There is too much going on here for me, I am getting lost. I am thinking at this point he needs to know if he broke that boss. If the bike started several times with the new CDI there really is no logical reason it won't start now. As the old one broke down when hot is the old available to try to start the bike. If the starter is just whirring thats bad, if the bike is turning over but not starting that is good.
It does sound like the CDI is set a little wrong with the bad performance at early throttle.
