1600 heating and head light fuse issues.
I have an '03 1600 classic with 48K on her and am experiencing some issues I think are age related, as opposed to being mile related.
First, I am constantly refilling the coolant system. This most recent time, there was a leak at the fan switching unit at the bottom of the radiator. So, now I want to test that switch to see if it still works, or if I need to replace it again. Also, is there supposed to be a washer or gasket on it as it goes back together?
Secondly, I keep popping the headlight fuse. This summer, (June, 2016) I started using a 15 amp fuse and only popped that once or twice during the summer. I have checked all the wiring I can get to and not found any wear through or burns. All wires are covered where they rub against metal, and headlight bulb is new. I replaced the bulb first, (last year) to see if that was the problem, it made no difference.
Thirdly, I'm getting a bit of slippage in the clutch plates again. I replaced them at 30K, and I'm expecting them to last a bit longer than 18K miles. Should I replace them and get new clutch plate coil springs as well?
Fourthly....is there a way to route a radiator fill hose and cap out to the front of the gas tank so you can access it without taking off the gas tank each time?
Thanks for your input and advice. I am open to helpful comments, but I've had guys tell me their war stories about a bike that is not a Vulcan 1600, and was built in the 1960's....of course that info did not help. Please understand I am handy with a wrench and know how to read the repair manual.