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Ok your service techs are idiots. It sounds to me like the steering head nut needs to be tightend. The head bearings are looseit is pretty comon problem, if the dealer cannot fix take it to another shop. Ask around to see where a good shop is in your area they should be able to take care of it with no problem. That is what I did and no problems with mine in over a year.
Two thing come to mind. Steering head bearing tension and now for something nobody has touched on. I notice the wheel weights on it to balance the tire. Not sure what method was used to balance it but it's important to have an equal mass rotating around the centerline of the wheel.(not the axel)If more weight is on one side of center it may appear to be ballanced but in fact it's not. Look for weight on both sides of the rim. If not find a good dynamic ballance machine. Your machining on the wheels indicates more metal in the wider areas. This in itself should not cause the problem you mentioned as correct wheel balancing will take care of it also. Hazzarding a guess and not really looking closely at Fatbob wheels it would appear they are cast aluminum. If that's the case all of them will exibit the same machining width differences. Ron
Harley needs to fix this stuff for you folks!!! My word, what kind of manufacturing standards yields a wheel with over a quarter inch machining difference. Ridiculous!!!
A big part of enjoying your bike is having access to quality service.....if YOU know there is a problem, I am quite sure a dealer service tech or a competent independent should be able to pick up on it also. I do most of my service work on my bikes, but on my 03 FXSTD-SE I also have a wobble at roughly 40-45 on deceleration mostly. I have noticed that there are no wheel weights on the front rim, so my first step will be to have the wheel balanced (at the local indi) and then I will tighten the steering head bearings as per HD procedure. I am 99.9% sure that between the balancing and head bearings the problem will be gone.....if it is not I guess I will be buying a new front rim quite a bit sooner than I had planned. I also have a 04 Fatboy......its solid as a rock.....but it does have wheel weights on the front rim.
If the wobble is the same during accleration and deceleration this is not the fix but if it is worse during deceleration it is the result of a too loose primary chain. The adjustment should have been done during the 1K service but probably wasn't. The too loose primary chain will set up a vibration that is transferred to the frame and the bars and they will resonate at their harmonic frequency. Because of the adjusting shoe for the primary chain the effect of the looseness is worse when slowing down, the chain just flops around with nothing to damp it resulting in the vibration. Remove the inspection cover with a T27 torx. Count the number of teeth/notches above the adjuster in the center slot. Loosen thelock nut and move the adjuster up one tooth/notch (a little bit of adjustment goes a long way). Tighten the lock nut, replace the cover and test ride. It should have gotten better. If not, it is not the primary chain and look elsewhere for the cause.
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