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Take it to another shop. Is everything stock on the bikes exhaust system? How's the temp gauge look when you notice the heat?

I ride my friends '04 and haven't noticed any heat issues.
 

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Harley doesn't say it's normal. Your crappy dealer says it's normal.



Take it to another dealer and see what they can find. Document everything every step of the way. If you still don't get any results, go on H-D's website and get the number for customer service in Milwaukee and call and explain the problem.



I own an '03 Glide and do not have any kind of overheating problem.
 

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I would say that is normal. Both my Dyna and Streetrod put out a lot of heat which becomes a bother when riding in traffic or waiting at the light. Doesn't bother me much as I never ride in traffic or around town.



If you do ride in shorts I would recommend you put on jeans - it will help with the heat and better than bare legs if you take a tumble.
 

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That heat may not be coming from the pipe. The heads give off lots of heat when sitting in traffic on a hot day, as I found out in Las Vegas last year. For the crossover to get hot enough to roast your thighs in the position that it's in, it would have to be glowing red. If your plugs look normal, then I bet it's the heat from the cylinder heads you are feeling.
 

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I was thinking he could be running really lean and that could really generate some heat.



The EFI bikes have a safety mechanism and will shut down if they get too hot.



So riding in Las Vegas in the summer is hot, eh?
 

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You did not state where you ride but I live on the Texas gulf coast and during the summer I am baked! My 06 Road Glide generates more heat to the rider than any motorcycle I have ever owned. I am riding in 90 degree + weather, and in full sun most of the time but I have also been riding in Texas for over 30 years and have never experienced a heat issue of this magnitude. Unfortunately it was in early spring when I rented the bike for a weekend "road test" and the issue was not apparent in cooler weather.



All I can say is dress properly. I used to wear mess pants because they were cooler and still provided me with some protection. Now I wear jeans and I also have switched to full height boots to better protect my legs.



All of you folks who live in cooler environments my not experience the issue but here in Texas it is starting to be talked about.

 

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Re: TWO WORDS: AIR COOLED

Unlike the heat on a liquid-cooled engine, which is routed to a radiator away from the rider, all of the heat from an air-cooled motor radiates directly from the engine toward whatever parts of the rider are nearby. This can become quite uncomfortable and even hazardous when the bike is stopped or run in low-speed traffic for extended periods of time. It's just the nature of the beast.
 

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I'm going to guess that it is normal. But, I'll take it back if;



1) The sparkplugs are white - they may be very light in color which would be normal because these bikes are leaned out to within an inch of their life.



2) The engine knocks or pings - fuel injected Harleys should never knock - right?



3) The engine backfires.



If the bike pulls good off idle and runs strong at freeway speeds it's probably running OK.



As far as heat goes - I've noticed excessive engine heat on hot days when the wind blows through the motor and right on my thigh, which is exactly where I notice the heat the most.



One more check of a hot running engine. immediately after a ride touch the rocker box cover - that's the top most part of the engine. It shouldn't burn your finger. It will be hot, but not so hot that you get burned right away. I've found that Harleys actually run pretty cool.



The most frustrating thing is taking a bike to a dealer for a problem that doesn't actually exist. So hopefully, there is something wrong. That didn't quite come out right, but you know what I mean.
 

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I am seeing a few people purchasing, at my local Harley Dealer, what looks like a diaper, that goes underneath the saddle, but protrudes somewhat, that is actually a heat shield to cure exactly what you are experiencing. And some people change the headers, so that there is no cross-over pipe to the right, on the rear cylinder. Harley also seels a Fan Kit for parade duty...
 

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You guys seemed to have missed the basics. Is the bike EFI or carburated? Since Harley has issues with emmisions I wonder if the motor (if EFI) is running so lean that the pipes are baking with the blow torch in the pipe. If EFI - lets get an aftermarket computer to richen it up and see what happens. Better yet - find a shop with a dyno and a exhaust gas analyzer and see what the scoup is. This will tell you right away if the bike has a mixture issue.
 

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I just bought a prev-owned 03 Ultra and my right leg does get pretty warm While I'm waiting on the light to turn green but even on a warm day (Dallas) it's not so bad that it turns my leg red. It's EFI btw. On another note Buzglyd, what is your engine turning at 60 mph? I traded in a 91 and this one seems to spin a little faster at any given speed.
 
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