Warranty saga for a friend of mine: Five weeks ago, he took his 2007 Ultra Classic (not CVO) to a local dealership's service department for a major oil leak in the transmission, or so he thought. As it turned out, not only was the transmission leaking oil but the engine crankcase was leaking too. The dealership submitted an extended repair order to rebuild both the transmission and split the cases on the engine. After five weeks he called the service department to check and they had more bad news. Upon reinstalling the rebuilt engine into the, freshly washed and cleaned frame, the mechanic noticed a crack in the frame on the left side of the front motor mount. Again, a repair order was submitted to National but this time he was told
"frames are not covered by an extended warranty" 
and would cost about $1800 just for the cost of the new frame, plus the labor to reinstall, etc. After a lot of help and negotiations with National from the dealership, National H-D that they would cover the cost of the new frame and up to 70% of the labor to install it, but it may take up to 3 weeks for a new frame to arrive.
All in all he was lucky, but it sure makes an extended warranty worth it in the long run. Also helps to have a sympathetic dealership on your side when dealing with the warranty 'screeners'.
