Looks like we've found the cause of the failure.
Dave has just calculated that he was putting in MUCH more than he realised and as a consequence was running too much advance.
That's one of the reasons I've not been in a rush to release the REVO systems, because unlike a fixed jet system they demand every ounce of your attention to every detail and the slightest oversight can lead to a major failure.
The actual main cause of this failure is the longggggggggggggg time between opportunities to run/race, because with such a new concept we all (my team & Dave) need frequent and closely timed repeat practices of the entire process, to get it all sunk in to a level where we operate all the functions by auto pilot. Without the opportunity to gain that experience, each time the bike is used its like starting over again but we haven't been fully appreciating that's the case and so vital procedures are overlooked.
For example, when we first started with this project I had Dave fit metering jets to limit the power and ensure the full flow mixture stayed correct and as we ramped up the power the jets were increased. However, when Dave started over again for this year, it was overlooked that these jets would be much bigger than the REVO level he INTENDED to run (a max of 150 HP), so that safegaurd was missing when the Max/REVO settings ended up higher than expected.
For the record the REVO mixture was far too rich (in theory as intended) and the results of his first static tests CONFIRM THAT CONCLUSIVELY as the engine died almost the instant the system was activated at just 20%.
Dave has since been able to adjust the mix to achieve a much better response, with the revs rising to just short of the red line, which in the current situation is PERFECT.
All he needs to do now is repeat the static tests at 20% increments and check/tune accordingly and we should be good to go now that he has the power toned down and the CORRECT restrictor jets fitted.
BTW his first comment after realising how much power he'd been adding was;
"bloody hell! no wonder it held the front wheel up until it died" 
All I can say is rather you than me Dave, because although I'd love to experience that amount of acceleration, I can't imagine the fear of doing it on ONE wheel, even though I've raced some very quick bikes (at the time) in my younger days.
