Page 1

2006 BUELL ULYSSES SERVICE MANUAL Part Number 99494-06Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices


MAINTENANCE Table Of Contents

SUBJECT

PAGE NO.

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 Suspension Damping Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 Throttle Cable and Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 Interactive Exhaust Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-5 1-6 1-9 1-12 1-15 1-23 1-24 1-27 1-31 1-33 1-37 1-38 1-40 1-42 1-43 1-45 1-47 1-49 1-50 1-51

1


HOME

GENERAL

1.1

SERVICING A NEW MOTORCYCLE 1WARNING Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a) Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL. The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation. See 1.3 MAINTENANCE SCHEDULE for details.

SAFE OPERATING MAINTENANCE ●

NOTES Do not attempt to retighten engine head bolts. Retightening can cause engine damage. During the initial break-in period, use only Harley-Davidson 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings.

A careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, to determine if additional maintenance is required.

SHOP PRACTICES Repair Notes ●

NOTE General maintenance practices are given in this section.

Repair = Disassembly/Assembly.

Replace = Removal/Installation.

All special tools and torque values are noted at the point of use. All required parts or materials can be found in the appropriate PARTS CATALOG.

Safety Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don’t just do the job – do the job safely.

Removing Parts Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.

1WARNING

Check: 1.

Tires for abrasions, cuts and correct pressure.

2.

Secondary drive belt for condition.

3.

Brakes, steering and throttle for responsiveness.

4.

Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and rotors for wear.

5.

Cables for fraying, crimping and free operation.

6.

Engine oil and transmission fluid levels.

7.

Headlight, passing lamp, tail lamp, brake lamp and turn signal operation.

Always check the capacity rating and condition of hoists, slings, chains or cables before use. Failure to do so can lead to an accident which could result in death or serious injury. Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.

Cleaning If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, filters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to ensure satisfactory operation. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed. Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris. 2006 Buell Ulysses: Maintenance

1-1


HOME

Disassembly and Assembly

Bushings

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when finished. Be sure that everything is done.

Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings that must be replaced.

Operate the vehicle to perform any final check or adjustments. If all is correct, the vehicle is ready to go back to the customer.

REPAIR AND REPLACEMENT PROCEDURES Hardware and Threaded Parts Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding specified torque. Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable thread chaser.

When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, flat end. Never use a hammer to drive bushings. Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned.

Gaskets Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part.

Lip Type Seals Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications.

Use Teflon pipe sealant on pipe fitting threads.

Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement.

Wiring, Hoses and Lines

Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings.

Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications.

Always discard seals after removal. Do not use the same seal twice.

Instruments and Gauges

O-Rings (Preformed Packings)

Replace broken or defective instruments and gauges.

Always discard O-rings after removal. Replace with new Orings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.

Replace all damaged or missing lubrication fittings.

Bearings Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a non-flammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings. Coat bearings with clean oil. Wrap bearings in clean paper. Be sure that the chamfered side of the bearing always faces the shoulder (when bearings installed against shoulders). Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Install bearings with numbered side facing out. Always use the proper tools and fixtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary.

Gears Always check gears for damaged or worn teeth. Lubricate mating surfaces before pressing gears on shafts.

Shafts If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force. Shafts fitted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly. Clean all rust from the machined surfaces of new parts.

Part Replacement Always replace worn or damaged parts with new parts.

1-2

2006 Buell Ulysses: Maintenance


HOME

CLEANING

Hammers ●

Never strike one hammer against a hardened object, such as another hammer.

Always grasp a hammer handle firmly, close to the end.

Strike the object with the full face of the hammer.

Never work with a hammer which has a loose head.

Discard hammer if face is chipped or mushroomed.

Part Protection Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected.

Cleaning Process Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting.

Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted.

TOOL SAFETY

Wear approved eye protection when using striking tools.

Protect bystanders with approved eye protection.

Punches/chisels ●

Never use a punch or chisel with a chipped or mushroomed end; dress mushroomed chisels and punches with a file.

Hold a chisel or a punch with a tool holder if possible.

When using a chisel on a small piece, clamp the piece firmly in a vise and chip toward the stationary jaw.

Wear approved eye protection when using these tools.

Protect bystanders with approved eye protection.

Air Tools Screwdrivers

Always use approved eye protection equipment when performing any task using air-operated tools.

On all power tools, use only recommended accessories with proper capacity ratings.

Don’t use a screwdriver for prying, punching, chiseling, scoring or scraping.

Do not exceed air pressure ratings of any power tools.

Use the right type of screwdriver for the job; match the tip to the fastener.

Bits should be placed against work surface before air hammers are operated.

Don’t interchange POZIDRIV®, PHILLIPS® or REED AND PRINCE screwdrivers.

Disconnect the air supply line to an air hammer before attaching a bit.

Screwdriver handles are not intended to act as insulation; don’t use on live electrical circuits.

Never point an air tool at yourself or another person.

Protect bystanders with approved eye protection.

Don’t use a screwdriver with rounded edges because it will slip – redress with a file.

Wrenches

Ratchets and Handles ●

Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit.

Never cock a wrench.

Never use a hammer on any wrench other than a STRIKING FACE wrench.

Never hammer or put a pipe extension on a ratchet or handle for added leverage.

Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism.

When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet’s gear wheel is engaged with the pawl.

Never use an extension on a wrench handle.

If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go.

● ●

Discard any wrench with broken or battered points.

Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/cutters/prybars ●

Plastic- or vinyl-covered pliers handles are not intended to act as insulation; don’t use on live electrical circuits.

Don’t use pliers or cutters for cutting hardened wire unless they were designed for that purpose.

Always cut at right angles.

Don’t use any prybar as a chisel, punch or hammer.

2006 Buell Ulysses: Maintenance

1-3


HOME

Sockets ●

Never use hand sockets on power or impact wrenches.

Select the right size socket for the job.

Never cock any wrench or socket.

Select only impact sockets for use with air or electric impact wrenches.

Replace sockets showing cracks or wear.

Keep sockets clean.

Always use approved eye protection when using power or impact sockets.

Storage Units ●

Don’t open more than one loaded drawer at a time. Close each drawer before opening up another.

Close lids and lock drawers and doors before moving storage units.

Don’t pull on a tool cabinet; push it in front of you.

Set the brakes on the locking casters after the cabinet has been rolled to your work.

1-4

2006 Buell Ulysses: Maintenance


HOME

FUEL AND OIL FUEL

1.2 ENGINE OIL

1WARNING Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion. Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00028a) Use a good quality unleaded gasoline (91 pump octane or higher). Pump octane is the octane number usually shown on the gas pump.

GASOLINE BLENDS CAUTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage and/or equipment malfunction. (00148a) Buell motorcycles were designed to give the best performance using unleaded gasoline. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. ●

DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline/methanol blends will result in starting and driveability deterioration and damage to critical fuel system components.

DO NOT USE RACE GAS OR OCTANE BOOSTERS. Use of these fuels will damage the fuel system.

ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%.

REFORMULATED OR OXYGENATED GASOLINES (RFG): “Reformulated gasoline” is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline. Your motorcycle will run normally using this type of gas.

Use the proper grade of oil for the lowest temperature expected before the next oil change. If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include CF-4, CG-4, CH-4 and CI4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the first opportunity, see a Harley-Davidson dealer to change back to 100 percent Harley-Davidson oil. See 1.5 ENGINE LUBRICATION SYSTEM for all service information.

WINTER LUBRICATION Combustion in an engine produces water vapor. During starting and warm-up in cold weather, especially in freezing temperatures, the vapor condenses to water before the crankcase is hot enough to exhaust it through the breather system. If the engine is run long enough for the crankcase to become thoroughly heated, the water returns to vapor and is then exhausted. An engine used for only short trips, and seldom allowed to thoroughly warm up, accumulates increasing amounts of water in the oil reservoir. Water mixed with oil forms a sludge that causes accelerated engine wear. In freezing temperatures, the water becomes slush or ice, which may clog oil lines and result in engine failure. Always change the engine oil more often in winter. If the engine is used for short runs, change the oil even more frequently. The farther below freezing the temperature drops the more often the oil should be changed.

You may find that some gasoline blends adversely affect the starting, driveability or fuel efficiency of your bike. If you experience one or more of these problems, we recommend you try a different brand of gasoline or gasoline with a higher octane rating.

2006 Buell Ulysses: Maintenance

1-5


HOME

MAINTENANCE SCHEDULE

1.3

Table 1-1. Regular Service Intervals For Buell Ulysses ITEM SERVICED

1000 mi

5000 mi

10,000 mi

15,000 mi

20,000 mi

25,000 mi

1600 km

8000 km

16,000 km

24,000 km

32,000 km

40,000 km

PROCEDURE

NOTES

Engine oil and filter

Replace

X

X

X

X

X

X

Oil lines and brake system

Inspect for leaks

X

X

X

X

X

X

Air cleaner

Inspect, service as required

X

X

X

X

Replace

1

X X

Tires

Check pressure, inspect tread

X

Transmission lubricant

Replace

X

X

X

X

X

X

X

X

Clutch

Check adjustment

X

X

X

X

X

X

1

Primary chain

Check adjustment

X

X

X

X

X

X

1

Rear belt, idler and sprockets

Inspect

X

X

X

X

X

X

Throttle, brake, and clutch con- Check, adjust and lubricate trols, jiffy stand, active muffler cable and active intake cable adj. (if equipped)

X

X

X

X

X

X

1

Brake fluid

Check levels and condition

X

X

X

X

X

X

1,2

Brake pads and discs

Inspect for wear

X

X

X

X

X

X

Spark plugs

Replace

Electrical equipment and switches Check operation

X

X

X

X

X

X

Engine idle speed

Check adjustment

X

X

X

X

X

X

Ignition timing

Check

Throttle position sensor (TPS)

Zero

Front fork oil

Replace

Steering head bearings

Perform resistance test

Oil cooler fins

Clean

Brake system, oil lines, front forks, Inspect rear shock, exhaust system, exhaust system mounting, evaporative emission system (if applicable) Critical fasteners

X

X

X

1

X

X

1

X

X

1

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

1

X

X

Check tightness Verify component and system functions

1

X

Engine mounts and stabilizer links Inspect Road test

X

X

X

1

1

X X

1

1 X

NOTES: 1.

Should be performed by an authorized Harley-Davidson/Buell dealer, unless you have the proper tools, service data and are mechanically qualified.

2.

Change brake fluid every two (2) years.

1-6

2006 Buell Ulysses: Maintenance


HOME

Table 1-2. Quick Reference Maintenance Chart ITEM SERVICED Engine oil and filter

SPECIFICATION

DATA

Drain plug torque

Apply Loctite 565 Thread Sealant and reinstall plug and tighten to 29-34 ft-lbs (40-46 Nm)

Oil capacity

2.5 quarts (2.4 liters) and includes the 4.0 ounces (0.12 liter) poured into the filter

Filter

Hand tighten 1/2-3/4 turn after gasket contact

Black filter part number

63806-00Y

Deflection with hot engine

1/4-3/8 in. (6.4-9.5 mm)

Deflection with cold engine

3/8-1/2 in. (9.5-12.7 mm)

Chain tensioner nut torque

20-25 ft-lbs (27-34 Nm)

Primary chain inspection cover torque

84-108 in-lbs (10-12 Nm)

Lubricant capacity

FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05) as required until fluid level is even with bottom of clutch diaphragm spring

Primary chaincase drain plug torque

Apply Loctite 565 Thread Sealant and reinstall plug and tighten to 14-30 ft-lbs (19-41 Nm)

Free play at adjuster screw

clockwise 1/4-1/2 turn

Free play at hand lever

1/16-1/8 in. (1.6-3.2 mm)

Clutch inspection cover torque

84-108 in-lbs (10-12 Nm)

Transmission lubricant

Lubricant level

FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05) as required until fluid level is even with bottom of clutch diaphragm spring

Tire condition and pressure

Pressure for solo rider

Front: 36 psi (248 kPa) Rear: 38 psi (262 kPa)

Pressure for rider and passenger

Same as Solo

Wear

Replace tire if 1/32 in. (0.8 mm) or less of tread pattern remains

D.O.T. 4 hydraulic brake fluid part numbers

99953-99A (12 oz.) 99973-05 (gal.).

Proper fluid level

1/8 in. (3.2 mm) from the top

Master cylinder reservoir cover torque

9-13 in-lbs (1.0-1.5 Nm)

Brake pad linings and discs

Minimum brake pad thickness

0.040 in. (1.0 mm) or less

Minimum brake disc thickness

0.18 in. (4.5 mm) or less

Air cleaner

Air cleaner cover screw torque

12-36 in-lbs (4-4 Nm)

Primary chain tension

Primary chain lubricant

Clutch adjustment

Brake fluid reservoir level

2006 Buell Ulysses: Maintenance

1-7


HOME

Table 1-2. Quick Reference Maintenance Chart ITEM SERVICED Clutch and throttle cables

SPECIFICATION

DATA

Lubricant

LUBIT-8 TUFOIL® CHAIN AND CABLE LUBE (Part No. HD-94968-85TV)

Handlebar clamp screw torque

60-84 in-lbs (6.8-9.5 Nm)

Handlebar switch housing screw torque

25-33 in-lbs (3-4 Nm)

Type

10R12A

Gap

0.035 in. (0.9 mm)

Torque

12-18 ft-lbs (16-24 Nm)

Engine idle speed

Idle speed

1050-1150 RPM

Front fork oil

Type

HYDRAULIC FORK OIL (TYPE E) Part No. 99884-80 4.45 in. (113 mm) from the top of the fork tube

Battery

Lubricant

ELECTRICAL CONTACT LUBRICANT Part No. 99861-02 (1 oz.)

Battery terminal torque

72-96 in-lbs (8-11 Nm)

Spark plugs

1-8

2006 Buell Ulysses: Maintenance


HOME

BATTERY MAINTENANCE

1.4

GENERAL

BATTERY TESTING

Buell motorcycle batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.

Voltmeter Test

Inspect the battery for damage or leaks and for clean, noncorroded connections: â—?

At the 1000 mile (1600 km) service interval.

â—?

At every scheduled service interval thereafter.

1WARNING

Refer to Table 1-4. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100% fully charged condition. If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then recheck the voltage after the battery has set for one to two hours. If the voltage reading is 12.7V or above, perform the load test described under 7.11 BATTERY.

b1142x7x

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING A warning label is attached to the top of the battery. See Figure 1-1.Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in warning, could result in death or serious injury. (00064a)

1WARNING Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

Table 1-3. Battery Electrolyte Antidotes CONTACT

SOLUTION

External

Flush with water.

Internal

Drink large quantities of milk or water, followed by milk of magnesia, vegetable oil or beaten eggs. Call doctor immediately.

Eyes

Figure 1-1. Battery Warning Label

Flush with water, get immediate medical attention.

Table 1-4. Voltmeter Test For Battery Charge VOLTAGE (OCV)

STATE OF CHARGE

12.7

100%

12.6

75%

12.3

50%

12.0

25%

11.8

0%

2006 Buell Ulysses: Maintenance

1-9


HOME

BATTERY DISCONNECTION AND REMOVAL 1.

1WARNING

Remove seat. See 2.45 SEAT.

1WARNING Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2.

Unthread fastener and remove battery negative cable (black) from battery negative (-) terminal.

3.

Pull back terminal cover boot.

4.

Unthread fastener and remove battery positive cable (red) from battery positive (+) terminal.

5.

Unhook strap and remove battery.

CLEANING AND INSPECTION 1.

STORAGE

Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. Clean battery top with a solution of baking soda (sodium bicarbonate) and water (5 teaspoons baking soda per quart or liter of water). When the solution stops bubbling, rinse off the battery with clean water.

2.

Clean cable connectors and battery terminals using a wire brush or sandpaper. Remove any oxidation.

3.

Inspect the battery screws, clamps and cables for breakage, loose connections and corrosion. Clean clamps.

4.

Check the battery posts for melting or damage caused by overtightening.

5.

Inspect the battery for discoloration, raised top or a warped or distorted case, which might indicate that the battery has been frozen, overheated or overcharged.

6.

Inspect the battery case for cracks or leaks.

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a) CAUTION Do not allow battery to completely discharge. The electrolyte in a discharged battery will freeze. The more discharged a battery is, the more easily it can freeze and crack the battery case. (00218a) If the motorcycle will not be operated for several months, such as during the winter season, remove the battery from the motorcycle and fully charge. See 7.11 BATTERY. See Figure 1-2. Self-discharge is a normal condition and occurs continuously at a rate that depends on the ambient temperature and the battery’s state of charge. Batteries discharge at a faster rate at higher ambient temperatures. To reduce the self-discharge rate, store battery in a cool (not freezing), dry place. Charge the battery every month if stored at temperatures below 60˚ F. (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F. (16˚ C). NOTE The H-D Battery Tender Automatic Battery Charger (Part No. 99863-93TA) may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling. When returning a battery to service after storage, fully charge the battery. See 7.11 BATTERY.

Effect of Temperature on Battery Self-Discharge Rate

f1732x8x

100 %

75%

50 %

C A P A C I T Y

at 77°F at 105°F

M O N T H S O F S TA N D 0

3

6

9

12

Figure 1-2. Battery Self-Discharge Rate

1-10

2006 Buell Ulysses: Maintenance

15


HOME

BATTERY INSTALLATION AND CONNECTION 1.

Place the fully charged battery in the mounting position, terminal side to the rear of motorcycle.

2.

Hook rubber strap around body of battery. CAUTION

Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical system. (00215a)

1WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) CAUTION Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a) 3.

Insert fastener through battery positive cable (red) into threaded hole of battery positive (+) terminal and tighten fastener to 72-96 in-lbs (8-11 Nm).

4.

Install terminal cover boot.

5.

Insert fastener through battery negative cable (black) into threaded hole of battery negative (-) terminal and tighten fastener to 72-96 in-lbs (8-11 Nm).

6.

Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.

1WARNING After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 7.

Install seat. See 2.45 SEAT.

2006 Buell Ulysses: Maintenance

1-11


HOME

ENGINE LUBRICATION SYSTEM

1.5

GENERAL

3.

The engine oil level can be checked with the oil and engine at ambient temperatures (cold check).

NOTE The area between the upper and lower registration marks is the operating range.

However, an accurate reading of the engine oil level can only be taken with the engine at normal operating temperature (hot check). Ride motorcycle for approximately 10 minutes to warm the oil and the engine to normal operating temperature.

Insert dipstick into oil tank filler hole, screwing dipstick in completely. DO NOT OVER TIGHTEN.

4.

See Figure 1-4. Unscrew and remove dipstick and read oil level.

5.

If the level is below the lower registration mark, add only enough oil to bring oil level between lower and upper registration marks.

NOTE The engine will require a longer warm up period in colder temperatures. Whether a cold or a hot check, the procedure is the same.

11107

During the pre-ride inspection: ●

Check for oil leaks from the oil filter and oil lines.

Check the engine oil level (cold check).

At every fueling stop: ●

Check engine oil level (hot check).

Change engine oil and filter: ●

At scheduled maintenance intervals.

When storing the motorcycle.

When removing the motorcycle from storage.

NOTE The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained more frequently. Figure 1-3. Dipstick Location/Engine Oil Level

ENGINE OIL LEVEL CHECK CAUTION

11500

Do NOT operate the engine when the oil level is below the add mark on the dipstick at operating temperature. Engine damage will result. (00187a) CAUTION Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and or equipment malfunction. (00190a) CAUTION Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a) 1.

The motorcycle must be on level ground, on the sidestand, with the engine off.

2.

See Figure 1-3. Unscrew and remove dipstick from oil tank/swingarm filler hole. Wipe dipstick clean.

1-12

2006 Buell Ulysses: Maintenance

2

1. 2.

1

Upper registration mark Lower registration mark Figure 1-4. Dipstick Oil Level Registration Marks


HOME

ENGINE OIL AND FILTER CHANGE

12036

Drain Oil 1.

Ride motorcycle for 10 minutes to warm oil to operating temperature. Turn engine off.

2.

See Figure 1-5. Place a container under the drain plug on the bottom left side of the oil tank/swingarm.

3.

Using a 5/8 in. wrench, remove drain plug from under oil tank/swingarm.

4.

Wipe debris from magnetic tip on drain plug.

5.

See Figure 1-6. Unscrew and remove dipstick from oil fill hole on top of oil tank/swingarm. Figure 1-5. Oil Tank Drain Plug

Change Filter 1.

Remove chin fairing See 2.38 CHIN FAIRING.

2.

See Figure 1-7. Remove oil filter using pliers or belt type OIL FILTER WRENCH.

3.

Clean filter gasket contact surface on crankcase. Surface must be smooth and free of debris or old gasket material.

4.

Apply a thin film of clean engine oil to filter gasket.

5.

Pour 4.0 ounces (0.12 liter) of clean engine oil into new filter (until filter is approximately 1/2 full).

6.

Screw filter onto adapter until filter gasket touches crankcase surface.

7.

By hand, turn filter an additional 1/2 to 3/4 turn.

11107

1WARNING Check that no lubricant gets on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047b)

Figure 1-6. Dipstick

11108

Figure 1-7. Oil Filter

2006 Buell Ulysses: Maintenance

1-13


HOME

Fill Engine with Oil 1.

Inspect drain plug o-ring for tears or damage. Replace if required. Wipe any foreign material from drain plug.

2.

Apply Loctite 565 Thread Sealant, install plug and tighten to 29-34 ft-lbs (40-46 Nm).

3.

Fill oil tank through filler (dipstick) hole with recommended oil from Table 1-5.

NOTE Oil tank capacity with filter change is approximately 2.5 quarts (2.4 liters) and includes the 4.0 ounces (0.12 liter) poured into the filter. Always verify proper hot oil level on dipstick. Do not overfill. 4.

Inspect o-ring on dipstick for rips or tears. Replace as required.

NOTE For ease of installation, apply a light film of clean engine oil to the dipstick o-ring. 5.

Install dipstick into oil tank/swingarm fill hole. Make sure dipstick is installed completely. DO NOT OVER TIGHTEN.

6.

Remove left side oil cooler scoop. See 2.40 AIR SCOOPS.

Table 1-5. Recommended Oil Grades VISCOSITY

HARLEYDAVIDSON RATING

LOWEST AMBIENT TEMP °F

COLD WEATHER STARTS BELOW 50° F (10° C)

H.D. Multi-Grade

SAE 10W40

HD 360

Below 40° (4°C)

Excellent

H.D. Multi-Grade

SAE 20W50

HD 360

Above 40° (4°C)

Good

H.D. Regular Heavy

SAE 50

HD 360

Above 60° (16°C)

Poor

H.D. Extra Heavy

SAE 60

HD 360

Above 80° (27°C)

Poor

HARLEY-DAVIDSON TYPE

8772a

1WARNING Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) 7.

See Figure 1-8. Blow out any debris from fins with compressed air from the inside of the oil cooler outward. Inspect cooler fins for debris or damage.

8.

Wipe up any spilled oil on muffler.

9.

Start engine. Verify that oil pressure signal light on instrument support turns off after a few seconds when engine speed is 1000 RPM or above.

10. Check for oil leaks at oil filter, drain plug, hoses and oil cooler. 11. Install chin spoiler. See 2.38 CHIN FAIRING. 12. Install air scoop 2.40 AIR SCOOPS. 13. Check (hot) oil level. See ENGINE OIL LEVEL Check.

1-14

2006 Buell Ulysses: Maintenance

Figure 1-8. Inside of Oil Cooler


HOME

BRAKE SYSTEM MAINTENANCE GENERAL

1WARNING

Check brake fluid level and condition: ●

When storing or removing the motorcycle for the season:

Replace D.O.T. 4 BRAKE FLUID. ●

Every 2 years:

Front brake hand lever and rear brake foot pedal must have a firm feel when brakes are applied. If not, bleed system as described. Inspect front and rear brake lines and replace as required. ●

Every 4 years:

Inspect caliper and master cylinder seals and replace as required. ●

1.6

Use only fresh, uncontaminated D.O.T. 4 fluid. Cans of fluid that have been opened may have been contaminated by moisture in the air or dirt. Use of contaminated brake fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury

1WARNING Use only new copper crush banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier silver banjo washers are not compatible with D.O.T. 4 fluid and will not seal properly over time. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury.

1WARNING

Every 2 years:

If determining probable causes of poor brake operation, refer to Table 1-6.

BLEEDING BRAKES 1CAUTION Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

1WARNING Never mix D.O.T. 4 with other brake fluids (such as D.O.T. 5). Use only D.O.T. 4 brake fluid in motorcycles that specify D.O.T. 4 fluid on the reservoir cap. Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury.

Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury. (00291a)

1WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) CAUTION D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239a)

2006 Buell Ulysses: Maintenance

1-15


HOME

Table 1-6. Brake Troubleshooting CONDITION

CHECK FOR

REMEDY

Excessive lever/pedal travel or spongy feel.

Air in system.

Bleed brake(s).

Master cylinder low on fluid.

Fill master cylinder with approved brake fluid.

Brake fade

Moisture in system.

Bleed brake(s). Replace fluid in master cylinder with approved brake fluid.

Chattering sound when brake is applied.

Worn pads.

Replace brake pads.

Worn D shape bushings

Replace rotor and bushings as set.

Loose mounting bolts.

Tighten bolts.

Warped rotor.

Replace rotor and bushings as set.

Low fluid level.

Fill master cylinder with approved brake fluid, and bleed system.

Piston cup not functioning.

Rebuild cylinder.

Ineffective brake – lever/pedal travel normal.

Distorted or glazed rotor.

Replace rotor and bushings as set.

Distorted, glazed or contaminated brake pads.

Replace pads.

Brake pads drag on rotor – will not retract.

Cup in master cylinder not uncovering relief port.

Inspect master cylinder.

Rear brake pedal linkage out of adjustment.

Adjust linkage.

Ineffective brake – lever/pedal travels to limit.

1-16

2006 Buell Ulysses: Maintenance


HOME

Bleed Front Brake

11136

NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pressurization. 1.

See Figure 1-9. With motorcycle upright, install end of plastic tubing over front caliper bleeder valve and place other end in a clean container.

CAUTION D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239a) 2.

Cover body surfaces, right handlebar switches and instrument panel to protect from spillage.

3.

See Figure 1-10. Remove two fasteners and reservoir cap, stiffener and diaphragm.

4.

Repeat the following steps until all air bubbles are purged and brake fluid flows from the plastic tubing. a.

Figure 1-9. Front Caliper Bleeder Valve (cap removed)

11147

See Figure 1-11. With motorcycle upright, add D.O.T. 4 BRAKE FLUID to master cylinder reservoir until the level matches level indicator in reservoir. NOTE

Do not reuse brake fluid. b.

Slowly squeeze and release brake lever several times to build up hydraulic pressure, then squeeze or apply pressure to brake lever.

c.

Open bleeder valve about 1/2-turn counterclockwise. Brake fluid will flow from bleeder valve and through tubing into container.

d.

When brake lever has moved 1/2 to 3/4 of its range of travel, close bleeder valve (clockwise).

e.

Allow brake lever to return slowly to its released position.

5.

Tighten front caliper bleeder valve (metric) to 36-60 inlbs (4-7 Nm).

6.

Verify fluid level at reservoir indicator.

7.

Install diaphragm, stiffener and cap to front master cylinder reservoir and tighten fasteners to 9-13 in-lbs (1.01.5 Nm).

8.

Remove protective cover from molded-in-color surfaces, right handlebar switches and instrument panel.

Figure 1-10. Fasteners, Cap, Stiffener and Diaphragm

11142

Figure 1-11. Reservoir Fluid Level Indicator 2006 Buell Ulysses: Maintenance

1-17


HOME

Bleed Rear Brake

11125

NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pressurization. 1.

See Figure 1-12. Remove rubber cap and install end of plastic tubing over rear caliper bleeder valve and place other end of tubing in a clean container.

CAUTION D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239a) 2.

See Figure 1-13. Unscrew cap from rear master cylinder reservoir.

3.

Repeat the following until all air bubbles are purged and only brake fluid flows from the plastic tubing. a.

With motorcycle upright, add D.O.T. 4 BRAKE FLUID to master cylinder reservoir until the level is between upper and lower marks on reservoir.

Figure 1-12. Rear Caliper Bleeder Valve

11124a

NOTE Do not reuse brake fluid. b.

Slowly depress and release brake pedal several times to build up hydraulic pressure, then hold brake pedal in the depressed position.

c.

While holding brake pedal in the depressed position, open bleeder valve about 1/2-turn counterclockwise. Brake fluid will flow from bleeder valve and through tubing into container.

d.

When brake pedal has moved 1/2 to 3/4 of its range of travel, close bleeder valve (clockwise).

e.

Allow brake pedal to return slowly to its released position.

4.

Tighten rear caliper bleeder valve to 36-60 in-lbs (47 Nm) and replace the rubber cap.

5.

Verify brake fluid level is between the upper and lower lines on the side of the reservoir.

6.

Thread cap on reservoir and tighten securely.

1-18

2006 Buell Ulysses: Maintenance

Figure 1-13. Rear Master Cylinder Reservoir


HOME

BRAKE PEDAL ADJUSTMENT

b1175x1x

1WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Before every ride, check rear brake pedal operation. NOTES â—?

â—?

See Figure 1-14. On the very end of the threaded brake rod, are two flat sides (2). To ensure thread engagement with the clevis (3), the flat sides must extend below the extruded nut (1) in the clevis by at least one full thread. This is the minimum brake rod engagement (4).

4

1 2

Also, there should be a minimum of 0.030 in. (0.8 mm) clearance (6) between brake rod end and brake pedal (6). This is the maximum brake rod engagement. (5)

5 3

1WARNING Threaded rod should not be adjusted to the point of contacting brake pedal. Improper adjustment could result in death or serious injury. 1.

2.

See Figure 1-15. Inspect for minimum and maximum brake rod engagement in brake clevis (4). Adjust as required. To adjust brake pedal: a.

See Figure 1-15. Loosen locknut (3) while holding rod adjuster (2). Move locknut away from top surface of clevis (4).

b.

Turn rod adjuster to set pedal height.

c.

Thread locknut (3) flush against top surface of clevis and tighten to 130-173.5 in-lbs (14.7-19.6 Nm).

6 1. 2. 3. 4. 5. 6.

Extruded nut Flat sides (on the end of the threaded brake rod) Clevis Minimum brake rod engagement Maximum brake rod engagement 0.030 in. (0.8 mm) clearance Figure 1-14. Brake Rod Engagement

11138

NOTE Brake pedal has no free play adjustment.

1 2

3 4 5

1. 2. 3. 4. 5.

Master cylinder Rod adjuster Locknut Clevis Clevis pin

Figure 1-15. Rear Brake Pedal Pushrod Adjustment

2006 Buell Ulysses: Maintenance

1-19


HOME

BRAKE PADS

7082

3

1WARNING Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

1

See Figure 1-16. Inspect both front and rear brake pads for wear and damage. If the friction material (1) of a pad is worn past the wear grooves (2) or if a pad is damaged, replace both pads as a set.

2

NOTE Wear grooves (2) disappear if friction material is worn to 0.040 in. (1.0 mm) or less.

BRAKE ROTORS 1WARNING

4 1. 2. 3. 4.

Friction material Wear groove Backing material Pad set

Check that no lubricant gets on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047b) See Figure 1-17. and Figure 1-18. Inspect and measure both front and rear brake rotors: ●

At the 1000 mile (1600 km) service interval.

At every 5000 mile (8000 km) service interval thereafter.

At every scheduled service interval:

1.

Inspect rotor. Replace rotor if warped or badly scored.

2.

Measure rotor thickness. Replace rotor if minimum thickness is less than 0.18 in. (4.5 mm).

Figure 1-16. Brake Pads

8347 8347

NOTE See 2.5 FRONT WHEEL or 2.6 REAR WHEEL for rotor replacement procedure. 3.

Figure 1-17. Front Brake Rotor

Whenever rotor is replaced, replace rotor drive bushings, fasteners, washers and springs.

8347 8347

Figure 1-18. Rear Brake Rotor

1-20

2006 Buell Ulysses: Maintenance


HOME

BRAKE PAD REPLACEMENT

8346

1

Front Pad Removal 1.

See Figure 1-19. Loosen pin hanger under pin hanger plug (3) but do not remove.

2.

Rotate wheel so that caliper is centered between rotor mounting fasteners (1).

3.

Remove lower caliper mounting fastener (4) that secures caliper to fork lower.

4.

Loosen but do not remove upper caliper mounting fastener (2) that secures caliper to fork lower.

5.

Remove pin hanger under pin hanger plug (3).

6.

Rotate caliper counterclockwise to allow access to outer pad.

7.

Remove outer pad from right side.

8.

Remove inner pad from left side by pulling rearward, rotating pad 90 degrees and pulling through wheel opening.

3

Front Pad Installation 1.

Remove front master cylinder reservoir cover.

NOTE As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 inch (3.2 mm) and overflow the reservoir. Watch the fluid level as the pistons are retracted and remove fluid from the reservoir if necessary. 2.

Push pistons in with suitable tool such as a clean paint scraper until fully seated in bores. Be careful not to damage rotor.

3.

Install new inner pad from left side of motorcycle.

4.

Install new outer pad from right side of motorcycle.

5.

See Figure 1-19. Install pin under pin hanger plug (3) making sure it engages hole on both pads and spring clip.

6.

Rotate caliper clockwise to align mounting fastener hole.

7.

See Figure fastener (4).

8.

Apply LOCTITE 272 and tighten both caliper mounting fasteners (2, 4) to 35-37 ft-lbs (48-50 Nm).

9.

Tighten pin under (3) to 11-14 ft-lbs (15-19 Nm).

1-19.

Install

lower

caliper

2

4

1. 2. 3. 4.

Figure 1-19. Front Brake Caliper

6487

3

mounting

2

10. Install pin plug (3). Tighten plug to 18-25 in-lbs (23 Nm). 11. Check fluid level and reinstall front master cylinder reservoir cover and tighten screws to 9-13 in-lbs (1-1.5 Nm). NOTE Avoid making hard stops for the first 100 miles (160 km) to allow new brake pads to “wear in� properly with the rotor.

Rear Pad Removal 1.

See Figure 1-22. Remove rear caliper pin plug (4) and loosen pin (3).

2.

Remove two mounting fasteners (1) securing brake caliper and carrier assembly to swingarm.

3.

Lift caliper and carrier assembly up and off of rotor.

4.

Remove pin hanger (3).

5.

Remove inner and outer pads, being careful not to dislodge pad spring.

Rotor mounting fastener (6) Upper caliper mounting fastener (behind fender) Front caliper pin plug Lower caliper mounting fastener

1 1. 2. 3. 4.

Rear caliper mounting fasteners Retainer Rear caliper pin plug Rear caliper hanger pin Figure 1-20. Rear Brake Caliper

2006 Buell Ulysses: Maintenance

1-21


HOME

Rear Pad Installation 1.

6487

Remove rear master cylinder reservoir cover.

NOTE As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 inch (3.2 mm) and overflow the reservoir. Watch the fluid level as the pistons are retracted and remove fluid from the reservoir if necessary. 2.

See Figure 1-22. Check that retainer (2) is present.

3.

See Figure 1-23. Check that pad spring is present. Should pad spring become dislodged, install with widest area of spring towards piston side of caliper.

4.

Push piston in with suitable tool such as a clean paint scraper until fully seated in bore.

5.

Install new inner and outer brake pads

6.

See Figure 1-22. Install hanger pin (4) making sure pin engages hole on both pads.

7.

Install brake caliper and carrier assembly over rotor.

8.

Apply LOCTITE 272 and install two mounting fasteners (1) through swingarm into carrier and tighten to 24-26 ftlbs (32.5-35 Nm).

9.

Figure 1-21. Rear Brake Pad Spring Location

b1143x1x

4 3

Tighten hanger pin to 11-14 ft-lbs (14.9-18.9 Nm).

10. Install pin plug (3). Tighten plug to 18-25 in-lbs (23 Nm). 11. Install fastener securing p-clamp and brake line assembly to swingarm and tighten to 36-60 in-lbs (4.1-6.8 Nm). 12. Check fluid level and re-install rear master cylinder reservoir cover.

2

NOTE Avoid making hard stops for the first 100 miles (160 km) to allow new brake pads to “wear in� properly with the rotor.

1

1. 2. 3. 4.

Rear caliper mounting fasteners Retainer, Rear caliper pin hanger Rear caliper pin plug Figure 1-22. Rear Brake Caliper

6487

Figure 1-23. Rear Brake Pad Spring Installed 1-22

2006 Buell Ulysses: Maintenance


HOME

TIRES AND WHEELS

1.7

TIRE INFLATION

bearing to fly apart, which could result in death or serious injury. Check front and rear wheel bearings for wear:

1WARNING Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a)

1WARNING Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

Every time a wheel is removed.

When storing or removing the motorcycle for the season.

Check wheel bearings for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only.

12112

Check tire pressure and tread: Before every ride.

Check for proper front and rear tire pressures when tires are cold. Compare pressure against Table 1-7.

Table 1-7. Tire Pressures TIRE

PRESSURE FOR SOLO RIDING

Front

36 PSI

248 kPa

Rear

38 PSI

262 kPa

Dunlop

PRESSURE AT GVWR Same as solo riding

Wear indicator bars 11231

TIRE REPLACEMENT See Figure 1-24. Treadwear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire tread remains. Arrows on tire sidewalls pinpoint location of wear bar indicators. Always remove tires from service before they reach the treadwear indicator bars (1/32 in. [0.8 mm] tread pattern depth remaining). New tires are needed if any of the following conditions exist. 1.

Tire wear indicator bars become visible on the tread surfaces.

2.

Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

3.

A bump, bulge or split in the tire.

4.

Puncture, cut or other damage to the tire that cannot be repaired.

Wear indicator sidewall arrow Figure 1-24. Tire Wear Indicators

WHEEL BEARINGS 1WARNING Never use compressed air to “spin-dry” bearings. Very high bearing speeds can damage unlubricated bearings. Spinning bearings with compressed air can also cause a 2006 Buell Ulysses: Maintenance

1-23


HOME

CLUTCH

1.8

GENERAL

12045

Transmission fluid capacity is approximately 1.0 quart (0.95 liter). For best results, drain fluid while hot.

TRANSMISSION FLUID 1.

When the engine reaches normal operating temperature, turn the engine off and position motorcycle on jiffy stand. this will allow the chaincase lubricant to drain out of the transmission. CAUTION

When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a) 2.

See Figure 1-26. Position a suitable container under drain plug. Remove plug and drain fluid.

3.

Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be drained from clutch compartment and will prevent chaincase lubricant from draining out of clutch cover opening when refilled.

4.

Wipe any foreign material from the magnetic drain plug and apply LOCTITE 565 THREAD SEALANT. Reinstall plug and tighten to 14-30 ft-lbs (19-4 0.6 Nm).

5.

Remove three fasteners and washers from clutch inspection cover. Remove clutch inspection cover with gasket from primary cover.

Figure 1-25. Clutch Inspection Cover

12046

CAUTION Do not overfill the primary chaincase/transmission with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)

Figure 1-26. Primary Drain Plug

b1144x1x

IMPORTANT NOTE Make certain primary chaincase is filled with proper amount of lubricant with motorcycle upright. If under filled, transmission can be damaged during vehicle operation. 6.

3 2

See Figure 1-27. Add FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05) as required until fluid level is even with bottom of clutch diaphragm spring (2).

7.

Install new clutch cover gasket.

8.

See Figure 1-25. Install clutch inspection cover tightening three fasteners and washers to 84-108 in-lbs (1012 Nm).

9.

Clean up any fluid that may have spilled on muffler.

4

1

NOTE Each time the clutch inspection cover is removed the gasket must be replaced.

1. 2. 3. 4.

Clutch diaphragm spring Clutch adjusting screw Primary cover Correct chaincase lubricant level Figure 1-27. Fluid Level

1-24

2006 Buell Ulysses: Maintenance


HOME

ADJUSTMENT

8411

If clutch slips under load or drags when released, first check control cable adjustment. If cable adjustment is within specifications, adjust clutch mechanism as described below.

1 2

When necessary, lubricate cable with LUBIT-8 TUFOILÂŽ CHAIN AND CABLE LUBE (Part No. HD-94968-85TV). 1.

Position the vehicle upright and level. This will prevent lubricate from draining out when clutch inspection cover is removed.

2.

See Figure 1-28. Slide rubber boot (1) upward to expose adjuster mechanism. Loosen jam nut (3) from adjuster (4). Turn adjuster to shorten cable housing until there is a large amount of free play at clutch hand lever.

3.

See Figure 1-25. Remove three fasteners and washers from clutch inspection cover. Remove clutch inspection cover and gasket from primary cover.

4.

See Figure 1-29. Remove spring (1) and lockplate (2). Using a flat tip screwdriver, turn adjusting screw (3) counterclockwise until it lightly bottoms.

5.

Turn adjusting screw clockwise 1/4-1/2 turn. Install lockplate and spring on adjusting screw flats. If hex on lockplate does not align with recess in outer ramp, rotate adjusting screw clockwise until it aligns.

3

4

1. 2. 3. 4.

Rubber boot Cable end Jam nut Adjuster Figure 1-28. Clutch Cable Adjuster Mechanism

NOTE Spring installs on outboard side of hex lockplate. 8405

2

3

1

1. 2. 3.

Diaphragm spring Lockplate Adjusting screw Figure 1-29. Clutch Adjustment (Typical

2006 Buell Ulysses: Maintenance

1-25


HOME 6.

Squeeze clutch hand lever to maximum limit three times. This sets the ball and ramp mechanism. Pull outer cable conduit and at the same time adjust cable adjuster to provide 1/16-1/8 in. (1.6-3.2 mm) free play at clutch hand lever. Adjust as follows: a.

See Figure 1-30. Pull ferrule (end of cable housing) away from bracket. Gap between ferrule and bracket should be 1/16-1/8 in. (1.6-3.2 mm).

b.

See Figure 1-28. Set free play by turning adjuster (4).

c.

Tighten jam nut (3) against adjuster (4).

d.

Slide boot (1) over cable adjuster mechanism.

7.

b0289x6x

1/16-1/8 in. (1.6-3.2 mm)

Ferrule Bracket

Change or add transmission fluid if necessary.

NOTE Each time the clutch inspection cover is removed the gasket must be replaced. 8.

See Figure 1-25. Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm).

1-26

2006 Buell Ulysses: Maintenance

Figure 1-30. Adjusting Clutch Free Play


HOME

DRIVE BELT GENERAL The drive belt tension on a new belt will loosen after approximately 1000 mi (1600 km). The drive belt tension is automatically adjusted by the idler pulley. Axle alignment is not adjustable. Inspect drive belt and idler pulley assembly: ●

1.9 Drive Belt Refer to Table 1-8. Inspect drive belt for: ●

Cuts or unusual wear patterns on both sides of belt.

Outside edge bevelling. Some bevelling is common, but it indicates that sprockets are misaligned.

Outside surface for signs of stone puncture. If cracks/ damage exists near edge of belt, replace belt immediately. Damage to center of belt will require belt replacement eventually, but when cracks extend to edge of belt, belt failure is imminent.

Inside (toothed portion) of belt for exposed tensile cords (normally covered by facing fabric). This condition will result in belt failure and indicates worn transmission sprocket teeth. Replace belt and transmission sprocket.

Signs of puncture or cracking at the base of the belt teeth. Replace belt if either condition exists.

At every 5,000 mile (8,000 km) service interval.

INSPECTION Rear Sprocket NOTE If gouges to rear sprocket are large enough to be harmful, they will leave a pattern on the belt face. 1.

2.

Inspect each tooth of rear sprocket for:

Idler Pulley

a.

Major tooth damage.

b.

Coating chips larger than 1/4 in. (6.35 mm) missing or removed.

c.

Gouges caused by hard objects.

See Figure 1-31. Inspect idler pulley for signs of uneven wear. Excessive lateral side play of 0.020 in. (0.5 mm) or roughness indicates worn bearings. Replace idler pulley as an assembly. See 6.6 DRIVE BELT SYSTEM.

Replace rear sprocket if major tooth damage or loss of coating in an area 1/4 in. (6.35 mm) or larger occurs. 10124

Figure 1-31. Checking Lateral Side Play on Idler Pulley with a Dial Indicator

CLEANING Keep dirt, grease, oil, and debris off the belt, idler pulley and sprockets. Clean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. Do not immerse belt in solution. Do not direct pressurized water on belt.

2006 Buell Ulysses: Maintenance

1-27


HOME

Table 1-8. Potential Limits to Belt Drive Service Life CONDITION

ROOT CAUSE

REQUIRED ACTION

Misalignment or bent drive structure

Check structure (bad bearing, bent members, etc.)

Bent or rough flange

Repair flange/replace sprocket

Damage due to handling (pry on, etc.)

Follow proper handling/installation procedure Inspect/replace belt

Debris damage to edge of belt Inspect for damaged or missing guards Check structure (bad bearing, bent members, etc.) Excessive Edge Wear (mistracking)

Belt hitting obstruction

Inspect for loose/missing fasteners Inspect for damaged or missing guards Replace idler assembly

Bent or loose idler bracket Inspect for loose/missing fasteners Check structure (bad bearing, bent members, etc.) Broken or loose guards

Inspect for loose/missing fasteners Inspect for damaged or missing guards

Excessive tooth wear NOTE The drive belt tension on a new belt will loosen after approximately 1000 mi (1600 km)

Rough or damaged sprocket

Inspect/replace sprocket

Worn sprocket

Inspect/replace sprocket Clean and protect drive

Debris in sprocket Inspect for damaged or missing guards Eliminate or control exposure Abrasive environment Inspect for damaged or missing guards Worn sprocket

Inspect/replace sprocket Clean and protect drive

Debris in sprocket Inspect for damaged or missing guards Apparent belt stretch

Idler bearing failure

Replace idler assembly

Aggressive riding/hard use

Riding practice/operator choice Eliminate or control exposure

Exposure to oils, solvents, harsh chemicals Clean and protect drive Idler/bearing binding

Replace idler assembly Eliminate or control exposure

Exposure to oils, solvents, harsh chemicals Clean and protect drive Cracks in back of belt

Inspect/replace sprocket Cut by sharp debris (not at belt edge) Continue to run but monitor condition frequently Inspect/replace sprocket Cut by sharp debris at belt edge Inspect/replace belt

1-28

2006 Buell Ulysses: Maintenance


HOME

Table 1-8. Potential Limits to Belt Drive Service Life CONDITION

ROOT CAUSE

REQUIRED ACTION Inspect/replace belt

Excessive load/shock load Riding practice/operator choice Worn sprocket

Inspect/replace sprocket Inspect/replace sprocket

Tooth shear/cracks Clean and protect drive Debris damage

Inspect/replace belt Continue to run but monitor condition frequently Inspect for damaged or missing guards Inspect/replace belt

Excessive load/Shock load Riding practice/operator choice Damage due to handling (pry-on, etc.)

Follow proper handling/installation procedure

Belt breakage Inspect/replace sprocket Debris in sprocket or belt

Clean and protect drive Inspect/replace belt Inspect/replace sprocket

Worn/damaged sprocket Missing/damaged belt guards Damaged flange

Repair flange/replace sprocket Check structure (bad bearing, bent members, etc.)

Damaged idler Replace idler assembly Follow proper handling/installation procedure Damaged belt Inspect/replace belt Excessive drive noise

Inspect/replace sprocket Clean and protect drive Debris stuck in belt Inspect/replace belt Missing/damaged belt guards Inspect/replace sprocket Follow proper handling/installation procedure Debris stuck in sprocket Inspect/replace belt Missing/damaged belt guards

2006 Buell Ulysses: Maintenance

1-29


HOME

NOTES

1-30

2006 Buell Ulysses: Maintenance


HOME

PRIMARY CHAIN INSPECTION

1.10 12047

See Figure 1-32. Measure primary chain tension through the inspection cover opening. Adjust primary chains not meeting vertical free play specifications. 1.

See Figure 1-32. Remove two fasteners with captive washers and primary chain inspection cover with gasket from primary cover.

2.

See Figure 1-33. Check primary chain tension by measuring vertical free play.

3.

a.

Measure vertical free play through chain inspection cover opening.

b.

Rotate engine to move primary chain to a different position on sprockets.

c.

Measure vertical free play several times, each time with primary chain moved so that the measurement is taken with sprockets rotated to the tightest chain position.

The tightest measurement taken in Step 2 must be within the specifications listed in Table 1-9. If necessary, adjust as described under 1.10 PRIMARY CHAIN in ADJUSTMENT.

Figure 1-32. Primary Chain Inspection Cover

b0085a6x

NOTE The initial primary chain vertical free play specification used at the assembly plant is 1/4-1/2 in. (6.4-12.7 mm) with a cold engine. The 1/4 in. (6.4 mm) minimum is only allowed at the absolute tightest point in the drive, as measured with specialized factory equipment. If a chain has less than 1/4 in. (6.4 mm) vertical free play (with a cold engine), adjust free play to the “field” specification of 3/8-1/2 in. (9.5-12.7 mm). The looser specification will avoid overtightening, which might otherwise occur during adjustment using “non-factory” equipment and methods. 4.

See Figure 1-32. Install primary chain inspection cover and new gasket to primary cover using two fasteners with captive washers. Tighten fasteners to 84-108 in-lbs (10-12 Nm).

Figure 1-33. Measuring Primary Chain Free Play

Table 1-9. Primary Chain Free Play ENGINE TEMPERATURE

in.

mm

Cold

3/8-1/2

9.5-12.7

Hot (normal running temperature)

1/4-3/8

6.4-9.5

2006 Buell Uylsses: Maintenance

1-31


HOME

ADJUSTMENT

8403

NOTE If vertical free play cannot be set within the limits specified, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary. See 6.5 PRIMARY CHAIN. 1.

2

1

See Figure 1-34. Loosen locknut (1).

2.

Turn adjusting fastener (2): a.

Clockwise (inward) to reduce free play.

b.

Counterclockwise (outward) to increase free play.

3.

Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm).

1. 2.

Locknut Adjusting Fastener Figure 1-34. Chain Tension Adjusting Fastener

1-32

2006 Buell Uylsses: Maintenance


HOME

SUSPENSION DAMPING ADJUSTMENTS GENERAL

1WARNING 1WARNING

Before evaluating and adjusting suspension settings, check the motorcycle’s tires. Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Buell dealer for replacements. Riding with excessively worn, unbalanced or underinflated tires can adversely affect stability and handling, which could result in death or serious injury. (00114a) Make all suspension adjustments in one or two click increments. Adjusting more than one or two clicks at a time may cause you to skip the best adjustment. Test ride after each adjustment. When an adjustment makes no difference, return to the previous adjustment and try a different approach. If both preload adjustments are correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. If you wish to fine tune these settings they can be changed according to the following procedures. NOTE Evaluating and changing the rebound and compression damping is a very subjective process. Many variables affect motorcycle handling under different circumstances. Approach all changes carefully and consult Table 1-10.

FINE TUNING SUSPENSION: BUELL MODELS The settings are the best balance of handling, ride, and stability. Suspension can be changed to accommodate rider preferences for ride quality and handling for road conditions and load changes.

1.11

NOTES Do not continue to repeat the steps involved with the following settings beyond those which are listed. Adjust suspension to the recommendation if possible, but never force adjusters beyond the mechanical stops.

1WARNING Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Buell dealer for repairs. Loose, worn or damaged steering or suspension components can adversely affect stability and handling, which could result in death or serious injury. (00113a)

Do not exceed the motorcycle Gross Vehicle Weight Rating (GVWR). Exceeding the GVWR can affect stability and handling, which could result in death or serious injury. (00016a) ●

GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of the rider, passenger and cargo that can be safely carried.

The GVWR is shown on the information plate, located on the frame steering head.

Ride Quality Enhancement The stock settings are designed to offer sufficient chassis control, but some may choose to enhance ride comfort over rougher road conditions or for long rides. Adjusting the compression setting will reduce both high and low speed damping. 1.

Adjust suspension for rider weight. Refer to Table 1-10.

2.

Increase ride quality by reducing front and rear compression damping by turning adjuster counterclockwise 1/4-1 turn.

3.

If additional ride quality is desired, reduce front preload by turning adjuster counterclockwise until an additional line is visible and also reduce rear preload 1 position.

4.

If maximum ride quality is desired, decrease front and rear rebound damping by turning adjusters counterclockwise by 1/4-1/2 turn.

Enchanced Steering Quickness The response to steering input (quickness) may be enhanced by adjusting the vehicles front/rear ride height. This adjustment effectively decreases the vehicles rake angle. This is achieved by adjusting the preload to increase front sag and reduce rear sag. 1.

Adjust suspension for rider weight. Refer to Table 1-10.

2.

Reduce steering effort by increasing the rear preload one position.

3.

If more enhanced steering and cornering control is desired, reduce front preload by turning adjuster counterclockwise until an additional line is visible.

4.

If additional enhanced steering and cornering control is desired, increase rear compression damping by turning adjuster clockwise by 1/4-1/2 turn.

5.

If maximum enhanced steering and cornering control is desired, increase front rebound damping by turning adjuster clockwise 1/4 turn.

Changes in Load Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload.

2006 Buell Uylsses: Maintenance

1-33


HOME

Chassis Control/Handling Enhancement To provide more road surface feedback on smoother road conditions, increase compression and rebound settings. 1.

Adjust suspension for rider weight. Refer to Table 1-10.

2.

Increase chassis/handling control by increasing front and rear compression damping by turning adjuster clockwise by 1/2-1 1/2 turns.

3.

If maximum chassis control/handling control is desired, increase front and rear rebound damping by turning adjuster clockwise by 1/4-1/2 turn.

Cold Weather Riding Less Than 65째 F (18째 C) The viscosity of the suspension fluid increases as the temperature decreases. As the fluid viscosity increases so does the damping. It is recommended to compensate for the varying fluid viscosity by readjusting the damping adjuster positions when operating outside the normal ambient temperature range of 65-95째 F (18-35째 C). 1.

Adjust suspension for rider weight. Refer to Table 1-10.

2.

Reduce front and rear compression damping and rebound damping by turning adjuster counterclockwise 1/4-1/2 turn.

Table 1-10. Recommended Suspension Settings for Rider Weight RIDER AND CARGO WEIGHT

LB. Less than 170

KG

FRONT FORK

REAR SHOCK

PRELOAD Turns in # OF *COMPRESSION *REBOUND from *COMPRESSION *REBOUND LINES Minimum**

77

7

2

1 3/4

0 (min)

3

2

170-200

77-91

6

1 3/4

1 3/4

4

2 1/2

1 1/2

200-230

91-104

5

1 1/2

1 5/8

8

2

1 1/4

230-260

104-118

4

1 1/2

1 1/2

12

1 1/2

7/8

260-290

118-132

3

1 1/4

1 1/2

16

1 1/4

3/4

290-320

132-145

3

1 1/4

1 1/2

20 (max)

1 1/8

5/8

145-GVWR

3

1

1 1/4

20 (max)

1

1/2

320-GVWR

* All damping adjustments are turns out from maximum. **Note: The rear preload knob has a click every 1/2 turn. For example: 4 turns from minimum would be 8 clicks. 5 turns (10 clicks) will move it one reference line.

1-34

2006 Buell Uylsses: Maintenance


HOME

SUSPENSION ADJUSTMENTS

9957

1

1WARNING 2

Both forks should display the same number of alignment lines. Forks that are not properly aligned can lead to loss of control, which could result in death or serious injury. (00124a)

3

NOTE All “turn settings” in Table 1-10. are “turns out from maximum”. That is, first gently turn adjustment screws fully clockwise (until they stop), then turn adjustment screws counterclockwise the amount specified. The recommended rebound and compression damping settings for various road and riding conditions are given in Table 1-10.

1. 2. 3.

Rebound adjuster screw Preload adjuster nut Four lines visible (factory setting)

Figure 1-35. Front Fork Preload And Rebound Adjuster

Setting Front Fork Preload 1.

Check number of lines (3) to be showing for your load condition. Refer to Table 1-10.

2.

See Figure 1-35. Adjust preload by turning the adjuster nut (2) with a wrench.

8361

Setting Front Fork Rebound Damping 1.

See Figure 1-35. Using a screwdriver, turn the slotted dial (1) clockwise until it stops. This is the maximum rebound damping setting.

2.

Then turn the dial counterclockwise the recommended amount specified in Table 1-10.

Setting Front Fork Compression Damping 1.

See Figure 1-36. Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum compression damping setting.

2.

Then turn the dial counterclockwise the recommended amount specified in Table 1-10.

Figure 1-36. Front Fork Compression Damping Adjuster

2006 Buell Uylsses: Maintenance

1-35


HOME

Set Rear Shock Preload ●

NOTES See Figure 1-37. Adjust the preload by turning the preload adjuster knob located on the left side of the vehicle according to Table 1-10.

Rotate adjuster clockwise to increase preload.

Rotate adjuster counter clockwise to decrease preload.

Set Rear Shock Rebound Damping 1.

See Figure 1-38. Using a screwdriver, turn the slotted rebound adjustment dial clockwise until it stops. This is the maximum rebound damping setting.

2.

Then turn the dial counterclockwise the number of turns recommended in Table 1-10.

Setting Rear Shock Compression Damping 1.

See Figure 1-39. Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum compression damping setting.

2.

Turn the dial counterclockwise the number of turns from maximum specified in Table 1-10.

10658a

11958

Figure 1-39. Rear Shock Compression Adjuster

Figure 1-37. Rear Shock Preload Adjuster

11121

Figure 1-38. Rear Shock Rebound Adjustment Dial

1-36

2006 Buell Uylsses: Maintenance


HOME

STEERING HEAD BEARINGS

1.12

GENERAL 8421

The steering head bearings are sealed, angular contact bearings and do not require additional lubrication. Check steering head bearing resistance: ●

At every 5000 mile (8000 km) service interval.

When storing or removing the motorcycle for the season.

INSPECTION NOTES Figure 1-40. Measuring Steering Head Bearing Resistance (Typical)

Check that throttle cables do not bind when measuring bearing resistance.

Steering head bearings are sealed and do not require additional lubrication.

DETERMINING PROPER RESISTANCE

Steering head bearing resistance is not adjustable. Replace bearings that do not meet resistance specifications.

1.

Detach clutch cable at handlebar and ensure that throttle cables do not bind before measuring steering head bearing resistance.

2.

Remove steering stem pinch fastener at upper triple clamp.

3.

Loosen steering stem capnut and back off several turns.

4.

Remove lower triple clamp pinch fasteners, two per side.

1WARNING

5.

Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm).

6.

Turn front wheel all the way to the right.

Steering must be smooth and free with no binding or interference. Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Buell dealer for repairs. Loose, worn or damaged steering or suspension components can adversely affect stability and handling, which could result in death or serious injury. (00113a)

7.

See Figure 1-40. Hook a spring scale into the hole in the front axle. With scale 90 degrees from fork leg, pull front wheel to center position.

8.

The desired resistance is between 1-7 lbs (0.5-3.2 kg).

1.

Detach clutch cable at handlebar.

2.

Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 2.32 EXHAUST SYSTEM.

3.

Check steering stem bearings for notches by turning front wheel full right and then left. Repeat if necessary.

4.

Next place wheel facing straight ahead and grabbing both fork sides at the bottom move front-end forward and back to check for steering head play.

5.

To inspect for correct steering head resistance turn front wheel all the way to the right.

6.

See Figure 1-40. Hook a spring scale into the hole in the front axle. With scale 90 degrees from fork leg, pull front wheel to center position.

7.

a.

The desired resistance to pull front wheel to center is between 1-7 lbs (0.5-3.2 kg).

b.

If steering head resistance measurement is not within specification, see DETERMINING PROPER RESISTANCE.

NOTE If the correct specification cannot be achieved, the steering head bearings must be replaced. See 2.18 STEERING HEAD BEARINGS. 9.

Once correct steering head resistance has been verified, apply LOCTITE 272 to steering stem pinch bolt, install and tighten to 23-25 ft-lbs (31-34 Nm).

10. Apply LOCTITE 272 to lower triple clamp fasteners, install and tighten to 20-22 ft-lbs (27-30 Nm). 11. When adjustment is complete, attach clutch cable and adjust. See 1.8 CLUTCH. 12. Remove scissor jack.

When adjustment is complete, attach clutch cable and adjust. See 1.8 CLUTCH.

2006 Buell Uylsses: Maintenance

1-37


HOME

SPARK PLUGS INSPECTION

1.13 4636

Check spark plugs: â—?

Replace every 10,000 mile (16,000 km) service interval.

â—?

Use only Harley-Davidson 10R12A spark plugs.

1.

Remove left side air scoop to access front cylinder spark plug. See 2.40 AIR SCOOPS.

2.

Disconnect spark plug wire from front spark plug.

3.

Using a 5/8 in. box end wrench and 5/8 in. spark plug socket, remove front spark plug.

4.

Remove seat. See 2.45 SEAT.

5.

Remove airbox assembly. See 4.44 AIR CLEANER ASSEMBLY.

6.

Disconnect spark plug wire from rear spark plug (use automotive spark plug boot remover/installer if required).

7.

Using a 5/8 in. wobble socket and 12 in. extension, remove rear spark plug.

8.

See Figure 1-41. Compare your observations of the plug deposits with the descriptions provided below. a.

A wet, black and shiny deposit on plug base, electrodes and ceramic insulator tip indicates an oil fouled plug. The condition may be caused by one or more of the following: worn pistons, worn piston rings, worn valves, worn valve guides, worn valve seals, a weak battery or a faulty ignition system.

b.

A dry, fluffy or sooty black deposit indicates an airfuel mixture that is too rich and/or engine idling for excessive periods.

c.

A light brown, glassy deposit indicates an overheated plug. This condition may be accompanied by cracks in the insulator or by erosion of the electrodes and is caused by an air-fuel mixture that is too lean, a hot-running engine, valves not seating or improper ignition timing. The glassy deposit on the spark plug is a conductor when hot and may cause high-speed misfiring. A plug with eroded electrodes, heavy deposits or a cracked insulator must be replaced.

d.

A plug with a white, yellow, tan or rusty brown powdery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals.

1-38

2006 Buell Uylsses: Maintenance

Figure 1-41. Typical Spark Plug Deposits


HOME

1WARNING

8389

Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) 9.

If the plugs require cleaning between tune-ups and replacement plugs are not available, proceed as follows: a.

Degrease firing end of spark plug using ELECTRICAL CONTACT CLEANER. Dry plug with compressed air.

b.

Use a thin file to flatten spark plug electrodes. A spark plug with sharp edges on its electrodes requires 25-40% less firing voltage than one with rounded edges.

Figure 1-42. Rear Spark Plug Access

10. If the plugs cannot be cleaned, replace with 10R12A spark plugs. 11. Check electrode gap with a wire-type feeler gauge. Gap should be 0.035 in. (0.9 mm). 12. Apply LOCTITE ANTI-SEIZE to threads of spark plugs. Install and tighten spark plugs to 12-18 ft-lbs (1624 Nm). ●

NOTES Start threading rear spark plug with 3/8” fuel hose being careful not to cross thread spark plug.

Start front spark plug with fingers.

An extension may be needed to push on rear spark plug boot to ensure it is seated properly.

13. Connect spark plug wires. Verify that wires are securely connected to coil and spark plugs. See 7.4 SPARK PLUG CABLES. 14. Install left side air scoop. See 2.40 AIR SCOOPS. 15. Install airbox assembly. See 4.44 AIR CLEANER ASSEMBLY.

1WARNING After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 16. Install seat. See 2.45 SEAT.

2006 Buell Uylsses: Maintenance

1-39


HOME

AIR CLEANER FILTER

1.14

REMOVAL 8373

CAUTION Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a)

2 3

Check air cleaner filter element: ●

Inspect at the 1000 mile (1600 km) service interval and at every 5000 mile (8000 km) service interval thereafter.

Replace at every 20,000 mile (32,000 km) service interval.

Inspect and replace air cleaner filter element more often if the motorcycle is run in a dusty environment.

Do not cover or restrict the air intake screen. Certain tank bags or accessories may cover or restrict the air intake screen. This may reduce power and performance.

1.

Remove seat. See 2.45 SEAT.

2.

Remove four fasteners, nylon washers and intake cover assembly. See 2.39 INTAKE COVER.

3.

See Figure 1-44. Remove fuel vent tube (3) from vapor valve at front of air cleaner cover and groove on top of air cleaner cover (1).

4.

Unlatch six latching tabs (6) and remove air cleaner cover from baseplate.

5.

See Figure 1-45. Remove the filter element (1) from baseplate (2). Inspect and replace if necessary.

NOTES

1 1. 2. 3.

Breather hoses (2) Intake air sensor Velocity stack Figure 1-43. Air Cleaner Baseplate Assembly

12049

6

2

1 5

7 3 4

CAUTION See Figure 1-45. Cover the velocity stack so nothing can drop into the motor.

CLEANING AND INSPECTION 1WARNING Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. (00101a) 1.

Check filter element. Hold filter element up to strong light source. The element can be considered sufficiently clean if light is uniformly visible through the element.

2.

Thoroughly clean baseplate and inside of air cleaner cover.

3.

See Figure 1-43. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in baseplate behind velocity stack (3).

1-40

2006 Buell Uylsses: Maintenance

1. 2. 3. 4. 5. 6. 7.

Air cleaner cover Actuator (interactive exhaust) Fuel vent tube Cable (interactive exhaust) Harness (interactive exhaust) Air cleaner cover latch tabs Vapor valve

Figure 1-44. Air Cleaner Cover, Fuel Vent Tube and Fuel Vapor Valve


HOME 12050

4

4.

Position actuator cable and harness in grooves on air cleaner cover.

5.

See Figure 1-44. Position fuel vent tube (3) in groove on top of air cleaner cover and connect to fuel vent valve (7). Secure vent tube to vent valve with new cable strap.

6.

Install intake cover assembly with four fasteners and nylon washers. Tighten fasteners to 12-36 in-lbs (44 Nm).

1

1WARNING 2

After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 7.

Install seat. See 2.45 SEAT.

3 1. 2. 3. 4.

Filter element Baseplate assembly Air cleaner cover latch tabs (6) Velocity stack Figure 1-45. Installed Air Cleaner Filter Element

INSTALLATION 1.

See Figure 1-45. Place filter element (1) on baseplate (2).

2.

Position air cleaner cover over baseplate. Make sure air filter remains correctly positioned.

3.

Install air cleaner cover by latching six latch tabs (3) to baseplate.

2006 Buell Uylsses: Maintenance

1-41


HOME

THROTTLE CABLE AND IDLE SPEED ADJUSTMENT THROTTLE CABLE

1.15

6853

1WARNING 5

Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. Be sure wires and throttle cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops. Steering must be smooth and free with no binding or interference. Anything interfering with steering system operation may cause loss of vehicle control, which could result in death or serious injury. NOTE If replacing the idle adjustment cable it will be necessary to apply anti-seize to the threads before installing to the throttle body assembly.

4 2 1 3 1. 2. 3. 4. 5.

Rubber boot Throttle control cable Idle control cable Cable adjuster Cable adjuster lock Figure 1-46. Throttle Control Cables

Check throttle cable adjustment: ●

Before every ride.

At every scheduled service interval.

11988

With engine running, turn handlebars through full range of travel. If engine speed changes during this maneuver, turn engine OFF and adjust throttle cables as follows: 1.

If replacing a throttle cable, remove air cleaner cover and baseplate. See 4.44 AIR CLEANER ASSEMBLY.

2.

Remove left air scoop. See 2.40 AIR SCOOPS.

3.

See Figure 1-46. Loosen cable adjuster lock (5) on each.

4.

Turn adjusters (4) in direction which shorten cable housings to minimum length.

5.

Point front wheel straight ahead. Twist throttle control grip to fully open position; hold in position.

6.

Turn adjuster on throttle control cable (2) until throttle cam stop touches stop plate. Tighten cable adjuster lock on throttle control cable adjuster; release throttle control grip.

will

7.

Turn handlebars fully to right. Turn adjuster on idle control cable (3) until end of cable housing just touches the cable guide.

8.

Twist and release throttle control grip a few times. Throttle plate must return to idle position each time throttle grip is released. If this is not the case, turn adjuster on idle control cable (shortening cable housing) until throttle control functions properly.

9.

Tighten cable adjuster lock on idle control cable. Recheck operation of throttle control.

10. Recheck engine slow idle speed; adjust if required. 11. Install left air scoop. See 2.40 AIR SCOOPS. 12. If it was necessary to remove airbox, baseplate and intake cover assembly, install at this time. See 4.44 AIR CLEANER ASSEMBLY.

1-42

2006 Buell Uylsses: Maintenance

Figure 1-47. Idle Adjuster (behind left fork)

IDLE SPEED NOTE See Figure 1-47. Run vehicle until engine temperature is 320 °F (160° C). Regular idle speed is 1050 - 1150 RPM. Set idle speed using idle adjuster. Turn adjuster clockwise to increase idle speed or counterclockwise to decrease idle speed.


HOME

INTERACTIVE EXHAUST CABLE ADJUSTMENT 1.

5.

Using a pair of pliers, fully open the exhaust valve in the muffler by pulling the cable core by the ferule that was disconnected from the cable wheel in the previous step until resistance is felt. Be careful not to damage the cable core.

6.

Mark the cable core with the marker all the way around where it comes out of the housing.

7.

Release the cable core and reattach the cable to the cable wheel and bracket.

8.

Tighten jam nut.

Remove four fasteners, nylon washers and intake cover assembly. See 2.39 INTAKE COVER.

NOTE When the ignition/light switch is turned off with the interactive exhaust valve in motion, the valve will stop partially open which will cause an inaccurate adjustment. For a description of the inactive exhaust operation, see 7.6 INTERACTIVE EXHAUST SYSTEM. 2.

1.16

To close the valve in the muffler, cycle the actuator: a.

Hold the throttle wide open.

b.

Turn the engine cut-off switch to RUN.

c.

Turn the ignition/light key switch ON.

d.

Watch the actuator cycle close/open/close.

CAUTION Do not overtighten jam nut on interactive exhaust cable.

10512a

10513

1

Figure 1-49. Checking For 1/8 in. (3.2 mm) Maximum Free Play In Either Direction For Proper Adjustment 10512a

9.

3 4

See Figure 1-49. Adjust interactive exhaust cable as follows: a.

See Figure 1-48. Move cable with your fingers from side to side. There should be no more than 1/8 in. (3.2 mm) side play in cable in either direction with 1/4 in. (6.4 mm) maximum overall side play.

b.

Adjust cable as needed using cable adjuster (1).

2

10. Cycle the actuator to verify cable and valve operation: a.

1. 2. 3. 4.

Adjuster Interactive exhaust cable Jam nut Cable wheel Figure 1-48. Interactive Exhaust Cable (Typical)

3.

See Figure 1-48. Loosen jam nut (3).

4.

Remove cable (2) from bracket and cable wheel (4).

NOTE For the next step in the procedure it will be necessary to obtain a permanent marker.

Hold the throttle wide open.

b.

Turn the engine cut-off switch to RUN.

c.

Turn the ignition/light key switch ON.

d.

Watch the actuator cycle close/open/close. CAUTION

DO NOT start vehicle in this mode. NOTE In this mode the exhaust valve in the interactive muffler should cycle from the closed position to the wide open position and back to the closed. When the exhaust valve moves to the open position, you should see the mark on the cable core made previously. This ensures the system is working properly. If you do not see the mark, verify previous cable adjustment. 2006 Buell Uylsses: Maintenance

1-43


HOME

10514a

1 2

1. 2.

Interactive exhaust cable Frame lug Figure 1-50. Correct Cable Routing Behind Frame Lug (Typical)

11. See Figure 1-50. Verify that the interactive exhaust cable (1) is routed behind the frame lug (2) before installing air intake cover.

CAUTION If cable is routed in front of the frame lug it will cause the muffler valve to stay open not allowing it to work properly. 12. Install air intake cover. See 2.39 INTAKE COVER.

1-44

2006 Buell Uylsses: Maintenance


HOME

IGNITION TIMING INSPECTION Check ignition timing after each removal of the cam position sensor.

CHECKING STATIC TIMING

1.17 10. If engine is coming up on the compression stroke for the REAR (incorrect) cylinder, the screen will be displaying HIGH - 5 volts as timing mark is just coming into view at left edge of window and will switch to LOW - 0 volts at same point as the timing mark continues through the window. (If this is observed, turn flywheel forward one revolution to bring engine to compression stroke for front cylinder.)

1CAUTION Always wear proper eye protection when drilling. Flying debris may result in minor or moderate injury.

NOTES ●

If timing mark check point is overshot, bump flywheel backwards till TDC mark is at left edge of inspection window and repeat test bumping flywheel in forward (normal) direction.

Never confirm timing while bumping flywheel backwards. This will give you an incorrect reading.

CAUTION Carefully drill hole, applying minimum pressure to drill out timer plate cover rivets. Applying too much pressure will damage cam position sensor and/or timer plate and cover. ●

NOTES It is not necessary to remove the spark plug to determine TDC compression stroke of the front cylinder in the following procedure.

Do not remove the timing inspection cover to check the static timing. If timing must be corrected, the inspection plate will then be removed.

1.

Raise rear wheel using a lift or jacking point. Tie down motorcycle for additional support.

2.

Remove timing inspection plug.

3.

Place transmission in 5th gear.

4.

Connect Digital Technician to data port on motorcycle and select the Static Timing procedure screen.

5.

Turn on ignition and move handlebar stop switch to the run position. Listen for fuel pump cycling to confirm ignition is active.

6.

Turn or gently bump the flywheel in a forward direction using the rear wheel. Position the flywheel TDC mark at the very left edge of the inspection hole.

7.

If the engine is coming up on the compression stroke for the FRONT (correct) cylinder, the screen will be displaying LOW - 0 volts with timing mark at left edge of window.

8.

Gently bump flywheel forward in tiny increments.

9.

See Figure 1-52. If the static timing is correct, the screen will switch to HIGH - 5 volts at the precise moment the timing mark exactly centers in the inspection window.

11. If timing is correct, install timing inspection plug and tighten to 120-180 in-lbs (14-20 Nm). If timing is not correct, see ADJUST TIMING in this section.

12138

Figure 1-51. Timing Plug

b1249x1x

Figure 1-52. Correct Timing 2006 Buell Uylsses: Maintenance

1-45


HOME

ADJUST TIMING 1.

b1247x1x

See Figure 1-53. Remove timing plate cover. a.

Drill rivets holding the timing plate cover.

b.

Using a hook, remove timing plate cover.

c.

Loosen sensor assembly fasteners.

2.

See Figure 1-55. If timing is advanced (mark appears on left side of window) rotate timing plate counterclockwise.

3.

Check timing. See CHECKING STATIC TIMING.

4.

See Figure 1-56. If timing is retarded (mark appears on right side of window) rotate timing plate clockwise.

5.

Tighten sensor assembly fasteners to 15-30 in-lbs (1.73.4 Nm).

6.

Recheck timing. Figure 1-55. Advanced Timing 12136 b1248x1x

Figure 1-53. Timer Cover 8391

Figure 1-56. Retard Timing

Figure 1-54. Cam Position Sensor

1-46

2006 Buell Uylsses: Maintenance


HOME

HEADLIGHTS

1.18

INSPECTION

b0949x1x

1WARNING

Lo w

Horizontal Line 34-36 in. (86-91 cm)

Do not modify ignition/light switch wiring to circumvent the automatic-on headlight feature. High visibility is an important consideration for motorcycle riders. Failure to have headlight on at all times could cause an accident, resulting in death or serious injury.

Be am

Check headlights for proper alignment: â—?

When the new owner takes delivery of the motorcycle.

â—?

When there is a change in load (adding luggage, etc.).

1.

In a location with low light, draw a horizontal line on a screen or wall that measures 34-36 in. (86-91 cm) above floor.

2.

See Figure 1-57. Position motorcycle 25 ft (7.6 m) away from a screen or wall by measuring the distance from the front axle to the screen/wall.

3.

Verify correct front and rear tire pressure. See 1.7 TIRES AND WHEELS.

4.

Load vehicle with rider/passenger/cargo/accessories. Weight will compress vehicle suspension slightly.

5.

Stand motorcycle upright with headlights aimed straight forward.

6.

Horizontal Line 34-36 in. (86-91 cm)

a.

See Figure 1-58. Turn ignition switch to IGN. Set handlebar headlight switch to LOW beam position.

b.

Check that the correct pattern of light is a double rectangular pattern and is aligned with the horizontal line as shown in Figure 1-57. Adjust headlight alignment. See which follows.

Hig hB ea m

Position Motorcycle 25 ft (7.6 m)

Check LOW beam (right lens) for alignment.

c.

7.

Position Motorcycle 25 ft (7.6 m)

Figure 1-57. Checking Headlight Alignment

9960

1

ADJUSTMENT

Check HIGH beam (left) for alignment. a.

See Figure 1-58. Set handlebar headlight switch to HIGH beam position.

2 NOTE Low beam lamp will not stay illuminated when high beam is activated. b.

c.

Check that the correct pattern of light is a circular pattern and is centered on the horizontal line as shown in Figure 1-57. Adjust headlight alignment. See section.

1. 2.

High beam Low beam Figure 1-58. Headlight Switch

ADJUSTMENT

2006 Buell Uylsses: Maintenance

1-47


HOME

ADJUSTMENT

11794

Horizontal Alignment See Figure 1-59. Loosen fasteners on right and left side of headlight housing to adjust the horizontal alignment.

Vertical Alignment See Figure 1-60. Loosen fastener on the bottom of headlight housing to adjust the vertical alignment. NOTE â—?

Only loosen headlight alignment fasteners enough to adjust headlight. Once headlights are aligned, tighten fasteners to 48-72 in-lbs (5-8 Nm).

â—?

See Figure 1-60. The vertical headlight adjustment screw is located under the front upper fender.

Figure 1-60. Vertical Headlight Adjustment Screw

b1213x1x

11792

11793

Figure 1-61. Front Fender Assembly Vertical Headlight Adjustment Screw

Figure 1-59. Horizontal Headlight Adjustment

1-48

2006 Buell Uylsses: Maintenance


HOME

THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

1.19

8390

NOTE If closed throttle TP degree reading is not between 5.1° - 6.2°, TPS should be re-calibrated. See ADJUSTMENT below. 1.

Connect vehicle to Digital Technician.

2.

Select calibrations screen/TPS Function.

3.

Select Buell TPS zero tab.

4.

Select TP volts on screen.

5.

See Figure 1-62. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.

6.

Open and snap shut throttle control grip 2-3 times.

Figure 1-62. Idle Adjuster (behind left fork)

NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration. 7.

With ignition and run switch in the on position with engine off and throttle in the closed position press the TPS zero button at the bottom of the screen.

8.

Select TPS zero button and perform TPS zero. NOTE

When calibration is complete, dialogue box will appear on Digital Tech screen with message display “Command Sent Successfully”. Press OK. 9.

Turn idle adjustment cable screw clockwise until TPS degrees read 5.2°-5.6°.

10. Run vehicle until engine temperature is at 320° F (160° C). 11. Set idle to 1050-1150 RPM.

2006 Buell Uylsses: Maintenance

1-49


HOME

STORAGE

1.20

GENERAL

REMOVAL FROM STORAGE 1WARNING

1WARNING

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

The clutch failing to disengage can cause loss of control, which could result in death or serious injury. Prior to starting after extended periods of storage, place transmission in gear and push vehicle back and forth several times to assure proper clutch disengagement. (00075a)

If the motorcycle will not be operated for several months, such as during the winter season, there are several things which should be done to protect parts against corrosion, to preserve the battery and to prevent the buildup of gum and varnish in the fuel system.

1.

Charge and install battery. See 1.4 BATTERY MAINTENANCE.

2.

Remove and inspect spark plugs. Replace if necessary. See 1.13 SPARK PLUGS.

3.

Inspect air filter element. Replace if necessary. See 1.14 AIR CLEANER FILTER.

4.

If fuel tank was drained, fill fuel tank with fresh gasoline.

5.

Start the engine and run until it reaches normal operating temperature. Check fluids and refill to proper levels if required.

1.

Warm motorcycle to operating temperature. Perform an oil change and turn engine over to circulate the new oil.

2.

Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabilizers following the manufacturer’s instructions. Run engine until treated gasoline has had a chance to reach fuel injectors.

3.

Remove battery and charge as needed to maintain the correct voltage. See 1.4 BATTERY MAINTENANCE.

4.

Remove the spark plugs, inject a few squirts of engine oil into each cylinder and crank the engine 5-6 revolutions. Reinstall spark plugs. See 1.13 SPARK PLUGS.

5.

Adjust primary chain. See 1.10 PRIMARY CHAIN.

6.

Check tire inflation. See 1.7 TIRES AND WHEELS. If the motorcycle will be stored for an extended period of time, securely support the motorcycle so that all weight is off the tires.

1WARNING Be sure that brake fluid or other lubricants do not contact brake pads or discs. Such contact can adversely affect braking ability, which could cause loss of control, resulting in death or serious injury. (00290a) 7.

Wash and polish molded-in-color, painted and chromeplated surfaces.

8.

If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do not breathe promote the formation of condensation.

1-50

2006 Buell Uylsses: Maintenance

6.

a.

Check engine oil level. See 1.5 ENGINE LUBRICATION SYSTEM.

b.

Check transmission fluid level. See 1.8 CLUTCH.

Perform all of the checks in the PRE-RIDING CHECK LIST in the Owner’s Manual.


HOME

TROUBLESHOOTING GENERAL The following check list can be helpful in locating most operating troubles. Refer to the appropriate sections in this Service Manual for detailed procedures.

ENGINE Starter Motor Does Not Operate or Does Not Turn Engine Over

1.21 Starts Hard 1.

Spark plugs in bad condition, have improper gap or are partially fouled.

2.

Wires are crossed.

3.

ATC in stuck open.

4.

Spark plug cables in bad condition and shorting.

5.

Battery nearly discharged.

6.

Loose wire connection at one of the battery terminals, at coil or at plug between ignition sensor and module.

7.

Throttle controls not adjusted correctly.

8.

Ignition coil not functioning.

9.

Engine oil too heavy (winter operation).

1.

Engine stop switch in OFF position.

2.

Ignition key switch not ON.

3.

Discharged battery or loose or corroded connections. (Solenoid chatters.)

11. Vapor vent valve plugged or fuel line closed off restricting fuel flow.

4.

Starter control relay or solenoid not functioning.

12. Water or dirt in fuel system.

5.

Electric starter shaft pinion gear not engaging or overrunning clutch slipping.

13. Air leak at intake manifold.

6.

Clutch lever not pulled in. Vehicle in gear.

7.

Starter interlock circuit malfunction.

15. TP Sensor and/or fast idle screw not set properly. See dealer.

Engine Turns Over But Does Not Start

10. Ignition not timed properly. See dealer.

14. Valves sticking.

16. Oxygen, IAT or ET sensors damaged or malfunctioning. See dealer.

Starts But Runs Irregularly or Misses

NOTE See 4.11 ENGINE CRANKS BUT WILL NOT START for specific tests.

NOTE See 4.15 MISFIRE for specific tests.

1.

Fuel tank empty.

1.

Spark plugs in bad condition or partially fouled.

2.

Discharged battery, loose or broken battery terminal connections.

2.

Spark plug cables in bad condition and shorting.

3.

Spark plug gap too close or too wide.

3.

Fouled spark plugs.

4.

Ignition coil not functioning.

4.

Loose or shorting spark plug cables or connections.

5.

Ignition module not functioning.

5.

Ignition timing badly out of adjustment.

6.

Ignition sensor not functioning.

6.

Loose wire connection at coil or battery connection or plug between ignition sensor and module. See Section 4.

7.

Battery nearly discharged.

8.

Damaged wire or loose connection at battery terminals or coil. Intermittent short circuit due to damaged wire insulation.

7.

Ignition coil not functioning.

8.

Ignition module not functioning.

9.

9.

Ignition sensor not functioning.

10. Water or dirt in fuel system and throttle body or filter.

10. Sticking or damaged valve or valves. 11. Engine oil too heavy (winter operation). 12. Ignition circuit interlock malfunction. 13. No output from the ECM. See dealer. 14. Inadequate fuel pressure in fuel lines (possible leak). See dealer.

11. Vapor vent valve plugged. 12. Throttle controls improperly adjusted. 13. Air leak at intake manifold or air filter. 14. Damaged intake or exhaust valve. 15. Weak or broken valve springs. 16. Incorrect valve timing.

15. Clogged fuel filter. See dealer.

17. Oxygen, IAT or ET sensors damaged or malfunctioning. See dealer.

16. Clogged fuel injectors. See dealer.

18. TP Sensor not set properly. See dealer.

17. Tripped bank angle sensor. Turn key to OFF, wait 15 seconds, and then back to IGN again to start bike.

19. Fuel level too low. Add gasoline.

18. TP Sensor/fast idle screw not set properly. See dealer.

20. Inoperative fuel injector. See dealer.

19. No output from CMP sensor. See dealer.

21. Obstructed fuel tank vent valve or pinched vent tube. See dealer.

20. Inoperative fuel pump. See dealer.

22. Air intake screen covered or restricted. 2006 Buell Uylsses: Maintenance

1-51


HOME

Spark Plug Fouls Repeatedly

ENGINE LUBRICATION SYSTEM

1.

Incorrect spark plug.

2.

Piston rings badly worn or broken.

Oil Does Not Return To Oil Tank

3.

Valve stem seals worn or damaged.

1.

Oil tank empty.

4.

Valve guides badly worn.

2.

Return pump gears damaged.

5.

Sensors damaged.

3.

Oil feed pump not functioning.

4.

Restricted oil lines or fittings.

6.

Air intake screen covered or restricted.

Pre-Ignition or Detonation (Knocks or Pings) 1.

Excessive carbon deposit on piston head or combustion chamber.

2.

Incorrect heat range spark plug.

3.

Spark plugs not firing.

4.

Ignition timing advanced.

5.

Fuel octane rating too low.

6.

Intake manifold vacuum leak.

Overheating 1.

Insufficient oil supply or oil not circulating.

2.

Clogged or damaged fins on oil cooler.

3.

Cooling fan not operating properly.

4.

Leaking valves.

5.

Heavy carbon deposit.

6.

Ignition timing retarded.

Valve Train Noise 1.

Hydraulic lifter not functioning properly.

2.

Bent push rod.

3.

Cam, cam gears or cam bushings worn.

4.

Rocker arm binding on shaft.

5.

Valve sticking in guide.

Excessive Vibration 1.

Engine tie-bars loose, broken or improperly spaced.

2.

Isolator mounting fasteners loose.

3.

Broken frame.

4.

Primary chain badly worn or links tight as a result of insufficient lubrication.

5.

Wheels not aligned and/or tires worn.

6.

Internal engine problem.

7.

Wheels not balanced correctly.

1-52

2006 Buell Uylsses: Maintenance

Engine Uses Too Much Oil or Smokes Excessively 1.

Piston rings badly worn or broken.

2.

Valve stem seals worn or damaged.

3.

Valve guides worn.

Engine Leaks Oil From Cases, Push Rods, Hoses 1.

Loose parts.

2.

Imperfect seal at gaskets, push rod cover, washers, etc. To aid locating leaks, use BLACK LIGHT LEAK DETECTOR (Part No. HD-35457).

3.

Restricted oil return line to tank.

4.

Restricted breather passage(s) to air cleaner.

ELECTRICAL SYSTEM Alternator Does Not Charge 1.

Regulator-rectifier module not functioning.

2.

Rectifier not grounded.

3.

Engine ground wire loose or broken.

4.

Loose or broken wires in charging circuit.

5.

Stator not functioning.

6.

Rotor not functioning.

Alternator Charge Rate Is Below Normal 1.

Regulator-rectifier module not functioning.

2.

Stator not functioning.

3.

Rotor not functioning.

4.

Weak battery.

5.

Loose connections.

FUEL SYSTEM Poor Fuel Economy 1.

Oxygen sensor damaged or malfunctioning (bike running rich). See dealer.

2.

Air intake screen covered or restricted.


HOME

TRANSMISSION

CHASSIS

Shifts Hard

Irregular/Inadequate Brake Action

1.

Clutch dragging slightly.

1.

Master cylinder low on fluid.

2.

Shifter forks (inside transmission) damaged.

2.

Brake line contains air bubbles or moisture.

3.

Corners worn off shifter clutch dogs (inside transmission).

3.

Master or wheel cylinder piston worn.

4.

Brake pads covered with grease or oil.

5.

Brake pads badly worn to minimum lining thickness.

6.

Brake rotor badly worn or warped.

7.

Brake pads dragging or excessive braking (brake fades due to heat buildup).

8.

Insufficient brake pedal or hand lever free play (brake drags).

Jumps Out of Gear 1.

Shifter engaging parts (inside transmission) badly worn and rounded.

2.

Shifter forks bent.

3.

Damaged gears.

CLUTCH Slips 1.

Clutch controls improperly adjusted.

2.

Worn friction plates.

Drags or Does Not Release 1.

Clutch controls improperly adjusted.

2.

Clutch plates excessively warped.

Chatters 1.

Handling Irregularities 1.

Tires improperly inflated. See 1.7 TIRES AND WHEELS. Do not overinflate.

2.

Loose wheel axle. Tighten front axle to 39-41 ft-lbs (5356 Nm). Tighten rear axle to 48-52 ft-lbs (65-70 Nm).

3.

Excessive wheel hub bearing play.

4.

Rims and tires out-of-true sideways (tire runout should not be more than 0.080 in. (2.03 mm)).

5.

Rims and tires out-of-round or eccentric with hub (tire runout should not be more than 0.060 in. (1.5 mm)).

6.

Irregular or peaked front tire tread wear.

7.

Tire and wheel unbalanced or weights on wrong side of wheel. (Front wheel weights must be on the brake rotor side.)

8.

Steering head bearings improperly tightened or worn. See 1.12 STEERING HEAD BEARINGS. Check for proper torque and replace worn bearings. See 2.17 FORK CLAMPS, UPPER AND LOWER.

9.

Shock absorber or front forks not functioning normally due to incorrect adjustment. See 1.11 SUSPENSION DAMPING ADJUSTMENTS.

Friction or steel plates worn, warped or dragging.

10. Heavy front end loading. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling.

2006 Buell Uylsses: Maintenance

1-53


HOME

SUSPENSION When making adjustments, remember there are two mediums in setting up a bike, geometry and suspension. Both components work together because suspension is a part of geometry. In order to solve handling problems, it is important to diagnose the problem’s true nature.

Chattering, sliding or an uncomfortable feeling are suspension-related. Handling and a swinging fork are geometryrelated, but often these unwanted characteristics can be solved by suspension adjustments. The following tables list possible suspension and operating troubles and their probable causes.

Table 1-11. General Suspension Problems TROUBLESHOOTING CONDITION

ADJUSTMENT SOLUTION

Bike wallows through turns. Feels loose or vague after bumps. Wheel tends to “pogo” after passing over a bump. This is noticeable by watching the bike continue to bounce as it travels over multiple bumps.

Increase rebound damping.

Wheel responds to bump, but doesn’t return to ground quickly after bumps. This is more pronounced over a series of bumps and is often referred to as “packing down.”

Reduce rebound damping.

The bike bottoms out or dips while cornering. Bike has excessive brake dive.

Increase compression damping.

Harsh ride particularly over washboard surfaces. Bumps kick through handlebars or seat. Suspension seems not to respond to bumps. This is evidenced by tire chattering (a movement with short stroke and high frequency) through corners or by jolting the rider over rough roads.

Reduce compression damping.

Table 1-12. Rear Suspension Problems TROUBLESHOOTING CONDITION “Pumping on the Rear” occurs when you are accelerating out of a corner. This problems occurs in two varieties. 1. The first type has a movement with a long stroke and a high frequency. 2.

The second version has a movement with a short stroke and high frequency.

ADJUSTMENT SOLUTION 1.

The shock is too soft. Increase compression damping. If the adjuster is already set to the maximum, add more preload to the spring (one turn maximum).

2.

In this case the shock is too hard. Decrease compression damping.

Chattering during braking.

Decrease the compression damping. If the problem persists, decrease rebound damping for a faster rebound rate. Less spring preload may also help.

Lack of tire feedback.

The suspension is too soft. Increase compression damping.

Sliding during cornering. Sliding may occur going into the corner or accelerating out of the corner.

The suspension is too hard. Decrease compression damping.

Table 1-13. Front Suspension Problems TROUBLESHOOTING CONDITION

ADJUSTMENT SOLUTION

Not absorbing bumps.

A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings.

Lack of tire feedback.

Increase compression damping.

Tire slides.

Decrease compression damping.

1-54

2006 Buell Uylsses: Maintenance


Table Of Contents

CHASSIS SUBJECT

2

PAGE NO.

2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Checking Cast Rim Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 Front Brake Master Cylinder and Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 Rear Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 Fork Clamps, Upper and Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Swingarm and Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 Front and Rear Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 Frame Pucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 Clutch Control/Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Headlight Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 Headlights and Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 Front Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 Rider and Passenger Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 Heel Guard and Footpeg Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 Sprocket Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 Chin Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 Intake Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 Air Scoops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41 Left Tail Section and Battery Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42 Center Tail Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43 Right Tail Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44 Windshield and Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46 Passenger Seat Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47 Sidestand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 Triple Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-5 2-6 2-8 2-10 2-17 2-21 2-22 2-26 2-27 2-31 2-33 2-36 2-40 2-42 2-45 2-53 2-55 2-58 2-62 2-63 2-64 2-65 2-67 2-68 2-69 2-73 2-74 2-77 2-79 2-81 2-82 2-85 2-86 2-87 2-88 2-89 2-90 2-91 2-92 2-93 2-97 2-98 2-100 2-101 2-102 2-104 2-106


HOME

SPECIFICATIONS

2.1

Table 2-1. Dimensions Table 2-4. Tire and Positions DIMENSIONS

IN.

MM

Wheel base (without rider)

54.1

1374

Seat height (with rider)

33.1

841

Ground clearance (without rider)

6.75

171

Trail

4.8

122

Rake (steering angle)

23.5 degrees

Rake (fork angle)

22 degrees

Table 2-2. Weight Specifications

SOLO RIDING

TIRE AND POSITION Front Dunlop D616F 120/70 R17

36 PSI (248 kPa)

Rear Dunlop D616 180/55 R17

38 PSI (262 kPa)

GVWR

Same as solo

Table 2-5. Brake Rotor Runout IN.

MM

Front radial

0.0177

0.45

431

Front lateral

0.0248

0.63

345

156

Rear radial

0.0177

0.45

GAWR - rear

685

311

Rear lateral

0.0154

0.39

Load capacity

452

205

WEIGHT

LBS.

KG

Wet weight

498

226

GVWR

950

GAWR - front

RUNOUT

11 1WARNING WARNING

All measurements include a full tank of fuel. NOTE Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on an information decal located on the steering head.

Table 2-3. Capacities CAPACITIES Fuel tank (inc. reserve) Reserve/Low fuel light at Oil tank (wet - for normal oil change) Fork oil (each fork) Transmission

Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

Table 2-6. Front Fork Service Wear Limits RUNOUT

U.S.

LITERS

4.4 gallons

16.7

0.83 gallons

3.1

2.5 quarts

2.4

17.75 ounces

0.53

1.0 quart

0.95

IN.

MM

Free length - fork spring

18.77

476.7

Runout - fork tube

0.008

0.2

2006 Buell Ulysses: Chassis

2-1


HOME

TORQUE VALUES

ITEM Axle (front)

TORQUE

NOTES

39-41 ft-lbs

53-56 Nm

ANTI-SEIZE, Left handed thread, page 2-17

48-52 ft-lbs

65.1-70.5

ANTI-SEIZE, Tighten to 23-27 ft-lbs (31.2-36.6 Nm) then back off 2 turns and final tighten, page 2-21

Axle pinch fastener, rear

40-45 ft-lbs

54-61 Nm

page 2-21

Axle pinch fasteners, front

20-22 ft-lbs

27-30 Nm

page 2-17

Battery terminal fasteners

72-96 in-lbs

8-11 Nm

page 3-68

Axle (rear)

Brake hand lever housing fasteners

80-90 in-lbs

9-10 Nm

page 2-30

Brake lamp switch fastener, front

7-10 in-lbs

0.8-1.0 Nm

page 2-30

Brake line bracket fasteners

48-60 in-lbs

5-7 Nm

page 2-42

Brake line p-clamp fastener, front

36-60 in-lbs

4-7 Nm

page 2-33

Brake line P-clamp on inside of lighting module

36-60 in-lbs

4-7 Nm

page 2-33

Brake pedal fastener

22-24 ft-lbs

30-33 Nm

LOCTITE 272, page 2-27

Brake pin hanger set, front

11-14 ft-lbs

15-19 Nm

page 2-35

Brake pin hanger set, rear

11-14 ft-lbs

15-20 Nm

page 2-44

24 in-lbs

2.7 Nm

page 2-44

Caliper banjo bolt, front

16-20 ft-lbs

22-27 Nm

metric, page 2-33

Caliper banjo bolt, rear

16-20 ft-lbs

22-27 Nm

page 2-42

Caliper bleeder valves

36-60 in-lbs

4-7 Nm

Caliper carrier, rear

24-26 ft-lbs

32-35 Nm

page 2-21

Caliper fasteners, front

15-19 ft-lbs

20-26 Nm

page 2-35

Brake pin plug, rear

metric, page 2-28

Caliper mounting fasteners, front

35-37 ft-lbs

47-50 Nm

page 2-35

Caliper mounting large fastener, rear (metric)

18-21 ft-lbs

24-28 Nm

page 2-45

Caliper mounting small fastener, rear (metric)

14-18 ft-lbs

19-24 Nm

page 2-45

Chin fairing fasteners

36-48 in-lbs

4-5 Nm

page 3-92

Clutch cable p-clamp

25-27 ft-lbs

33.9-36.6 Nm

page 3-74

Clutch cable wire form retainer

84-92 in-lbs

9.5-10.4 Nm

page 3-64

Clutch cable wire form

84-92 in-lbs

9.5-10.4 Nm

page 3-74

Clutch inspection cover fasteners

84-108 in-lbs

9.5-12.2 Nm

Tighten in a crosswise pattern, page 3-74

Deflector fasteners

24-36 in-lbs

2.7-4.1 Nm

page 3-70

Deflector jam nuts

39-48 in-lbs

4.4-5.4 Nm

page 3-70

Deflector pivot shaft riser

43-49 in-lbs

4.8-5.5 Nm

page 3-70

ECM fasteners

36-60 in-lbs

4.0-6.8 Nm

page 3-101

Engine shroud air scoop

12-36 in-lbs

1-4 Nm

page 3-94

Exhaust header mounting nut

72-96 in-lbs

8-11 Nm

page 3-85

132-144 in-lbs

15-16 Nm

LOCTITE 272, page 3-88

22-29 ft-lbs

30-39.3 Nm

page 2-52

132-144 in-lbs

14.9-16.2 Nm

page 2-52

Fork center bolt

22-30 ft-lbs

30-40 Nm

page 2-51

Fork clamp, lower

20-22 ft-lbs

27-30 Nm

LOCTITE 272 (red), page 2-53

Fork clamp, upper

23-25 ft-lbs

31-34 Nm

LOCTITE 272, page 2-53

Fork damper locknut

22-30 ft-lbs

30-40 Nm

page 2-51

Footpeg mount Fork cap to damper rod Fork cap to fork tube

2-2

2006 Buell Ulysses: Chassis


HOME ITEM

TORQUE

NOTES

Front fasteners, passenger grab handles

96-120 in-lbs

11.0-13.5 Nm

page 3-109

Front fender fasteners

36-48 in-lbs

4-4.5 Nm

page 3-90

Front isolator bolt

49-51 ft-lbs

66-69 Nm

page 3-64

Front isolator bracket mounting fastener

49-51 ft-lbs

66-69 Nm

page 3-64

Front isolator snubber, upper

12-36 in-lbs

1-4 Nm

page 3-64

Front isolator threaded frame insert

59-61 ft-lbs

80-82.7 Nm

LOCTITE 222, page 3-64

Front muffler mount

16-18 ft-lbs

1.7-24.4 Nm

page 3-86

Hand lever pivot fastener

39-48 in-lbs

4.4-5.4 Nm

page 2-30

Handlebar clamp screws

10-12 ft-lbs

14-16 Nm

Tighten front screws first, page 3-81

Horn

36-60 in-lbs

4-6.7 Nm

page 3-78

License plate light screws

12-36 in-lbs

1.4-4 Nm

page 3-99

Lower belt guard

12-36 in-lbs

1-4 Nm

page 3-91

Lower front fender fasteners

36-48 in-lbs

4-5.4 Nm

page 3-90

Master cylinder banjo bolt, front

16-20 ft-lbs

22-27 Nm

page 2-33

Master cylinder banjo bolt, rear

16-20 ft-lbs

22-27 Nm

page 2-42

Master cylinder cover fasteners, front

9-13 in-lbs

1.0-1.5 Nm

page 2-31

Master cylinder mounting fasteners, rear

72-96 in-lbs

8-11 Nm

page 2-40

Muffler mounting block fastener, rear

32-36 ft-lbs

43-49 Nm

page 3-85

Muffler strap fastener, front

108-120 in-lbs

12-14 Nm

page 3-86

Muffler strap fastener, rear

48-60 in-lbs

5-7 Nm

page 3-86

Negative battery cable at battery terminal

72-96 in-lbs

8-11 Nm

page 3-74

Nuts, license plate light

12-36 in-lbs

1.4-4 Nm

page 3-109

Oil cooler air scoop

48-72 in-lbs

5.4-8 .0 Nm

page 3-94

Oil drain plug

29-31 ft-lbs

39-42 Nm

page 3-62

Oil feed line swingarm p-clamp

48-72 in-lbs

5.4-8 Nm

page 3-85

Pivot shaft pinch bolt

17-19 ft-lbs

23-26 Nm

page 3-63

Preload adjuster mounting

36-60 in-lbs

4.0-6.7 Nm

page 3-68

Ram air scoop

12-36 in-lbs

1-4 Nm

page 3-94

Rear brake bracket fasteners

48-72 in-lbs

5.4-8.1 Nm

page 3-88

Rear fasteners, passenger grab handles

23-25 ft-lbs

31-34 Nm

page 3-109

Rear fender fastener

12-36 in-lbs

1-4 Nm

page 3-90

Rear fender/belt guard

12-36 in-lbs

1-4 Nm

page 3-91

Rear remote master cylinder reservoir fastener

48-72 in-lbs

11-14 Nm

page 2-40

Rear shock reservoir fastener

80-88 in-lbs

9.0-9.9 Nm

page 3-101

108-132 in-lbs

12-15 Nm

page 3-63

20-22 ft-lbs

27.1-29.8 Nm

page 3-101

108-132 in-lbs

12-15 Nm

page 3-63

Right tail section to frame/fuel tank

21-23 ft-lbs

28.5-31.2 Nm

Rotor mounting fasteners, front

25-27 ft-lbs

34-37 Nm

Right footpeg mount Right rear tail section to center tail loop Right side rider footpeg mount

page 3-101 Replace with new, page 2-16 2006 Buell Ulysses: Chassis

2-3


HOME ITEM

TORQUE

NOTES

Rotor mounting fasteners, rear

25-27 ft-lbs

34-37 Nm

Replace with new, page 2-20

Seat lock

72-96 in-lbs

8-10.8 Nm

page 3-104

Shift lever pinch screw

48-60 in-lbs

5.4-6.8 Nm

page 3-73

Shift pedal flange head bolt

22-24 ft-lbs

30-32.5 Nm

page 3-73

Shock absorber, lower

15-17 ft-lbs

20.3-23 Nm

page 3-63

Shock mounting fastener, upper

48-52 ft-lbs

65-70.5 Nm

page 3-68

Shock reservoir clamp fastener

80-88 in-lbs

9.0-9.9 Nm

page 3-68

Sidestand bracket fasteners

25-27 ft-lbs

34-37 Nm

page 3-107

Sidestand pivot bolt

18-20 ft-lbs

24-27 Nm

page 3-107

Sprocket cover fastener

12-36 in-lbs

1-4 Nm

page 3-89

Sprocket fasteners

35-37 ft-lbs

48-50 Nm

Replace with new, page 2-20

Steering head pinch bolt

23-25 ft-lbs

31-34 Nm

page 3-59

Steering stem capnut

38-42 ft-lbs

52-57 Nm

page 3-56

Steering stem pinch fastener

23-25 ft-lbs

31-34 Nm

LOCTITE 272, page 3-56

Stone guard

12-36 in-lbs

1-4 Nm

page 3-91

Swingarm brace mounting fasteners

25-27 ft-lbs

34-37 Nm

page 3-63

Swingarm pivot shaft

24-26 ft-lbs

32-35 Nm

page 3-63

Switch housing fasteners, right

25-33 in-lbs

3-4 Nm

page 3-69

Tail sections to tail loop

20-22 ft-lbs

27-30 Nm

page 3-99

Torca clamp

28-30 ft-lbs

38-40.6 Nm

page 3-86

Triple tail plastic collar screw

36-48 in-lbs

4.0-5.4 Nm

page 3-109

Trunk pan

48-72 in-lbs

5.4-8.1 Nm

page 3-99

Upper module fastners

36-60 in-lbs

4.1-6.8 Nm

page 3-79

Valve stem nut

40-44 in-lbs

4.5-4.9 Nm

page 2-24

Windscreen fasteners

10-12 in-lbs

1.1-1.4 Nm

page 3-102

Wire cover screws

36-48 in-lbs

4.0-5.4 Nm

page 3-109

2-4

2006 Buell Ulysses: Chassis


Thank you very much for your reading. Please Click Here Then Get More Information.

2006 BUELL XB12X ULYSSES Service Repair Manual  
2006 BUELL XB12X ULYSSES Service Repair Manual  
Advertisement