Reconstructed!

I finished the maintenance on the bike. New clutch and brake fluid, new antifreeze, rerouted the custom wiring for the air horn, driving lights, accessory plug, LED accent lights , etc. I also did a once over on the bike, tightening all connections - this appears to be a common problem as the bikes come out of the factory.

I was amazed at the crap that came out of the brake lines. There was black crude that flushed out of both the front and back rotors. While I have not experienced any problems with the hydrolics, it was a problem in the making.

The clutch fluid is hidden behind the engine cover which was a real pain to remove! There are only four bolts which go through rubber grommets. Since the cover has not been removed since it was initially assembled clear back in 2006, it did not slide off easily. I spent 15 or 20 mins trying to gently wiggle it off. I gave up and went in for lunch. I came back out and applied some muscle. The thing finally released!

I took Kermit (the bike) for a test run, and it shorted out about one block away. I never knew how hard it was to push an 800 lb bike! Thankfully, my neighbor came out to help me get the bike up the driveway and back into the garage.

There were only two harness connections that I disconnected. So I took the first one apart and reconnected it. This time, I made sure all the wiring was correct. Unfortunately, I did not check to see if it was wrong before taking it apart, so I dont know for sure that this was the problem. I did the other connector, and then reconnected the battery. Started right up!

I need to test ride it again, but waiting until I have someone to help if I break down. But things look good and I dont expect problems.