I'm kind of late to the party but I would definitely suggest revisiting the spark issue.
I had custody of an XB12S that had intermittant issues until it finally gave out. The coils have been replaced a few times and it seems to be a recurring issue.
I believe the root cause was either poor coil placement or wire routing, iirc.
Even though the bike was out of warranty, HD/Buell covered it because it was a design flaw.
The bike is my Dad's and he knows all the details. I'll call him tonight and have better info for you later.
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