I just got an 03 Ultra Classic and there are a few things I'm not sure about....I've had a Dyna so I'm not used to or familiar with the classic at all.....1st when I let the clutch out in 1st gear it feels like there is a clunk or jerk before it catches...sort of hard to explain.....I'm thinking adjustment but I don't know the nature of these bikes...2nd..I have already burned my leg on the left side pipe..it gets really hot, I thought maybe I was running lean but spoke with a friend and apparently the guy that had the bike did some work to it, which he said will make it run hot..so the question is how well will heat tape or wrap work and then putting the heat shield back on..will there be room for air to still flow between them? If you guys can help I sure would appreciate it......other then these thing...this bike rides like a couch...love it.

 

You should not hear or feel a clunk when letting the clutch out. I would for sure check the primary chain adjustment. Also adjust the clutch.

 

My clutch is adjusted correctly and I feel a suerge when it fully engages - not an issue, but knowledge that it isn't slipping. Same with deceleration - I feel a slight surge when the RPM gets low. Normal for my bike. I wouldn't wrap the pipes at all; adjust the mixture to run a little more rich to reduce the heat.

 

That's was normal for my bike until the 107 kit and power commander. It used to drive me nuts. I think it was in the H-D map. Anyway, the surge is gone now and I'm a happy camper. Bike's a lot cooler too.

 

Probably a little lean surge when the throttle is all the way off. Add a little fuel at zero throttle position and I bet it goes away.

 

With regard to the clunk, I would adjust the clutch and the primary chain cam, also change the primary oil to make sure there isnt an automotive energy conserving oil with additives in there. Also check the year drive pully to rear hub and make sure not worn and ck the drive belt tension.

 

Thanks guys for all the suggestions! I have it schedualed for a Dyno next week...