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Originally Posted by venik
try lowering your gap, 40 thousanths is extremely high, i was getting spark blowout at .036 with almost no load, with dr650s i'd say 28-30 thousanths
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Thanks for the suggestion, but I already tried narrowing my gap down to 0.28 (with iridiums) and all it did was give me a bit rougher idle and the misfires in 2600-3200 rpm range continued.
How old are you coils and what AFR are you tuning to? What brand of plugs are yu using and are they copper/platinum/iridium plugs? The only time I ever saw spark blow out, using new coils, was when I was running pig rich and seeing WOT AFRs of 8-9 (NB:0.99V)

Plus, if it was blow out, it should get worse as boost increases. This problem seems to get better as boost increases, althought I doubt its directly related.
Declan