2009 Fat Boy post repair road test

This bike was a nightmare right from the start. It had been sitting at another shop for 4 years. It was at that shop because it wasn't running right. It barely ran and wouldn't idle when it came to us. I replaced the intake manifold seals, fuel injector o-rings and MAP sensor to fix the vacuum leaks and idle issue. The charging system was not working due to the stator being burned up, so I replaced the stator, rotor and voltage regulator. While I had the primary opened up I found that the shift lever at the transmission was worn out and the shift shaft was leaking, so I replaced those. I also replaced the inner primary seal on the transmission input shaft and the inner primary to engine case seal. The derby cover was damaged so it got a new derby cover and gasket once the primary was back together and filled with oil. I inspected the wiring on that runs under the gas tank because the customer was concerned with a wiring issue due to the flickering headlight, no issues there, the headlight itself is broken (cheap Chinese LED light from the internet). I replaced both tires. I extended all the wiring for the handlebars, replaced the throttle cables, clutch cable, and front brake line and bled the front brake as part of installing new, taller, handle bars and new grips and internally wired the new bars. I also fixed the rear suspension as the rear shocks had loosened up and were practically falling out of the bike. This all took almost two months due to diagnostic time, waiting for customer approval for the work, and most of all, the time it took for parts to arrive.
I'm glad that the customer was patient and understanding. He was happy to finally have his bike back and rode it for several hours before it died on him later that same day. It'll be waiting for me when I get to work Tuesday. Even with all the work I did to fix it up, it's still a 15-year-old bike...
Recorded Saturday 13 July 2024