My 04 softail standard has developed a notchy, click when turning the bars, always in exactly the same spot, new bearings etc less than 2000 mls ago, fall away test is spot on and nothing visually obvious, any suggestions where to start before l restrip the front end?...(doesn't happen with the wheel off the ground)

 

Neck bearing probably needs a look.

 

Exactly this..

 

This probably means that water got into the bearings and the rollers / race is badly pitted. I give my neck zerk fitting a small pump of grease every year.