premature engine failure:

After having my 2001 Sportster wiped out by a " nice old (80) lady at a busy intersection, then she claimed that the left turn signal "Was green the last time I looked" I was lucky to have suffered only a slight cerebral contusion, but the bike was totaled.  I took my Insurance money to look for a new 2004 "rubber mounted engine" 1200,  After not having any luck finding one near me I took a drive to Yuba City HD, where I found the last 2004 in their back room.  As I looked at the black beauty a mechanic excused himself, stating he had to service it. :-)) I bought that one on July 9 2004,  got the extended 5 yr warranty, and have since been to Sturgis in 2005 and enjoyed a total of 35,550 miles on it.  Then some months ago The engine started making a noticeable "clacking sound.  I took it by the HD Store here locally and the consences of opinion was " It's probably just the primary chain needing adjustment. I ran it by some M/C knowledgable friends and they agreed, "Yeah it sounds like the primary to me"  I changed oil every 2500 miles, using HD synthetic oil( at $10.00 a qt.  I finally relented to the HD guys suggestions and took it in.  (Starter broke that morn'  $316.00 repair and adjusted the  primary.  Had the service writer start it.  KNOCK-KNOCK.  "I stood back.  "Thats not aceptable' I said.  "Sounds like a lower end noise to me" I said.  Well, it's a 4 hour job to check it out." he says.  Result: $3500.00   repair or $5600.00 to replace.  WTF! One of the mechs said he's seen 5 or 6 2004 Sportsters  with the same problem.  nothing after 2004, just that year.  After more than 10 oil changes. Have you seen any thing like this.  By the way, my 5 year extended warranty ran out 7/09/2009.  They don't have any extra time available for their customers.  Thanks!  Harley is replacing  the necessary parts at nearly $1800.00 , but I'm eating the 21 hours labor, $85.00 hr., less the 4 hours I paid to find out I got the "shaft", so to speak. I need some back up stories about this circumstance with other 2004 owners.  Got any  

The 1st thing I'd suggest is to go to this website:
http://www-odi.nhtsa.dot.gov/
Select
report defect.
If you find a number of other people who have the same problem, the government will force a recall to correct the defect. Don't get your hopes up. I belive it's somewhere over 2.5% of all vehicles to get a declared defect.

Other choice, (and the 1 I did with my Subaru) is to contact Harley direct, and ask for a special accommodation. They usually won't pick up the full tab, but, since you are like me, the warranty just ran out, they usually are willing to hork up half. They don't want you totally pi$$ed off, you could interfere with future sales.
If they do it like Subaru, they will contact your dealer to see what level of service you did on the bike. If you had some of the work done elsewhere, tell them, it's in your best interest.

If they do get involved, you owe me a beer, at some rally to be named later.  If we can't get to the same rally, we can each buy 2 at a rally in our neighborhood. and do a toast that way.