I checked the fuel QD seals, etc and re-seated it. I get the click so it seems the connection is good. Also double checked the electrical connections inside and outside the tank and they’re good. Now it tries to start but fires a few times or just “sputters”. Any ideas? Thanks.

 

Something happened during that work you were doing.. I would look real hard at the spark wires and how well they are pushed onto the coils and re-seat them on the plugs. They might have gotten disturbed and aren't making good contact. Also, hearing the click is good but you should pull on the QD to make certain it is fully locked in place. Mine looked like it was on but it pulled off easily when it wasn't locked.
I keep thinking you had to pop the tank off to work on it but the big twins have access to the pump without doing that. I'll leave you in the hands of the BT guys.

 

I agree with you on that; the chance of failure of something else is too much of a coincidence. I checked the plug wires before I tried to fire it up and they were good. I’m thinking something in the fuel pump assembly isn’t right. Maybe one of the hoses is not seated correctly. I hear the pump run when I hit the ignition switch but it doesn’t sound like it did before. I can hear fuel rushing around vs more of a pump priming noise. Not sure if those are technical terms but I’m gonna go with it. Thanks for your help.

 

The fuel pump should run (prime) until it makes pressure and then will shut off until the engine begins to run...

Does your fuel pump run for a few seconds and then stop....???

If not, something is definitely wrong with the hoses...

 

Finally getting back - it’s been a busy week. I gave up and took the bike to a shop. Turns out one o-ring on the pump assembly was missing (must have fallen out during my not so handiwork) and another o-ring was damaged/broken. Explains the rushing sound I heard when turning the ignition on. Fuel was squirting around inside the tank. Thanks for all your help. The bike runs great with one minor glitch. . . . . .
I’m starting another thread “ThunderMax”.

 

THanks for the follow-up, the information may help someone in the future.