOW TO COIL FROM CDI:
ME: .32 on crank
RED & WHITE/GREEN CDI
FACTORY: 9.23 ohmns
ME: 9.23 ohmns
TRIGGER ON STATOR WHITE/RED
FACTORY: .12 ohms with switch off
FACTORY: .17 ohms with switch on
FACTORY: .4 volts cranking
I hope this helps others in the future. I will carry these readings in my box from this day forward.