I have been chasing a rattling noise for a couple of weeks now and just found it Thursday. The heat shield on the front exhaust was cracked almost in two pieces. The crack was just below the middle foot peg mounting bar and was not visible until I got down to the level of the shield while washing.
I took it to the dealer Friday and the service writer said they would have to order the part and call me when it comes in to be replaced. The service writer said she has seen it before, although not many times.

 

Mine had cracked same place tbone right where its notched out for midpegs.seeing as I had forward controlls I asked dealer to order the wglide full shield under warranty also looks better to.Also

 

In early 06 they had a cut out in the front heat shield, and mid year they changed the design to a Impression in the front heat shield to keep it solid. They were cracking and covering them as warrenty... Just a thought..

[IMG]local://upfiles/24219/6B6B4E7C03664D48A44F7CA1A506831E.jpg[/IMG]

 

Also you can plan on a cracked front fender and rivits in headlightbucket looseing up.

 

Yeah, mine is an early '06.
I don't have the forward controls so I guess the wideglide shield is out.
I've been watching the front fender, also.
And listening for the primary bearing.
I'm averaging about 1,000 miles a month. I 'm trying to put as many miles on asI possibly canin 2 years so if something breaks it will be under warranty.
I wish I didn't have to work so I could put about 50,000 while under the 2 yr. unlimited mileage warranty.

 

heat shield cracked less then 5k miles fender cracked right bout 10k headlightbucket loose from day 1

 

well got my new headight bucket today which the rivits in old was loose and it had a crack.also noticed I have a second fender cracked again both sides rear rivits again! The first fender it cracked on just one side behind the rivit. This Is BS that HD is putting out anymores.
For the ones that dont ride em much HD will be off the hook on em after 2 yrs.My warranty expires this sept.Currently have 24k miles on it.The first fender cracked around 10k so this one lasted 14k miles.