OK.... Update for those that care.
Disassembled the whole mess again and checked everything.
Through tests found that for what ever reason the original routing had all of a sudden been to aggressively sharp a bend on the final up to base of speedo???
Played with the routing all the way and now needle is dead calm from 0 to 60 mph
Ciao
A few days late, but wanted to report another successful 3-day 700 mile Catskill Mountains tour. Return home day 3 was moderate rain the whole way, but no issues whatsoever. Same goes for my friend's Duc. [emoji123]