KZ1000P sputters and spits when riding

I have a 2000 kzp1000 with 19k miles on it. The bike idles fine and revs ok in neutral but underway it coughs and sputters so bad i feel like its going to buck me off sometimes. In September i took the carbs off cleaned and rebuilt them. Put them back on and synced them and it still did it. I replaced the plugs and wires and it seemed ok. Took it for a test ride and melted the ignitor. I replaced the ignitor and put my old plugs and wires back on. The bike ran great. I put almost 600 miles on it since september. Took it out yesterday and the same old thing happened again. What would cause it to run great when i park it in the garage one day then run like crap the next? I did adjust the clutch prior to taking it for a ride yesterday. That wouldn't make a difference wouldn't it? I also hear the starter clutch catching when its sputtering. I rebuilt it last year so im not sure if it would be that. I also cleaned and oiled the pickup coil and checked the battery cables. I know some of you are going to suggest dyna ignition but i don't want to get into that. Any information or suggestions would be appreciated.

Based on what you describe, I think I would look for a loose or corroded connector, broken wire or missing insulation in the primary ignition wiring.