Motorcycle Repair: drive train vibration, clutch actuation, loose clutch


Question
2004 XL1200C, 10K, vibration in handle bars that numbs my hands, vibration in foot pegs. Kicker is, when I pull in the clutch ALL vibration stops immediately. I ran the troubleshooting chart in my maintenance manual and checked everything except the last step/possible cause, which is internal engine wear. Local Dealer "lead tech" says it's normal for a sportster to vibrate. (Funny it didn't vibrate like this two months ago) He also gave me some BS possible causes, i.e., windshield, front tire 1/32 below recomended wear limit. But he couldn't/wouldn't address the part of the vib going away with clutch actuation. After the service department waste of time, I completed the 10K mile inspection, the lower steering bearing was in need of repacking, but not dry. I spent 22 years chasing vibrations in Air Force helicopters and can tell the difference in vibration frequencies by touch. This vib is not "normal", I've given up on the local "experts" at the dealership and plan to teardown the motor/transmission myself. My question is: in your experience, have you ever seen a vibration in the drive train that goes away as soon as you pull in the clutch?

Answer
Vibrations in harleys can come from many different places, but in your case it sounds like it is coming from the motor and nothing else. Yes I have seen this type of vibration. It can be somthing simple, like a loose clutch basket or a lose motor sprocket nut to somthing as big as out of balance flywheels. Since you bike is a 2004 and you only have 10,000 miles on it is it still under warrenty? I think befor you go to the trouble of tearing it down you get a second opinion at another shop and see what they say.
Good luck and happy riding
Mike