Well that was it! It was the contacts in the throttle housing. Just wanted to say thanks so much for your help. I would have never known that was in there. He has been riding for a couple weeks now with no problems.

One last question - today it started idleing higher and would bog down and almost die at full throttle. Im guessing when it ran out of fuel it may have sucked some trash in the carb and I just need to clean it out again. Once I do that and reinstall do you have any reccomended settings on the carb. How many turns on the main screw or how to adjust idle?

Thanks again for helping me hunt down that firing issue - it was driving me crazy!! LOL

 

Check how many turns in to a lightly seated position you now have on the air/fuel screw. Usually setting is between 1 to 1 3/8 turns out. Just clean the carb again as you mentioned and see if this helps on the idle. If still high just turn the large idle adjust screw down a little.
Glad you found the main problem..