I had a similar experience, only not nearly to this extent.
When I arrived to pick up my SERK the salesman goes, "I have bad news." Oh chit what could this be. So he shows me a small bad spot in the paint on the front lip of the front fender. The sales guy said that they had already ordered the replacement fender, and the spot was very small (no one else has noticed it). Here is where it got interesting. The salesman tells me that this is the third SERK that they have gotten in and ALL of them have had the same problem! I was shocked! So I asked him if they had notified the MoCo of this, and he says, "No point, it won't change anything."
Lets face it, the MoCo doesn't care if the dealers are having problems or not, they only care (hopefully) if WE are happy or not. The really sad part is, no one at the MoCo will take notice unless we stop buying the bikes, and the parts, and the clothes, and everything else with H-D on it. [smiley=soapbox.gif]
Finally, I was wondering if anyone thinks it would be a good idea to post pictures of some of these problems others have encountered so that others will know what to look for before they take home their new bikes. I was very glad the tech at my dealer caught the issue and reported, because I would have never seen it until the first polishing.
Ghost