Thanks for shedding light, and offering your take on the CDI failure issue. I ride an '03 with around 60,000 miles using the original CDI... however, I do have a Procomm sitting in reserve just in case. It seems to be a bit hit and miss with these bloody units. A couple of years back I was riding in the rain when my bike began to sputter and cough. Later on I hit ALL connections with dielectric grease and haven't had a problem since but can't say it was the CDI getting wet causing the issue. I did notice hairline cracks in the 'bakelite' resin on the CDI but based on the autopsy your performed, that may not have contributed to any problems.
