a buddy of mine got one of the first 04's. he had the same problem. the shop had it forever because like you said, it was a design flaw and they were going to have to pull a new motor off the line to get him another. he ended up getting it lemon lawed because it took too long to get it out of the shop. he did buy his new from the dealer though.
I figured the lesson was not to buy the first year model of a new production bike. I had even told him not to get it yet, let them work the bugs out of it.
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