Thanks for the reply.
I put in a Emgo Universal Ignition Coil 24-71532 that I got from the Kaw dealer, apparently the old OEM one is discontinued. States it works with both 6v & 12v, points or CDI. It has a single primary terminal, so I soldered the two original primary wires on the harness to a new blade terminal to plug to it (I think they are the green/white wires).
More on the electrical side, I checked the resistance to the new ignition coil, exciter and pulser coils and got resistances lower than in the manual:
External ignition coil to ground 0.9 ohms (spec 1.2-2.5 ohms)
Secondary (spark plug lead) coil to ground 6.3Kohms (wire only) 14Kohms (with cap)
Exciter coil 122 ohms (220 ohms is spec.)
Signal coil 47.3 ohms (75 ohms is spec.)
Didn't know how critical these values are. Also -- wasn't sure what the cap on the plug resistance should be (see above).
On the rotary valve, I've got the dimple on the phenolic disc aligned with the dowel pin on the crankshaft. I think I am OK there at least according to the manual.
I can't even get it to fire one time when kicking with starting fluid.
On the airleak test, I have put a new rotary valve cover with a new oil seal in the cover, new 120mm o-ring around the cover, new o-ring on the end of teh crankshaft between the key and the spacer, I got a better fitting used carb holder intake manifold, no cracks in rubber, etc.
On Friday I did take the crankcase pump apart and the diaphram was rotted. I didn't see any parts online for that, so I made a paper gasket the same shape as the diaphram to replace it just to see if that was the leak, still no fire. I figure that it won't work long term, but thought I'd try it. Not sure what material original is made out of.
I haven't checked the seal on the magneto side of the crank, still trying to find a puller. I'll check there next.
By oil fitting, do you mean the banjo on the end of the oil injection pipe where it goes into the right side case?
On running the air leak test, how do you recommend I block the exhaust and intake? Where do I get a fitting to attach a hand pump to the spark plug hole? My compression tester hose has a valve in the end of it, other wise maybe I could connect to my air compressor fitting.
Compression test, I am getting 135psi max.
Thanks again, look forward to more input.