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Buell Ulysses 2006 Service Manual

Buell Ulysses 2006 Service Manual

2006 buell ulysses

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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

Table of Contents

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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...
Page 2 Edit Me: Printed September 13, 2005 9:36 am...
Page 3 Part No. B-45521 Steering Head Bearing Remover/ Installer Part No. B-43721 Front Fork Seal Driver Part No. HD-39302 Steering Head Bearing Race Installer (Used with B-45521) Part No. B-46279 7/8" Axle Wrench (Hex) Part No. B-59000B Pro Level Oil Gauge 2006 Buell Ulysses: Appendix A...
Page 4 Part No. HD-45966 Fork Spring Compressing Tool Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-41177 Fork Tube Holder Part No. HD-B-45520 Gear Detent Assembly Aid Part No. HD-44060 Wheel Bearing Remover/Installer Part No. HD-28700 Tire Bead Expander 2006 Buell Ulysses: Appendix A...
Page 5 Part No. HD-35758-B Neway Valve Seat Cutter Set Part No. HD-35667A Cylinder Leakdown Tester Part No. HD-96921-52A Oil Pressure Gauge Part No. HD-34902-B Bearing Race Remover/Installer Part No. HD-35457 Black Light Leak Detector Part No. HD-43984 Crankshaft Locking Tool 2006 Buell Ulysses: Appendix A...
Page 6 Part No. HD-39964 Reamer Lubricant (Cool Tool) Part No. B-45524 Valve Guide Installer Part No. HD-39782 Cylinder Head Support Part No. B-45523 Valve Guide Reamer (7mm) Part No. HD-39786 Cylinder Head Holding Fixture Part No. B-45525 Valve Guide Hone 2006 Buell Ulysses: Appendix A...
Page 7 Part No. HD-33446A Cylinder Torque Plates Part No. HD-95952-33B Connecting Rod and Torque Plate Bolts Part No. HD-33446-86 Clamping Tool Part No. HD-34623C Piston Pin Part No. HD-95970-32D Piston Pin Bushing Tool Retaining Ring Installer/Remover 2006 Buell Ulysses: Appendix A...
Page 8 (HD-95770-69) and 8 (HD-95771-69) are optional. Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-38515-A Clutch Spring Compressing Tool and Part No. HD-38515-91 Forcing Screw Part No. HD-41354 Speedometer Tester Part No. J-5586 Transmission Shaft Retaining Ring Pliers 2006 Buell Ulysses: Appendix A...
Page 9 Main Drive Gear Bearing Installer HD-47250 Part No. HD-47250 Intake Manifold Wrench Part No. HD-38515-A Clutch Spring Compressor HD-47258 Part No. HD-47258 Rocker Cover Wrench Part No. HD-44750-P29 Panasonic Toughbook (touch screen) and HD-44750-P50 Panasonic Toughbook (non-touch screen) 2006 Buell Ulysses: Appendix A...
Page 10 Installer Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-45926 Clutch Shell Bearing Remover (use with HD-95637-46A) Part No. HD-95637-46A Wedge Attachment fo Claw Puller Part No. B-45676 Sprocket Shaft Seal Installer (use with HD-95635-46) 2006 Buell Ulysses: Appendix A...
Page 11 HOME Part No. B-45522 Fuel Pressure Gauge Adapter Part No. HD-26792 Spark Tester Part No. B-45657 Fuel Pump Puller Part No. HD-39978 Fluke 78 Multimeter (DVOM)F 2006 Buell Ulysses: Appendix A...
Page 12 HOME A-10 2006 Buell Ulysses: Appendix A...
Page 13: Amp Multilock Electrical Connectors
Pin terminal Secondary lock open Pin housing Socket housing Latch Latch Secondary lock open Button Latch Secondary lock open Socket terminal Figure B-1. 10-Place Amp Multilock Connector 2006 Buell Ulysses: Appendix B...
Page 14 Figure B-3. Multilock Connector Cutaway View engage latches on both sides of connector. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Install connector on retaining device, either attachment or rosebud clip. 2006 Buell Ulysses: Appendix B...
Page 15 Pin terminal Socket housing Button Pin housing Secondary lock Pin terminal Secondary lock Socket terminal Latch Button Pin housing Latch Socket housing Secondary lock Socket terminal d0245x2x Figure B-4. 3-Place and 6-Place Amp Multilock Connectors 2006 Buell Ulysses: Appendix B...
Page 16 Release contacts locking bar. locking bar GAUGE CRIMP TOOL WIRE NEST Front Middle Rear Close and squeeze crimp tool. Raise locking bar and remove contact. d0246x8x Figure B-5. Amp Multilock Crimping Procedure 2006 Buell Ulysses: Appendix B...
Page 17: Deutsch Electrical Connectors
“clicks” in place. Verify that socket will not back out of rear wire seal. chamber; a slight tug on the wire will conﬁrm that it is properly locked in place. 2006 Buell Ulysses: Appendix B...
Page 18 (Part No. HD-41475-100). See Figure B-10. Figure B-9. Depress Terminal Latches/Back Out Pins Gently depress terminal latches inside pin housing and back out pins through holes in wire seal. 2006 Buell Ulysses: Appendix B...
Page 19 The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same. 2006 Buell Ulysses: Appendix B...
Page 20 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2006 Buell Ulysses: Appendix B...
Page 21 SOCKET SIDE PIN SIDE Socket terminal Locking wedge Wire seal Latch cover Socket housing Pin housing External latch 10. Wire seal Internal seal 11. Pin terminal Locking wedge Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors 2006 Buell Ulysses: Appendix B...
Page 22 MAP sensor connector [80]. d0258x8x Locate tang on latch side of chamber. Push on wire end of lead to remove terminal. Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard Connectors B-10 2006 Buell Ulysses: Appendix B...
Page 23 NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. 2006 Buell Ulysses: Appendix B B-11...
Page 24 Repeat the step if the terminal is still locked in place. NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. B-12 2006 Buell Ulysses: Appendix B...
Page 25 11. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal. Insulation Insulation crimp Core crimp Figure B-16. Inspect Core and Insulation/Seal Crimps 2006 Buell Ulysses: Appendix B B-13...
Page 26: Electrical Connectors
HOME ELECTRICAL CONNECTORS GENERAL Connector numbers are listed in [brackets] in this manual. The following table provides a brief description of the connec- tors found on the Buell Ulysses. Table B-2. Electrical Connector and Location Table CONNECTOR COMPONENT(S) DESCRIPTION LOCATION...
Page 27 [164] Interactive exhaust circuit to ECM under seat [161] Interactive exhaust to solenoid under airbox cover [178] Active intake system to solenoid under airbox cover [179] Active intake system to ECM under seat 2006 Buell Ulysses: Appendix B B-15...
Page 28 INDEX TO WIRING DIAGRAMS Table B-3. Wiring Diagrams DIAGRAM PAGE Main harness B-17 Engine management circuit B-18 Lighting circuit B-19 Horn and instruments circuit B-20 Starting circuit B-21 Charging circuits B-22 Component Circuits B-23 B-16 2006 Buell Ulysses: Appendix B...
Page 29 R/BK SPEEDOMETER LT.GN/R [91A] [39A] R/BK GN/Y LH TURN SIGNAL [95B] R/BK OIL PRESSURE SW [120B] [31B] CLUTCH SW GN/Y 12V AUX. R/BK [160B] [120A] 12V AUX. MALE [180] FEMALE 2006 Ulysses Model Main Harness 2006 Buell Ulysses: Electrical B-17...
Page 30 HOME 2006 Ulysses Model Main Harness 2006 Ulysses Model Main Harness B-18 2006 Buell Ulysses: Electrical...
Page 31 ASSEMBLY [134B] LT.GN/GY BK/W GN/W GN/W W/BK W/BK BK/W BK/W BANK ANGLE SENSOR [14A] [14B] GY/O GY/O DATA LINK SPEEDOMETER LT.GN/R [95B] [39A] [91A] CLUTCH SW R/BK R/BK R/BK 2006 Ulysses Model Engine Management Circuit 2006 Buell Ulysses: Electrical B-19...
Page 32 HOME 2006 Ulysses Model Engine Management Circuit 2006 Ulysses Model Engine Management Circuit B-20 2006 Buell Ulysses: Electrical...
Page 33 KEY SWITCH [39B] 1 2 3 4 5 6 7 8 9 10 FUSE/RELAY [24A] ASSEMBLY [38B] [62B] LH CONTROLS LH TURN SIGNAL SPEEDOMETER [39A] [GRD5 R/BK [31B] R/BK R/BK 2006 Ulysses Model Lighting Circuit 2006 Buell Ulysses: Electrical B-21...
Page 34 HOME 2006 Ulysses Model Lighting Circuit 2006 Ulysses Model Lighting Circuit B-22 2006 Buell Ulysses: Electrical...
Page 35 1 2 3 4 5 6 7 8 9 10 [24A] 1 2 3 4 5 6 7 8 LH CONTROLS FUSE/RELAY ASSEMBLY [62B] SPEEDOMETER TN/LT.GN [39A] GN/Y OIL PRESSURE SW [120B] R/BK GN/Y [120A] R/BK 2006 Ulysses Model Horn & Instruments Circuit 2006 Buell Ulysses: Electrical B-23...
Page 36 HOME 2006 Ulysses Model Horn & Instruments Circuit 2006 Ulysses Model Horn & Instruments Circuit B-24 2006 Buell Ulysses: Electrical...
Page 37 15 AMP GY/O R/BK KEY SWITCH 15 AMP NEUTRAL SW TN/Y [131B] [131A] [62B] RELAY CENTER W/BK W/BK GY/O GY/O BK/R TN/LT.GN R/BK [95B] CLUTCH SW R/BK MALE R/BK FEMALE 2006 Ulysses Model Starting Circuit 2006 Buell Ulysses: Electrical B-25...
Page 38 HOME 2006 Ulysses Model Starting Circuit 2006 Ulysses Model Starting Circuit B-26 2006 Buell Ulysses: Electrical...
Page 39 HOME bs0021au BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] FUSE/RELAY ASSEMBLY [61B] BATTERY, 30A TO VOLTAGE REGULATOR [77B] [77A] VOLTAGE REGULATOR STATOR (HD 3-PHASE) [46A] [46B] 2006 Ulysses Model Charging Circuit 2006 Buell Ulysses: Electrical B-27...
Page 40 HOME 2006 Ulysses Model Charging Circuit 2006 Ulysses Model Charging Circuit B-28 2006 Buell Ulysses: Electrical...
Page 41 Front Auxilary [85B] Outlet ENGINE TEMP SENSOR Outlet PK/Y [90A] [90B] FUEL PUMP MAIN HARNESS BANK ANGLE SENSOR [89A] BN/Y INTAKE AIR TEMP [86B] LT.GN/GY [89B] FUEL BK/W SENSOR [134B] [134A] 2006 Ulysses Model Component Circuits 2006 Buell Ulysses: Electrical B-29...
Page 42 HOME 2006 Ulysses Model Component Circuits 2006 Ulysses Model Component Circuits B-30 2006 Buell Ulysses: Electrical...
Page 43 44.45 79.37 114.30 .8268 2.126 3.425 4.724 10.160 45.72 80.96 115.89 .8661 2.165 3.464 4.764 11.112 46.04 81.28 116.84 .9055 2.205 3.504 4.803 12.700 47.62 82.55 117.47 .9449 2.244 3.543 4.842 14.288 48.26 83.82 119.06 2006 Buell Ulysses: Appendix C...
Page 44 (Imp.) x 1.201 = pints (U.S.) liters x 2.113 = pints (U.S.) quarts (Imp.) x 1.201 = quarts (U.S.) liters x 1.057 = quarts (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.) liters x 0.264 = gallons (U.S.) 2006 Buell Ulysses: Appendix C...
Page 45 HOME HOSE AND WIRE ROUTING b1114absxu Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 46 HOME b1115acsxu Figure D-2. Rear Brake Systems, Top View...
Page 47 HOME b1116adsxu Figure D-3. Rear Brake Systems, Left Side View...
Page 48 HOME b1117acsxu Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 49 HOME b1118acsxu To induction module From fuel tank (California) From induction module (California) From fuel tank to atmosphere (49 state) Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View...
Page 50 HOME b1119absxu To active intake solenoid (Japan only) Fuel pump Intake air temperature sensor (IAT) Active intake to ECM (Japan only) Figure D-6. Wiring Harness, Left Side View...
Page 51 HOME b1120acsxu Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Figure D-7. Wiring Harness, Top View...
Page 52 HOME b1121xdsxu Speedometer sensor Cable, starter to battery positive Solenoid Transmission vent line Voltage regulator Switch, oil pressure Cam position sensor Figure D-8. Wiring Harness, Right Side View...
Page 53 HOME b1122absxu Vent line Feed oil line from the oil pump to the oil cooler Feed oil line Return oil line from the oil cooler to the oil ﬁlter housing Return oil line Figure D-9. Oil Lines, Right Side View...
Page 54 HOME b1123absxu Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 55 HOME b1124absx Exhaust valve actuator Mufﬂer valve Figure D-11. Clutch Cable and Exhaust Valve Actuator, Right Side View...
Page 56 HOME b1125acsxu Exhaust valve actuator Cable, seat lock Mufﬂer valve Figure D-12. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator, Left Side View...
Page 57 HOME b1126acsxu TPS adjuster Cable, seat lock EVA mounted on top of functional airbox cover. Figure D-13. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator, Top View...
Page 58 HOME NOTES D-14 2006 Buell Ulysses: Appendix D...
Page 59 Using TEST CONNECTOR KIT (Part No. HD-41404), attach that the throttle plate is fully open. Brown pin probe and patch cord to [179] (1,2). If the throttle plate does not fully open, see CABLE ADJUST- MENT this section. 2006 Buell Ulysses: Appendix E...
Page 60 (4) away from the solenoid bracket (3) until free- play is achieved. 10957f Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position 2006 Buell Ulysses: Appendix E...
Page 61 1/32 in. (0.79 mm) or greater. 10956f Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position 2006 Buell Ulysses: Appendix E...
Page 62 Adjust stop screw, while reading the TPS on Digital CLEANER FILTER. Technician, until setting is between the range of 10.4 to 10.9. 10925 10924 Cable stop screw Active cable wheel Figure E-3. Active Intake Cable Stop Screw 2006 Buell Ulysses: Appendix E...
Page 63 HOME Active Intake Solenoid Figure E-4. Active Intake System 2006 Buell Ulysses: Appendix E...
Page 64 Continuity present? Go to page 2 Repair open in Page 2 of 2 W/GY wire. Repair open in GY/O wire. DIAGNOSTIC NOTE If DTC is historic, wiggle harness while performing measurements in chart to locate intermittents. 2006 Buell Ulysses: Appendix E...
Page 65 Does solenoid attempt to pull throttle almost closed? Replace solenoid Hold throttle wide open. Energize active intake solenoid. Does throttle close to an angle less than 11 degrees? Replace ECM CABLE ADJUSTMENT in this section. 2006 Buell Ulysses: Appendix E...
Page 66 Cable connector Active intake cable Fasteners (2), bracket to solenoid Cable adjusting nut Active intake solenoid Cable bracket Solenoid bracket Active cable jam nut 10. Air cleaner baseplate assembly Figure E-5. Disconnecting Active Intake System 2006 Buell Ulysses: Appendix E...
Page 67: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 69: Safe Operating Maintenance
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...
Page 70: Repair And Replacement Procedures
Clean all rust from the machined surfaces of new parts. Bearings do not usually need to be removed. Only remove Part Replacement bearings if necessary. Always replace worn or damaged parts with new parts. 2006 Buell Ulysses: Maintenance...
Page 71: Part Protection
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...
Page 72: Storage Units
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. 2006 Buell Ulysses: Maintenance...
Page 73: Fuel And Oil
If the engine is run long enough for the crankcase to age and/or equipment malfunction. (00148a) become thoroughly heated, the water returns to vapor and is Buell motorcycles were designed to give the best perfor- then exhausted. mance using unleaded gasoline. Some fuel suppliers sell An engine used for only short trips, and seldom allowed to gasoline/alcohol blends as a fuel.
Page 74: Maintenance Schedule
Engine mounts and stabilizer links Inspect Road test Verify component and system functions NOTES: Should be performed by an authorized Harley-Davidson/Buell dealer, unless you have the proper tools, service data and are mechanically qualiﬁed. Change brake ﬂuid every two (2) years. 2006 Buell Ulysses: Maintenance...
Page 75 Brake pad linings and Minimum brake pad thickness 0.040 in. (1.0 mm) or less discs 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) 2006 Buell Ulysses: Maintenance...
Page 76 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) 2006 Buell Ulysses: Maintenance...
Page 77: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Buell motorcycle batteries are permanently sealed, mainte- Voltmeter Test nance-free, valve-regulated, lead/calcium and sulfuric acid Refer to Table 1-4. The voltmeter test provides a general indi- batteries. The batteries are shipped pre-charged and ready to cator of battery condition.
Page 78: Cleaning And Inspection
Inspect the battery case for cracks or leaks. 100 % at 77 ° F at 105 ° F 50 % M O N T H S O F S T A N D Figure 1-2. Battery Self-Discharge Rate 1-10 2006 Buell Ulysses: Maintenance...
Page 79 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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Maintenance 1-11...
Page 80: Engine Lubrication System
(00184a) The motorcycle must be on level ground, on the side- stand, with the engine off. Figure 1-3. Unscrew and remove dipstick from oil tank/swingarm ﬁller hole. Wipe dipstick clean. 1-12 2006 Buell Ulysses: Maintenance...
Page 81: Engine Oil And Filter Change
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...
Page 82 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...
Page 83: Brake System Maintenance
5). Use only D.O.T. 4 brake ﬂuid in motorcycles that spec- age. (00239a) ify 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 seri- ous injury. 2006 Buell Ulysses: Maintenance 1-15...
Page 84 Distorted, glazed or contaminated Replace pads. brake pads. Brake pads drag on rotor – Cup in master cylinder not uncovering Inspect master cylinder. will not retract. relief port. Rear brake pedal linkage out of Adjust linkage. adjustment. 1-16 2006 Buell Ulysses: Maintenance...
Page 85 Install diaphragm, stiffener and cap to front master cylin- der reservoir and tighten fasteners to 9-13 in-lbs (1.0- 1.5 Nm). Remove protective cover from molded-in-color surfaces, right handlebar switches and instrument panel. Figure 1-11. Reservoir Fluid Level Indicator 2006 Buell Ulysses: Maintenance 1-17...
Page 86 Tighten rear caliper bleeder valve to 36-60 in-lbs (4- 7 Nm) and replace the rubber cap. Verify brake ﬂuid level is between the upper and lower lines on the side of the reservoir. Thread cap on reservoir and tighten securely. 1-18 2006 Buell Ulysses: Maintenance...
Page 87 Thread locknut (3) ﬂush against top surface of clevis and tighten to 130-173.5 in-lbs (14.7-19.6 Nm). 11138 NOTE Brake pedal has no free play adjustment. Master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-15. Rear Brake Pedal Pushrod Adjustment 2006 Buell Ulysses: Maintenance 1-19...
Page 88: Brake Pads
NOTE 2.5 FRONT WHEEL 2.6 REAR WHEEL for rotor replacement procedure. 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...
Page 89: Brake Pad Replacement
Remove two mounting fasteners (1) securing brake cali- per and carrier assembly to swingarm. Lift caliper and carrier assembly up and off of rotor. Remove pin hanger (3). Remove inner and outer pads, being careful not to dis- lodge pad spring. 2006 Buell Ulysses: Maintenance 1-21...
Page 90 “wear in” properly with the rotor. 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...
Page 91: Tires And Wheels
WARNING WARNING Every time a wheel is removed. Use only Buell approved tires. See a Buell dealer. Using When storing or removing the motorcycle for the season. non-approved tires can adversely affect stability, which Check wheel bearings for wear and corrosion. Excessive play could result in death or serious injury.
Page 92: Transmission Fluid
84-108 in-lbs (10- 12 Nm). Clutch diaphragm spring Clean up any ﬂuid that may have spilled on mufﬂer. Clutch adjusting screw Primary cover Correct chaincase lubricant level Figure 1-27. Fluid Level 1-24 2006 Buell Ulysses: Maintenance...
Page 93 Adjuster adjusting screw clockwise until it aligns. Figure 1-28. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-29. Clutch Adjustment (Typical 2006 Buell Ulysses: Maintenance 1-25...
Page 94 Each time the clutch inspection cover is removed the gasket must be replaced. Figure 1-25. Install clutch inspection cover and new Figure 1-30. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). 1-26 2006 Buell Ulysses: Maintenance...
Page 95: Drive Belt
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...
Page 96 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...
Page 97 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...
Page 98 HOME NOTES 1-30 2006 Buell Ulysses: Maintenance...
Page 99: Primary Chain
Install primary chain inspection cover ENGINE and new gasket to primary cover using two fasteners TEMPERATURE with captive washers. Tighten fasteners to 84-108 in-lbs (10-12 Nm). Cold 3/8-1/2 9.5-12.7 Hot (normal running 1/4-3/8 6.4-9.5 temperature) 2006 Buell Uylsses: Maintenance 1-31...
Page 100 Loosen locknut (1). Turn adjusting fastener (2): Clockwise (inward) to reduce free play. Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Locknut Adjusting Fastener Figure 1-34. Chain Tension Adjusting Fastener 1-32 2006 Buell Uylsses: Maintenance...
Page 101: Suspension Damping Adjustments
Inspect your GVWR is the sum of the weight of the motorcycle, acces- tires regularly and see a Buell dealer for replacements. sories, and the maximum weight of the rider, passenger Riding with excessively worn, unbalanced or under- and cargo that can be safely carried.
Page 102 * 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...
Page 103 Using a screwdriver, turn the slotted dial Figure 1-36. Front Fork Compression Damping Adjuster clockwise until it stops. This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. 2006 Buell Uylsses: Maintenance 1-35...
Page 104 Then turn the dial counterclockwise the number of turns recommended in Table 1-10. 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...
Page 105: Steering Head Bearings
With scale 90 degrees from fork leg, pull front or damaged steering or suspension systems. Contact a wheel to center position. Buell dealer for repairs. Loose, worn or damaged steer- The desired resistance is between 1-7 lbs (0.5-3.2 kg). ing or suspension components can adversely affect sta-...
Page 106: Spark Plugs
A plug with eroded electrodes, heavy deposits or a cracked insulator must be replaced. A plug with a white, yellow, tan or rusty brown pow- dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals. 1-38 2006 Buell Uylsses: Maintenance...
Page 107 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...
Page 108: Air Cleaner Filter
Thoroughly clean baseplate and inside of air cleaner cover. Figure 1-43. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). 1-40 2006 Buell Uylsses: Maintenance...
Page 109 INSTALLATION Figure 1-45. Place ﬁlter element (1) on baseplate (2). Position air cleaner cover over baseplate. Make sure air ﬁlter remains correctly positioned. Install air cleaner cover by latching six latch tabs (3) to baseplate. 2006 Buell Uylsses: Maintenance 1-41...
Page 110: Throttle Cable And Idle Speed Adjustment
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...
Page 111: Interactive Exhaust Cable
This ensures the system is working prop- For the next step in the procedure it will be necessary to erly. If you do not see the mark, verify previous cable adjust- obtain a permanent marker. ment. 2006 Buell Uylsses: Maintenance 1-43...
Page 112 If cable is routed in front of the frame lug it will cause the mufﬂer valve to stay open not allowing it to work prop- erly. 12. Install air intake cover. See 2.39 INTAKE COVER. 1-44 2006 Buell Uylsses: Maintenance...
Page 113: Ignition Timing
Gently bump ﬂywheel forward in tiny increments. 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. Figure 1-52. Correct Timing 2006 Buell Uylsses: Maintenance 1-45...
Page 114 Tighten sensor assembly fasteners to 15-30 in-lbs (1.7- 3.4 Nm). 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...
Page 115 Check that the correct pattern of light is a circular Low beam pattern and is centered on the horizontal line as shown in Figure 1-57. Figure 1-58. Headlight Switch Adjust headlight alignment. See ADJUSTMENT section. 2006 Buell Uylsses: Maintenance 1-47...
Page 116 48-72 in-lbs (5-8 Nm). b1213x1x Figure 1-60. The vertical headlight adjustment screw is located under the front upper fender. 11792 11793 Figure 1-61. Front Fender Assembly Vertical Headlight Adjustment Screw Figure 1-59. Horizontal Headlight Adjustment 1-48 2006 Buell Uylsses: Maintenance...
Page 117 If closed throttle TP degree reading is not between 5.1° - 6.2°, TPS should be re-calibrated. See ADJUSTMENT below. Connect vehicle to Digital Technician. Select calibrations screen/TPS Function. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-62. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 118: Removal From Storage
Wash and polish molded-in-color, painted and chrome- plated surfaces. 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...
Page 119: Troubleshooting
18. TP Sensor/fast idle screw not set properly. See dealer. 21. Obstructed fuel tank vent valve or pinched vent tube. 19. No output from CMP sensor. See dealer. See dealer. 20. Inoperative fuel pump. See dealer. 22. Air intake screen covered or restricted. 2006 Buell Uylsses: Maintenance 1-51...
Page 120: Electrical System
Primary chain badly worn or links tight as a result of insufﬁcient lubrication. Poor Fuel Economy Wheels not aligned and/or tires worn. Oxygen sensor damaged or malfunctioning (bike running Internal engine problem. rich). See dealer. Wheels not balanced correctly. Air intake screen covered or restricted. 1-52 2006 Buell Uylsses: Maintenance...
Page 121 See 1.11 SUSPENSION DAMPING ADJUSTMENTS. 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...
Page 122 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...
Page 123 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 125: Specifications
4.4 gallons 16.7 Runout - fork tube 0.008 Reserve/Low fuel light at 0.83 gal- lons Oil tank 2.5 quarts (wet - for normal oil change) Fork oil (each fork) 17.75 0.53 ounces Transmission 1.0 quart 0.95 2006 Buell Ulysses: Chassis...
Page 126: Torque Values
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 2006 Buell Ulysses: Chassis...
Page 127 Right side rider footpeg mount 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 page 3-101 Rotor mounting fasteners, front 25-27 ft-lbs 34-37 Nm Replace with new, page 2-16 2006 Buell Ulysses: Chassis...
Page 128 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 2006 Buell Ulysses: Chassis...
Page 129: Tire Specifications
8423 WARNING WARNING Tires must be correctly matched to wheel rims. 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) Figure 2-1. Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface.
Page 130: Vehicle Identification Number
Figure 2-2. Buell Vehicle Identiﬁcation Number (V.I.N.) Typical (All Models Built Before May 2005) Table 2-8. Buell 2006 XB Models V.I.N. Description (All Models Built Before May 2005) ITEM...
Page 131 HOME b1203x1x Figure 2-3. Typical 2006 Buell Vehicle Identiﬁcation Number (All Models Built After May 2005) Table 2-9. Buell 2006 XB Models V.I.N. Description (All Models Built After May 2005) ITEM DESCRIPTION POSSIBLE VALUES WMI Code 4MZ = Buell vehicles originally manufactured for sale...
Page 132: Wheels
Damper tubes. Check for leaks. See 2.16 FRONT FORK. Shock absorbers. Check damping action and mounts. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. Swingarm bearings. Check for proper torque and replace worn or damaged bearings. 2.19 SWINGARM AND BRACE. 2006 Buell Ulysses: Chassis...
Page 133 WARNING WARNING To prevent death or serious injury, use the following Buell tires are equipped with wear bars that run horizon- guidelines when installing a new tire or repairing a ﬂat: tally across the tread. When wear bars become visible and only 1/32 in.
Page 134: Front Wheel
Figure 2-6. Raise the wheel up until the rotor clears 8441 the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal. Remove wheel. Figure 2-6. Front Wheel Removal 2-10 2006 Buell Ulysses: Chassis...
Page 135 Forcing screw Figure 2-9. Expand the Collet Figure 2-10. Place the bridge (1) against the wheel hub. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2006 Buell Ulysses: Chassis 2-11...
Page 136 WARNING Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM MAINTENANCE. 2-12 2006 Buell Ulysses: Chassis...
Page 137: Bearing Installation
Bearing Installer/Remover (Part No. HD-44060), with the Remove the nut, bearing, washer, FRONT BEARING smaller diameter toward the wheel hub. Insert the forcing INSTALLER (Part No. B-43993-9) and forcing screw. screw and backing plate into the wheel hub. 2006 Buell Ulysses: Chassis 2-13...
Page 138 (6) until the bearing contacts the spacer. 14. Remove the nut, bearing, washer, FRONT BEARING INSTALLER (Part No. B-43993-10) and forcing screw. 15. Install the wheel. See INSTALLATION under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-16. Install the Spacer 2-14 2006 Buell Ulysses: Chassis...
Page 139 (8) toward center of wheel. which could result in death or serious injury. Align reference dot on front rotor with the valve stem. 2006 Buell Ulysses: Chassis 2-15...
Page 140 Install right side fender fasteners. See 2.36 FENDERS. 8419 NOTE Locate and secure the front brake line grommet between the right side and the lower fender. Axle (left handed thread) Front axle pinch fasteners (2) Figure 2-20. Front Wheel Mounting 2-16 2006 Buell Ulysses: Chassis...
Page 141: Rear Wheel
See BRAKE ROTORS 1.6 BRAKE SYSTEM MAINTENANCE. Remove rear wheel bearings using BUSHING AND BEARING PULLER (Part No. B43993-8) and WHEEL BEARING REMOVER AND INSTALLER (Part No. HD- 44060). Remove rear wheel spacer (4). 2006 Buell Ulysses: Chassis 2-17...
Page 142 HOME b0936x2x Rotor mounting fastener (6) Brake rotor Wheel bearing (2) Wheel spacer Wheel Sprocket Sprocket fastener (6) Axle Figure 2-23. Rear Wheel Assembly 2-18 2006 Buell Ulysses: Chassis...
Page 143 35-37 ft-lbs (48-50 Nm). Install rear rotor (2). Position rear brake rotor (2) on wheel (5). Install brake rotor (2) with new rotor mounting fas- teners (1) and tighten to 25-27 ft-lbs (34-37 Nm). 2006 Buell Ulysses: Chassis 2-19...
Page 144 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 11169 result in death or serious injury. (00289a) Figure 2-27. Rear Brake Caliper Carrier Fasteners 2-20 2006 Buell Ulysses: Chassis...
Page 145: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-11. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-29. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2006 Buell Ulysses: Chassis 2-21...
Page 146: Tires
Inadequate tread depth can cause an accident which could result in death or serious injury. Buell front and rear tires are not the same. Inter- changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 147 Installing a tire with the wrong rotation could result in death or serious injury. Buell front and rear tires are not the same. Inter- Figure 2-33. Starting Bead on Rim (Typical) changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 148 Figure 2-34. Checking Tire Lateral Runout Install tire and again check tire radial runout. Table 2-12. Tire Runout b0088x2x RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 Gauge Figure 2-35. Checking Tire Radial Runout 2-24 2006 Buell Ulysses: Chassis...
Page 149: Wheel Balancing
Allow eight hours for adhesive to cure completely before using wheel. NOTE If wheel assembly is out of speciﬁcation (1 oz. front, 2 oz. rear) rotate tire on rim and rebalance until wheel is within speciﬁcation. 2006 Buell Ulysses: Chassis 2-25...
Page 150: Brake Pedal
Install new cotter pin (7). 11128 Rear master cylinder body Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-38. Brake Pedal Assembly Figure 2-37. Brake Pedal 2-26 2006 Buell Ulysses: Chassis...
Page 151: Front Brake Master Cylinder And Hand Lever 2.10
Pivot bolt nut (metric) 10. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-39. Front Brake Hand Lever Assembly 2006 Buell Ulysses: Chassis 2-27...
Page 152: Front Master Cylinder
Inspect outlet port that mates with brake line ﬁtting. As a master cylinder reservoir (4) and discard. critical sealing surface, replace housing if any scratches, dents or other damage is noted. 8424 Piston assembly Circlip Figure 2-40. Piston Assembly in Master Cylinder 2-28 2006 Buell Ulysses: Chassis...
Page 153: Front Master Cylinder
(15) and banjo bolt (13) (metric) and tighten to 16-20 ft-lbs (22-27 Nm).LOCTITE 272 (red) Ridge on rubber boot Circlip Groove on piston Primary seal of piston Spring Figure 2-41. Front Master Cylinder Piston Assembly 2006 Buell Ulysses: Chassis 2-29...
Page 154 (00316a) 11. Turn ignition key switch to ON. Apply brake hand lever to test brake lamp operation. Turn ignition key switch to OFF. Figure 2-44. Reservoir Brake Fluid Level 2-30 2006 Buell Ulysses: Chassis...
Page 155: Front Brake Line
P-clamp (behind front module) P-clamp on fork tube Brake line Right lower fender fasteners Front brake caliper Figure 2-46. Front Brake Line Bleeder valve Banjo bolt Copper washers Figure 2-45. Bleeder Valve and Banjo Bolt (Caliper) 2006 Buell Ulysses: Chassis 2-31...
Page 156 Install brake line to caliper. Figure 2-45. Install new copper washer (3), brake line, new copper washer (3) onto banjo bolt (2). Finger tighten banjo bolt onto front caliper and posi- tion brake line as show in ﬁgure. 2-32 2006 Buell Ulysses: Chassis...
Page 157: Front Brake Caliper
11116 Pin hanger set Caliper pad spring Caliper fasteners Bleeder valve Figure 2-48. Pad Spring (Typical) 6495 Brake line Banjo bolt (metric) Mounting fasteners (2) Figure 2-47. Front Brake Caliper Figure 2-49. Removing Pistons (B-42887) 2006 Buell Ulysses: Chassis 2-33...
Page 158 Install two new o-rings (6) in grooves of each piston bore. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2-34 2006 Buell Ulysses: Chassis...
Page 159 HOME b0976x2x Pin hanger set Brake bleeder Bleeder cap Caliper Piston Piston o-rings Pad spring Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-50. Front Caliper Assembly 2006 Buell Ulysses: Chassis 2-35...
Page 160: Rear Brake Master Cylinder
Figure 2-51. Brake Bleeder Valve, Rear Caliper PEDAL. Remove seat. See 2.45 SEAT. Figure 2-53. Disconnect brake light connector 11127 located under the seat. Reservoir hose Cotter pin Banjo bolt (metric) Fasteners (2) Figure 2-52. Rear Master Cylinder 2-36 2006 Buell Ulysses: Chassis...
Page 161 Pedal bearing Sleeve Brake pedal fastener Brake pedal 10. Cotter pin 11. Rear master cylinder mount screw (2) Figure 2-55. Rear Master Cylinder Assembly Reservoir Clamp Fastener and washer Remote reservoir hose Figure 2-54. Remote Reservoir 2006 Buell Ulysses: Chassis 2-37...
Page 162 Circlip must be snapped into the groove of the master cylinder body. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-38 2006 Buell Ulysses: Chassis...
Page 163 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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Chassis 2-39...
Page 164: Rear Brake Line
10. Remove brake line from motorcycle. NOTE Damaged banjo bolt seating surfaces will leak when reas- sembled. Prevent damage to seating surfaces by carefully removing brake line components. Remove banjo bolt (3) from rear caliper. Discard copper washers. 2-40 2006 Buell Ulysses: Chassis...
Page 165 If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 11. Test ride motorcycle and check for proper brake opera- tion. 2006 Buell Ulysses: Chassis 2-41...
Page 166: Rear Brake Caliper
Figure 2-62. Removing Rear Brake Caliper Piston Figure 2-62. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. 2-42 2006 Buell Ulysses: Chassis...
Page 167 Install a new bleeder valve (metric) if necessary and Replace both pads as a set if the friction material of tighten to 36-60 in-lbs (4-7 Nm). either pad is worn to 0.04 in. (1.0 mm) or less. 2006 Buell Ulysses: Chassis 2-43...
Page 168 Low visibility of rider can result in death or serious injury. (00316a) NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rotor. 2-44 2006 Buell Ulysses: Chassis...
Page 169: Front Fork
Remove fork from lower fork clamp (3). Repeat 4 through 6 on opposite side. Screw, pinch fastener Triple clamp, upper Triple clamp assembly, lower Screw, pinch fastener Figure 2-65. Upper and Lower Fork Clamp Assembly b0992x2x Figure 2-66. Stopper Ring 2006 Buell Ulysses: Chassis 2-45...
Page 170 TOOL (1) (Part No. HD-41177) in a vise and install the upper part of the front fork in the holding tool. Remove snap ring (2). Figure 2-69. Removing Fork Cap From Outer Tube Figure 2-69. Remove fork cap from outer tube. 2-46 2006 Buell Ulysses: Chassis...
Page 171 FORK SPRING COMPRESSING TOOL (HD-45966) assembly. comes with a cup and screw that are for FLT models only and not to be used with Buell. Remove preload washer (4) and slider piston (5). Figure 2-70. Expand fork and remove from FORK When using the FORK SPRING COMPRESSING TOOL SPRING COMPRESSION TOOL.
Page 172 Slider piston Inner slider piston o-ring 16. Spring 25. Oil seal stopper ring Snap ring 17. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-72. Front Fork Assembly 2-48 2006 Buell Ulysses: Chassis...
Page 173 (9) counter clockwise till it stops. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2006 Buell Ulysses: Chassis 2-49...
Page 174: Fork Assembly
Install the centering plate (12) onto the damper assembly (11) and insert the damper assembly into the slider fork (27). 11. Replace the sealing washer (13) and center bolt (14) (metric). Tighten the center bolt to 22-30 ft-lbs (30- 40 Nm). 2-50 2006 Buell Ulysses: Chassis...
Page 175 Thread fork cap (3) into fork tube (18) and tighten to 132-144 in-lbs (14.9-16.2 Nm). 24. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (1). 25. Install snap ring (8). 2006 Buell Ulysses: Chassis 2-51...
Page 176 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.36 FENDERS. 13. Check headlight alignment. See 1.18 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. 2-52 2006 Buell Ulysses: Chassis...
Page 177: Fork Clamps, Upper And Lower
FORK. b1136x2x Stem capnut Stem pinch fastener Upper fork clamp pinch fastener (2) Upper fork clamp Head bearing (2) Lower fork clamp with stem Lower fork clamp pinch fastener (4) Figure 2-78. Steering Stem Assembly 2006 Buell Ulysses: Chassis 2-53...
Page 178 Repeat previous two steps on second fork assembly. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 272 (red) and tightening to 23-25 ft-lbs (31-34 Nm). 2-54 2006 Buell Ulysses: Chassis...
Page 179: Steering Head Bearings
(upper bearing removed for clarity) NOTE Discard steering head bearings and replace with new. Steer- ing head bearings are not reusable. Wheel Bearing Backing Plate (Part No. B-43993-12) Figure 2-80. Steering Head Bearings Installation Tools 2006 Buell Ulysses: Chassis 2-55...
Page 180 Install the bearing (4), washer (5) and nut (6) from the STEERING HEAD BEARING RACE INSTALLER (Part No. HD-39302) onto the forcing screw (1). Tighten the nut (6) by hand, until the bearing is started into the bore in the steering head. 2-56 2006 Buell Ulysses: Chassis...
Page 181 11. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). 12. Use LOCTITE 272 (red) on steering stem pinch fastener and tighten to 23-25 ft-lbs (31-34 Nm). 13. Install headlight assembly and support bracket. See 2.28 HEADLIGHTS AND SUPPORT BRACKET. Figure 2-83. Install Bearings 2006 Buell Ulysses: Chassis 2-57...
Page 182: Swingarm And Brace
2.34 HEEL GUARD AND FOOTPEG MOUNTS. Fender/upper belt guard b1217x1x Fender/upper belt guard fasteners Lower stone guard Lower belt guard Lower belt guard fasteners Sprocket cover Lower stone guard fastener Figure 2-85. Belt Guard Assembly 2-58 2006 Buell Ulysses: Chassis...
Page 183 TION SYSTEM. Remove rear fender. See 2.36 FENDERS. Figure 2-85. Remove lower belt guard (4). Remove rear wheel. See 2.6 REAR WHEEL. Remove chin fairing and sprocket cover. See 2.38 CHIN FAIRING 2.35 SPROCKET COVER. 2006 Buell Ulysses: Chassis 2-59...
Page 184 34 ft-lbs (39-46 Nm). mine air ﬂow rates. (00061a) Thoroughly clean all components in solvent. Blow dry with compressed air. 11972 11963a Return. Vent Feed Figure 2-87. Jiffy Tite, Quick Disconnect Oil Lines and Fittings 2-60 2006 Buell Ulysses: Chassis...
Page 185 Tighten rear axle to 48-52 ft-lbs (65-70 Nm). Tighten rear axle pinch fastener (12) to 40-45 ft-lbs (54- 61 Nm). Install right footpeg mount. Tighten to 9-132 in-lbs (12- 15 Nm). See 2.34 HEEL GUARD AND FOOTPEG MOUNTS. 2006 Buell Ulysses: Chassis 2-61...
Page 186: Front And Rear Isolator
10. Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). 11. See Figure 2-88. Install clutch cable wire form. Tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). 2-62 2006 Buell Ulysses: Chassis...
Page 187: Frame
Install rear shock. See 2.23 REAR SHOCK ABSORBER. Install tail frame. See 2.41 LEFT TAIL SECTION AND BATTERY PAN. Install exhaust header. See 2.32 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2006 Buell Ulysses: Chassis 2-63...
Page 188: Frame Pucks
Align the corners with the pencil marks and tack the puck to the frame at the corners. Figure 2-93. Pressing Puck to Frame From the tacked corners, pivot the puck onto the frame keeping the directional point aligned with the horizontal crease. 2-64 2006 Buell Ulysses: Chassis...
Page 189: Rear Shock Absorber
Rear shock body 13. Lower shock mount fastener Remote reservoir clamp fastener 14. Upper shock mount fastener Remote reservoir clamp 15. Rear shock spring Remote reservoir 16. Shock spring retainer kit Figure 2-94. Rear Shock Absorber Assembly 2006 Buell Ulysses: Chassis 2-65...
Page 190 (00070a) Figure 2-94. Lower rear shock assembly, preload 12. Install seat. See 2.45 SEAT. adjuster assembly and remote reservoir into position. NOTE Rear brake switch wiring is routed over the remote reservoir. 2-66 2006 Buell Ulysses: Chassis...
Page 191: Throttle Control
Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.15 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install airbox assembly. See 4.44 AIR CLEANER ASSEMBLY. 10. Install right handlebar deﬂector. See 2.25 DEFLEC- TORS/HANDLEBARS. 2006 Buell Ulysses: Chassis 2-67...
Page 192: Deflectors
Install new deﬂector fasteners (2) and tighten to 24-36 in-lbs (2.7-4.1 Nm). b1170x2x Deﬂectors Deﬂector fasteners (4) Clutch pivot shaft Pivot shaft riser Pivot shaft jam nut Brake pivot shaft Handlebar end cap Figure 2-98. Deﬂectors 2-68 2006 Buell Ulysses: Chassis...
Page 193: Clutch Control/Cable
Wind deﬂector standoff Rubber boot Clutch hand lever Cable adjuster Clutch adjuster Clutch cable adjuster boot Jam nut Cable end Clutch cable ferrule Figure 2-99. Clutch Cable Adjuster Mechanism Figure 2-101. Clutch Hand Control Assembly 2006 Buell Ulysses: Chassis 2-69...
Page 194 Engine shift lever Shifter bracket Shift pedal assembly Drain plug Figure 2-102. Shifter Linkage 8413 11168 Outer ramp and hook Coupling Cable end Figure 2-103. Clutch Release Mechanism (Typical) Figure 2-104. Clutch Cable and Fitting 2-70 2006 Buell Ulysses: Chassis...
Page 195: Clutch Cable
After applying LOCTITE 272 (red), tighten engine shift Shift linkage assembly lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). Figure 2-105. Installing Shift Linkage NOTE HOSE AND WIRE ROUTING in Appendix D. Route clutch cable through upper triple clamp. 2006 Buell Ulysses: Chassis 2-71...
Page 196 11. Install new clutch cover gasket. 12. See Figure 2-102. Install clutch inspection cover (2) with three TORX screws with washers. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm). 2-72 2006 Buell Ulysses: Chassis...
Page 197: Headlight Grill
ﬁts snugly on the head- and spread to remove grill. lights. Spread headlight grille with hands and snap it back in place over the headlights. 12051 Figure 2-107. Headlight Grille 2006 Buell Ulysses: Chassis 2-73...
Page 198: Headlights And Support Bracket
Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-108. Headlight and Support Bracket 2-74 2006 Buell Ulysses: Chassis...
Page 199 For alignment of rubber boots, 7.12 HEADLIGHT. b1226x2x b1150x2x Boot (2) Bulb holder (2) Bulb (2) Headlight housing Wiring harness Position bulb socket (used for HDI only) Headlight connector Figure 2-109. Headlight Assembly 2006 Buell Ulysses: Chassis 2-75...
Page 200 Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-110. Headlight and Support Bracket 2-76 2006 Buell Ulysses: Chassis...
Page 201: Front Modules
(00070a) clamp. 11. See Figure 2-112. Remove the left front module. 12. Install seat. See 2.45 SEAT. 12. See Figure 2-111. Remove the ﬁnal fastener and the right front module. 2006 Buell Ulysses: Chassis 2-77...
Page 202 Figure 2-111. Right Front Module Fastener and Brake Line P-Clamp Fastener (Typical) b1192x2x b1193x2x Left and right front module Right front module overlaps left front module Right front module Left front module Upper module Figure 2-112. Front Module 2-78 2006 Buell Ulysses: Chassis...
Page 203: Handlebars
Place the upper handlebar clamp in position and thread the four screws in place after applying LOC- TITE 272 (red). Tighten both front screws to 10-12 ft-lbs (14-16 Nm). Then tighten both rear screws (2) 10-12 ft-lbs (14-16 Nm). 2006 Buell Ulysses: Chassis 2-79...
Page 204 HOME b1209x1x Endcap (2) Handlebar Handlebar clamp Clamp fasteners (4) Left hand grip Harness retainer (4) Figure 2-113. Handlebar Assembly 2-80 2006 Buell Ulysses: Chassis...
Page 205: Mirrors
Loosen mount (3) and remove from bracket (4). NOTE Before tightening adjuster nut, position mirrors for rider. Install mirror (1) and tighten adjuster to 115-130 in-lbs (13-14.7 Nm). b1210x1x 12066 Mirror Adjuster nut Mount Bracket Figure 2-114. Mirrors and Mounting Hardware 2006 Buell Ulysses: Chassis 2-81...
Page 206: Exhaust System
SERVICE. ing the exhaust header. Remove oxygen sensor. See 4.33 OXYGEN SENSOR. Figure 2-116. Remove exhaust header (2) by removing mounting fasteners (3). Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2-82 2006 Buell Ulysses: Chassis...
Page 207 3.3 ENGINE ROTATION FOR NOTE SERVICE. For assembly details of the interactive exhaust system, see INSTALLATION under 7.6 INTERACTIVE EXHAUST SYS- Rear Mufﬂer Bracket TEM. Figure 2-115. Slide rear mufﬂer bracket over oil feed line. 2006 Buell Ulysses: Chassis 2-83...
Page 208 Torca mufﬂer clamps have eliminated the need for silicone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Buell recommends that mufﬂer clamp assemblies be discarded and replaced each time they are removed.
Page 209: Rider And Passenger Footpegs
Check that footpeg clicks in the up and down position. Install clip (3) b0934a2x Footpeg mount Footpeg mount fasteners (3) Clip, footpeg Passenger footpeg Detent plate Ball Spring Spring 10. Rider footpeg Figure 2-117. Rider Footpeg, Mount and Heel Guard Assembly 2006 Buell Ulysses: Chassis 2-85...
Page 210: Heel Guard And Footpeg Mounts
Apply LOCTITE 272 (red) to footpeg mount fasteners (2), install and tighten to 132-144 in-lbs (15-16 Nm). Install brake pedal fastener. See 2.9 BRAKE PEDAL. Figure 2-119. Heel Guard 12076 Figure 2-120. Rear Brake Master Cylinder Location 2-86 2006 Buell Ulysses: Chassis...
Page 211: Sprocket Cover
36 in-lbs (1-4 Nm). Figure 2-121. Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. See 2.38 CHIN FAIRING. b1187x2x Long fastener and washer Sprocket cover Short fastener and washer (2) Figure 2-122. Sprocket Cover 2006 Buell Ulysses: Chassis 2-87...
Page 212: Fenders
10. Rear fender and brake line. 11. Rear fender fastener (5) Apply LOCTITE 272 (red) and install rear fender (10) with fasteners and washers (11). Tighten to 12-36 in-lbs Figure 2-123. Front and Rear Fenders (1-4 Nm). 2-88 2006 Buell Ulysses: Chassis...
Page 213: Belt Guard
Remove scissor jack from motorcycle. the metal stone guard (5). b1217x1x Rear fender/upper belt guard Rear fender/belt guard fasteners (2) Lower belt guard Lower belt guard fasteners (2) Stone guard Figure 2-124. Belt Guard Assembly 2006 Buell Ulysses: Chassis 2-89...
Page 214: Chin Fairing
Figure 2-125. Chin Fairing Turn wheel full right or left for easier access to center fasten- ers. Align left section (3) and loosely install left side fasteners and washers (4). Tighten all fasteners to 36-48 in-lbs (4-5 Nm). 2-90 2006 Buell Ulysses: Chassis...
Page 215: Intake Cover
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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Chassis 2-91...
Page 216: Air Scoops
Oil cooler air scoop fastener and washer (2) Oil cooler air scoop Ram air scoop fastener and washer (3) Ram air scoop Engine scoop fastener and washer (3) Engine scoop Figure 2-127. RAM Air Scoop, Engine Shroud, Oil Cooler 2-92 2006 Buell Ulysses: Chassis...
Page 217: Left Tail Section And Battery Pan
Remove the shock reservoir fastener and retainer. Push the reservoir aside to access the fastener. Remove remaining fasteners securing right front trunk pan to right side tail sections. Remove remaining components on trunk pan as needed. 2006 Buell Ulysses: Chassis 2-93...
Page 218 Fuse block and relay center 12. Auxiliary power outlet Main harness ground wire [GRD 2] 13. Trunk pan Main harness with plastic grommet 14. Left tail section Figure 2-128. Main Harness and Electrical Components Under Seat 2-94 2006 Buell Ulysses: Chassis...
Page 219 72-96 in-lbs (8-11 Nm). Install fuse block and relay center (5). Install main harness and plastic grommet (7) into battery pan. Install Bank Angle Sensor (2) and connect. Connect rear brake light switch connector [121]. Install ECM. 2006 Buell Ulysses: Chassis 2-95...
Page 220 Front trunk pan fastener to side tail section (2) Seat latch assembly Trunk pan assembly 10. Rear trunk pan fastener to center tail loop (2) 11. Battery pan Figure 2-129. Tail Frame and Trunk Pan Assembly 2-96 2006 Buell Ulysses: Chassis...
Page 221: Center Tail Loop
Right turn signal connector [18]. Tail loop License plate bracket Left turn signal connector [19]. Wire cover License plate lamp connector [45] Tail light connectors [93]. Figure 2-130. Wire Cover/Tail Loop/License Plate Bracket Auxiliary power outlet [180] 2006 Buell Ulysses: Chassis 2-97...
Page 222: Right Tail Section
ECM to one side and loosely install the fastener to retain the nut in the correct location. The rear fastener attaches directly to the battery pan. Remove ECM. Remove rear shock reservoir fastener and retainer. Disconnect the rear brake light switch. 2-98 2006 Buell Ulysses: Chassis...
Page 223 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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Chassis 2-99...
Page 224: Windshield And Windscreen
(6). Remove six windscreen fasteners (5). Remove windscreen (6). b1198a7x Headlight mounting bracket Left front module Windscreen fastener (4) Windshield Windscreen fasteners (6) Windscreen Fairing support, center Right front module Figure 2-134. Flyscreen and Windscreen 2-100 2006 Buell Ulysses: Chassis...
Page 225: Seat
Grip the rear of the seat and pull towards the rear of the Pull up on rear of seat to make sure latch is engaged. motorcycle. Remove ignition key from seat lock. Front tab Seat hook Seat lock latch Figure 2-135. Seat Attachments 2006 Buell Ulysses: Chassis 2-101...
Page 226: Seat Lock
While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install cable strap around seat lock cable in original loca- tion. Install seat. See 2.45 SEAT. 2-102 2006 Buell Ulysses: Chassis...
Page 227 HOME b1214x2x Seat lock Plate Retainer Cable end Cable Cable end Latch screw (metric) (2) Latch Latch bracket 10. Trunk pan 11. Center tail loop Figure 2-136. Seat Lock Assembly 2006 Buell Ulysses: Chassis 2-103...
Page 228: Sidestand
Retract sidestand leg. Extension plate Spring Remove sidestand spring (7) and spring extension plate (6) using SNAP-ON SPRING TOOL (Part No. HE-52B). Figure 2-138. Sidestand Assembly (Extended) Remove sidestand pivot bolt (1s). Extend sidestand leg and remove. 2-104 2006 Buell Ulysses: Chassis...
Page 229 Install sidestand to frame. Apply LOCTITE 272 (red) to fasteners and tightening s to 25-27 ft-lbs (34-37 Nm). Figure 2-140. Threaded Area for Loctite Application Install mufﬂer. See Mufﬂer and Straps 2.32 EXHAUST SYSTEM. Inspect sidestand. 2006 Buell Ulysses: Chassis 2-105...
Page 230: Triple Tail
Hold the RH grab handle and using a Snap-on seal and bushing driver, tap in the bushing. Hold the LH grab handle and assemble the detent and pin. Using a Snap-on seal and bushing driver, tap in the bushing. Figure 2-141. Triple Tail Positions 2-106 2006 Buell Ulysses: Chassis...
Page 231 10. Collar, tail rack Bearing (2) 11. Rear fastener with washer, grab handle Tail rack 12. Front fastener, grab handle Spring 13. LH grab handle 14. Tail loop Figure 2-142. Triple Tail, Passenger Backrest and Luggage Rack 2006 Buell Ulysses: Chassis 2-107...
Page 232 HOME NOTES 2-108 2006 Buell Ulysses: Chassis...
Page 233 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 235 59.1 mm 2.325. (min) 59.1 mm (min) Intake 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg Exhaust 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg 2006 Buell Ulysses: Engine...
Page 236 Side play between ﬂywheels 0.005-0.031 in. 0.1-0.8 mm 0.036 in. 0.9 mm Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm Connecting rod race ID 1.6245-1.6250 in. 41.2623-41.2750 mm 1.6270 in. 41.3258 mm 2006 Buell Ulysses: Engine...
Page 237 Bearing outer race ﬁt in crankcase 0.006 in. 0.2 mm (tight) Interference fit Bearing inner race ﬁt on shaft 0.006 in. 0.2 mm (tight) Interference fit Flywheel endplay in crankcase .003-.010 in. 0.08-0.25 mm .010 in. 0.25 mm 2006 Buell Ulysses: Engine...
Page 238 5-5.5 Nm page 3-36 Oil line ﬁttings at swingarm 108-156 in-lbs 12-17.6 Nm page 3-74 Oil line p-clamp fastener 48-72 in-lbs 5.4-8 Nm page 3-36 Oil pressure signal light switch 50-70 in-lbs 6-8 Nm page 3-84 2006 Buell Ulysses: Engine...
Page 239 23-25.8 Nm page 3-31 Swingarm pivot shaft 24-26 ft-lbs 32.5-35.2 Nm page 3-31 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-14, 3-33 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-36 2006 Buell Ulysses: Engine...
Page 240 “oxygenate” the gas. Your compression by itself, however, may indicate improperly motorcycle will run normally using this type of gas. Buell seated valves, in addition to or in lieu of worn piston rings. recommends you use it when possible, as an aid to cleaner air in our environment.
Page 241: Diagnosing Smoking Engine Or High Oil Consumption
Use a CYLINDER LEAKDOWN TESTER (Part No. HD- 35667A) and follow the speciﬁc instructions supplied with the tester. The following are some general instructions that apply to Buell motorcycle engines: Run engine until it reaches normal operating tempera- ture. 2006 Buell Ulysses: Engine...
Page 242: Engine Rotation For Service
This step is always performed in order to purge fuel lines. 10646a Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-1. Fuel Line and DDFI Electrical Connections (Typical) 2006 Buell Ulysses: Engine...
Page 243 Oxygen sensor connection [137] Throttle cables Figure 3-2. Electrical Connections and Throttle Cables (Typical) 11. See Figure 3-2. Disconnect the ignition coil (2) [83] and remove. 12. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 2006 Buell Ulysses: Engine...
Page 244 Figure 3-3. Remove mufﬂer. See 2.32 EXHAUST SYSTEM. 14. Remove transmission sprocket side cover. 15. Remove idler pulley. See 6.6 DRIVE BELT SYSTEM. NOTE 7.6 INTERACTIVE EXHAUST SYSTEM for speciﬁc details on removal of interactive components. 3-10 2006 Buell Ulysses: Engine...
Page 245 Slide clutch cable adjuster boot (2) up to access clutch adjuster. Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. Wire form Clutch cable adjuster boot Figure 3-4. Clutch Cable Wire form and Adjuster Boot 2006 Buell Ulysses: Engine 3-11...
Page 246 Nut for one fastener for front tie bar assembly 20. Bolt 10. Center tie bar mount 21. Rear tie bar assembly 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-5. Engine Mounting System 3-12 2006 Buell Ulysses: Engine...
Page 247 23. Loosen rear isolator bolt. DO NOT REMOVE. Figure 3-7. Front Isolator and Tie Bar Assemblies 24. See Figure 3-7. Remove front isolator bolt (1). 25. Remove front isolator mount (2) from engine. 26. Rotate engine down. 2006 Buell Ulysses: Engine 3-13...
Page 248 Install center tie bar to engine and tighten to 25-27 ft-lbs (33.9-36.6 Nm). Figure 3-5. Install “V” bracket to main frame from the left side of the vehicle and tighten to 120-144 in-lbs (13.6-16.3 Nm). Remove scissors jack. 3-14 2006 Buell Ulysses: Engine...
Page 249 See SPECIFICATIONS. Install wire form and tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). Figure 3-9. Clutch Cable Wire form Retainer 10501a Figure 3-10. Oil Cooler Feed and Return Oil Line 1/8-1/4 in. (3.175-6.35 mm) Clearance 2006 Buell Ulysses: Engine 3-15...
Page 250 Figure 3-11. Electrical Connections and Throttle Cables (Typical) 11. Connect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 12. See Figure 3-11. Install the ignition coil and connect (2) [83] and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 3-16 2006 Buell Ulysses: Engine...
Page 251 It is important that the front mufﬂer mount is tightened last in order to ensure proper alignment of the exhaust system. When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 2006 Buell Ulysses: Engine 3-17...
Page 252 AND FOOTPEG MOUNTS. 22. Install sprocket cover. See 2.35 SPROCKET COVER. 23. Install chin fairing. See 2.38 CHIN FAIRING. 24. Install air scoops, right and left sides. See 2.40 AIR SCOOPS. 25. Connect fuel pump. 3-18 2006 Buell Ulysses: Engine...
Page 253: Stripping Motorcycle For Engine Service
(-) battery cable before proceeding. (00048a) 10646a Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-14. Fuel Line and DDFI Electrical Connections (Typical) 2006 Buell Ulysses: Engine 3-19...
Page 254 Figure 3-15. Electrical Connections and Throttle Cables (Typical) Figure 3-15. Disconnect the ignition coil connector (2) and remove. 10. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 11. Disconnect throttle cables from induction module/throttle body. 3-20 2006 Buell Ulysses: Engine...
Page 255 13. Remove fasteners and chin fairing. ACTIVE EXHAUST SYSTEM. 14. Remove transmission sprocket side cover. 16. See Figure 3-16. Remove mufﬂer. See 2.32 EXHAUST 15. Remove rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. SYSTEM. 2006 Buell Ulysses: Engine 3-21...
Page 256 Figure 3-17. Remove oil ﬁlter (8). NOTE Remove the right side footrest mount and secure towards 18. Remove left and right side rider footrest mounts. See rear of vehicle. 2.34 HEEL GUARD AND FOOTPEG MOUNTS. 3-22 2006 Buell Ulysses: Engine...
Page 257 Remove the three cable straps holding regulator wir- ing harness in order to extend the harness to remove “V” bracket Remove front tie-bar from “V” bracket. Remove front tie-bar from engine. Unbolt “V” bracket from main frame. 2006 Buell Ulysses: Engine 3-23...
Page 258 Disconnect oil return line (4) at swingarm/oil reser- voir (1). See 3.10 OIL LINE FITTINGS/ REMOVAL. Disconnect oil return line (4) at oil pump (14) and remove. 29. Disconnect and remove oil cooler oil lines. See 3.11 OIL COOLER. 3-24 2006 Buell Ulysses: Engine...
Page 259 Remove clutch cable ferrule from hand lever. 31. See Figure 3-21. Remove sidestand assembly. b0946c2x Pivot bolt Spring extension plate Spring post Sidestand bracket Sidestand bracket fasteners (2) Sidestand leg Figure 3-21. Sidestand Assembly (Extended) 2006 Buell Ulysses: Engine 3-25...
Page 260 Anytime front tie-bar is removed, it must ﬁrst be removed from the “V” bracket and then the engine. When reinstalling the tie bar, ﬁrst mount to engine and then to “V” bracket in order to prevent damage to threaded area of crankcase. 3-26 2006 Buell Ulysses: Engine...
Page 261 36. Lower engine with scissors lift all the way down. 37. Move the engine assembly from under the main frame to the right side of the lift. 38. Remove engine. Figure 3-24. Rear Isolator Bolt and Swingarm Pivot Shaft (Typical) 2006 Buell Ulysses: Engine 3-27...
Page 262 Aluminum bushings from front exhaust mount. Timer cover. Figure 3-29. Front Exhaust Mount Bushings (2 piece) Figure 3-30. Wire guard located under the sprocket cover. 8724 8729 Figure 3-30. Wire Guard Figure 3-28. Removing Threaded Insert 3-28 2006 Buell Ulysses: Engine...
Page 263 42. Route a ratcheting tie down through the swingarm bear- ings, up over the main frame, through the top stabilizer area, back down to the ratchet mechanism and secure swingarm to main frame. 2006 Buell Ulysses: Engine 3-29...
Page 264: Engine Installation
Hand thread pivot shaft into crankcase prior to installing the threaded insert. Remove pivot shaft after installing the threaded insert. Figure 3-37. Front Exhaust Mount Bushings (2 piece) Figure 3-36. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. 3-30 2006 Buell Ulysses: Engine...
Page 265 Install cable strap to secure transmission vent line in place. Inspect vent line to verify space between vent line and rear exhaust. 2006 Buell Ulysses: Engine 3-31...
Page 266 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-43. Engine Mounting System 3-32 2006 Buell Ulysses: Engine...
Page 267 120-144 in-lbs (13.6-16.3 Nm). Install front tie-bar to “V” bracket and tighten to 25- 27 ft-lbs (33.9-36.6 Nm). Attach regulator wiring harness to bracket nylon cable straps. 18. Remove scissors jack. 2006 Buell Ulysses: Engine 3-33...
Page 268 At this point it will be necessary to install the oil lines. It is important to follow this procedure to ensure correct ori- entation of oil lines in order to establish the proper clear- ances needed between the oil lines and varied components on the vehicle. 3-34 2006 Buell Ulysses: Engine...
Page 269 Leave all oil line ﬁttings loose at the engine at this time. See 3.10 OIL LINE FITTINGS. NOTE The feed oil line (3) is routed through the right side of the rear mufﬂer bracket (10). 2006 Buell Ulysses: Engine 3-35...
Page 270 13 ft-lbs (16.3-17.6 Nm). 24. See Figure 3-46. Install oil line clamp (13) attaching vent oil line (2) to return oil line (4) in front of starter motor and tighten to 40-50 in-lbs (5-5.5 Nm). 3-36 2006 Buell Ulysses: Engine...
Page 271 29. Verify that the clutch cable and feed line have 1/8-1/4 in. (3.175-6.35 mm) clearance. NOTE When torquing the oil cooler feed and return lines to the oil cooler, verify that the lines do not twist while torquing. 2006 Buell Ulysses: Engine 3-37...
Page 272 Figure 3-49. Oil Cooler Oil Lines b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 6 o’clock Figure 3-50. Oil Cooler Feed and Return Oil Lines Location and Orientation 3-38 2006 Buell Ulysses: Engine...
Page 273 Neutral switch [131]. Speedometer sensor [65] (install cable strap). Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. 2006 Buell Ulysses: Engine 3-39...
Page 274 Connect clutch cable to handlebars and adjust to speciﬁcations. See CLUTCH. Install wire form retainer and tighten fastener to 84- 92 in lbs (9.5-10.4 Nm). Figure 3-52. Correct Routing of Wiring Harnesses and Interactive Mufﬂer Cable 3-40 2006 Buell Ulysses: Engine...
Page 275 HOME b0986x3c Clamp, Torca Mufﬂer Mufﬂer strap, front Front mufﬂer strap fastener Front mufﬂer mount Rear mufﬂer bracket Rear mufﬂer strap fastener Mufﬂer strap, rear (2) Figure 3-54. Mufﬂer and Mounting System 2006 Buell Ulysses: Engine 3-41...
Page 276 [83]. Tighten ignition coil fasteners to 120-144 in-lbs (13.6-16.3 Nm). 10647a Ignition coil Coil connection [83] Cylinder head temperature sensor connection [90] Oxygen sensor connection [137] Throttle cables Figure 3-55. Electrical Connections and Throttle Cables (Typical) 3-42 2006 Buell Ulysses: Engine...
Page 277 The connection for fuel pump is just above the pump located at the rear of the fuel tank on the left side of the vehicle. 47. Install rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. 2006 Buell Ulysses: Engine 3-43...
Page 278: Cylinder Head
20. Gasket (push rod cover) 21. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-57. Rocker Arm and Push Rod Cover Assemblies 3-44 2006 Buell Ulysses: Engine...
Page 279 Remove rocker arms; mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. Figure 3-59. Removing Rocker Arm Shafts 2006 Buell Ulysses: Engine 3-45...
Page 280 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-60. Head Screw Loosening/Tightening Sequence 8684 Figure 3-61. Valve Spring Compressor (Part No. HD-34736B) 3-46 2006 Buell Ulysses: Engine...
Page 281 11. Cylinder o-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-62. Cylinder Head, Cylinder and Piston Assembly 2006 Buell Ulysses: Engine 3-47...
Page 282 Never use a ﬁle or SERVICE WEAR LIMIT of 0.006 in. (0.152 mm). other hardened tool which could scratch or nick valve. Polish valve stem with very ﬁne emery cloth or steel wool. 3-48 2006 Buell Ulysses: Engine...
Page 283 Figure 3-65. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 2006 Buell Ulysses: Engine 3-49...
Page 284: Valve Guides
If the seat is loose or is not fully seated in the head, then seat movement will prevent the proper transfer of heat from the valve. The seat surface must be ﬂush with (or below) the head surface. See 3.1 SPECIFICATIONS for valve seat-to-cylinder head ﬁt. 3-50 2006 Buell Ulysses: Engine...
Page 285 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part No. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-70. Replacing Rocker Arm Bushings 2006 Buell Ulysses: Engine 3-51...
Page 286 Figure 3-72. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. Valve guide brush (Part No. HD-34751) Cylinder head holding ﬁxture (Part No. HD-39786) Figure 3-72. Cleaning Valve Guides 3-52 2006 Buell Ulysses: Engine...
Page 287 Clamp tool in vise and further tighten cylinder head onto the ﬁxture to prevent any movement during operation. Place cylinder head at a 45° angle or one that offers a comfortable working position. 2006 Buell Ulysses: Engine 3-53...
Page 288 0.062 in. (1.575 mm), pro- ceed to the next step. b0972x3x Intake & Exhaust Valve and Seat 60˚ Min. 0.040 in. (1.016 mm) Max. 0.062 in. (1.575 mm) Margin 31˚ 46˚ Figure 3-74. Valve and Seat Dimensions 3-54 2006 Buell Ulysses: Engine...
Page 289 11. Cylinder o-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-75. Cylinder Head, Cylinder and Piston Assembly 2006 Buell Ulysses: Engine 3-55...
Page 290 Failure to use a protective sleeve on the valve stem keeper groove when installing the valve stem seal and collar assem- bly will result in damage to the seal causing leakage around the valve stem, excessive oil consumption and valve sticking. 3-56 2006 Buell Ulysses: Engine...
Page 291 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat Steps 4-11 for the remaining valve. 2006 Buell Ulysses: Engine 3-57...
Page 292 17909-02 Orange/Brown (272.948 mm) NOTE After head(s) have been installed do not turn engine over until both push rods can be turned with ﬁngers. Otherwise, dam- age to push rods or rocker arms may result. 3-58 2006 Buell Ulysses: Engine...
Page 293: Cylinder Head Installation
Tighten each bolt to 13-15 ft-lbs (18-20 Nm). Figure 3-83. Tightening Head Screws Figure 3-83. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 2006 Buell Ulysses: Engine 3-59...
Page 294 20. Gasket (push rod cover) 21. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-84. Rocker Arm and Push Rod Cover Assemblies 3-60 2006 Buell Ulysses: Engine...
Page 295 Place a new inner gaskets on lower rocker box assemblies. Place a new lower gaskets on lower rocker cover. Install upper rocker cover using screws with washers and new ﬁber seals. Tighten screws to 120-156 in- lbs (13.6-17.6 Nm). 2006 Buell Ulysses: Engine 3-61...
Page 296: Cylinder And Piston
Ring set Piston Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-86. Cylinder and Piston 3-62 2006 Buell Ulysses: Engine...
Page 297 Figure 3-89. Removing Piston Rings Remove circlip from claw and discard. Figure 3-89. To remove piston rings spread outward until they clear grooves in piston and lift off. 2006 Buell Ulysses: Engine 3-63...
Page 298 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 3-64 2006 Buell Ulysses: Engine...
Page 299: Deglazing Cylinder
If cylinder clearance exceeds service wear limit, cylinders and remains white. The cylinder is now clean. pistons should be replaced with new components. See SPECIFICATIONS. With the cylinder at room temperature, check the cylinder clearance. See SPECIFICATIONS. 2006 Buell Ulysses: Engine 3-65...
Page 300 No. 240 grit ﬂexible hone to facilitate ring seating. Piston ring sets must be properly ﬁtted to piston and cyl- inder: Ring sets are available to ﬁt standard and oversize pistons. 3-66 2006 Buell Ulysses: Engine...
Page 301 Figure 3-95. Ring End Gap Position Figure 3-95. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. 2006 Buell Ulysses: Engine 3-67...
Page 302 Hone bushing to ﬁnal size using WRIST PIN BUSHING HONE (Part No. HD-35102). Use a liberal amount of honing oil to prevent damage to hone or bushing. Use care to prevent foreign material from falling into the crankcase. 3-68 2006 Buell Ulysses: Engine...
Page 303 Make sure the ring groove is clean. Ring must be fully seated pointing towards the front of the engine. in the groove with the gap away from the slot at the bottom. Install piston pin. 2006 Buell Ulysses: Engine 3-69...
Page 304 PISTON SUPPORT PLATE (Part No. HD-42322). Lubricate cylinder wall, piston, pin and rod bushing with engine oil. Remove protective sleeves from cylinder studs. Install a new cylinder base gasket. Make sure the piston does not bump the studs or crankcase. 3-70 2006 Buell Ulysses: Engine...
Page 305: Lubrication System
A vehicle used only for short runs in cold 1.5 ENGINE LUBRICATION SYSTEM for more informa- weather must have the engine oil drained frequently. tion on checking oil level and changing oil and ﬁlter. 2006 Buell Ulysses: Engine 3-71...
Page 306: Oil Hose Routing And Oil Reservoir
Feed oil line from oil pump to oil cooler 12. P-clamp Feed oil line from oil cooler to crankcase 13. Oil line clamp Oil tank drain plug 14. Oil pump Figure 3-109. Oil Lines and Connections 3-72 2006 Buell Ulysses: Engine...
Page 307: Oil Line Fittings
Repeat to remove the remaining oil lines. Remove oil line ﬁttings and plug the holes until they can Figure 3-110. Oil Line Remover (B-41623-B) be replaced. 10369 Figure 3-111. Oil Line Fitting with Spring Clip 2006 Buell Ulysses: Engine 3-73...
Page 308 ﬁtting and the spring clip is seated in the oil line ﬁtting groove. Check oil level and add oil if required. After running engine, Inspect oil ﬁttings for oil leaks. Check oil level and add oil if required. Figure 3-112. Flanged Oil Line 3-74 2006 Buell Ulysses: Engine...
Page 309: Oil Cooler
Place a container under the motorcycle to catch excess oil lines from oil cooler before removing from bracket. oil. NOTE Figure 3-113. Remove clamp (3) from oil cooler oil lines. The oil cooler should be checked for dirt and debris. 2006 Buell Ulysses: Engine 3-75...
Page 310 Feed oil line to oil cooler 1/8-1/4 in. (3.175-6.35 mm) clearance Return oil line from oil cooler Feed oil line Figure 3-114. Oil Cooler Feed Oil Line Orientation (Approximately 2 O’Clock) and Oil Line Clearances 3-76 2006 Buell Ulysses: Engine...
Page 311: Oil Pressure
At 2500 RPM, oil pressure will vary from 10- Dead battery (see NOTE). ating engine). 17 psi (69-117 kPa). At idle speed (950-1050 RPM), oil pres- sure will vary from 7-12 psi (48-83 kPa). 2006 Buell Ulysses: Engine 3-77...
Page 312: Crankcase Breathing System
PCV Valves (2) Grommet The oil mist collects and eventually returns to the crankcase Rocker cover (2) through oil passageways in the cylinder head. Figure 3-117. Crankcase Breathing System, 3-78 2006 Buell Ulysses: Engine...
Page 313 (3). b1033x3x Reed valve fastener Reed valve Reed valve stop Reed block Figure 3-118. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-119. Reed Valve Stop and Reed Valve 2006 Buell Ulysses: Engine 3-79...
Page 314: Oiling System
The return gears pump oil back to the oil reservoir. travels to the right ﬂywheel where it is routed through the ﬂywheel to the crankpin. Oil is forced through the crank- pin to properly lubricate the rod bearing assembly. 3-80 2006 Buell Ulysses: Engine...
Page 315: Oil Pump
Thrust washer Retaining ring Gerotor return set Separator plate 10. Gerotor feed set 11. Cover º 12. 45 Fitting 13. Sems screw (2) 14. TORX screw (2) 15. Rear connector ﬁtting Figure 3-120. Oil Pump 2006 Buell Ulysses: Engine 3-81...
Page 316 6) on both sides of the oil pump. 11973 Feed line connection Cover TORX screw (2) Return line Oil pump Mounting screw and washer (2) Feed connection to oil cooler Convolute covering (for return oil line only) Figure 3-121. Oil Pump Hardware 3-82 2006 Buell Ulysses: Engine...
Page 317 11. Attach feed line connections to both sides of the oil pump and tighten to 27-29 ft-lbs (36.6-39.3 Nm). Install new oil ﬁlter and ﬁll oil reservoir with proper oil. 1.5 ENGINE LUBRICATION SYSTEM. 13. Install chin fairing. See 2.38 CHIN FAIRING. 2006 Buell Ulysses: Engine 3-83...
Page 318: Oil Filter Mount
Apply several drops of LOCTITE 243 (blue) to last few threads on that end of the ﬁlter adapter which is installed into ﬁlter mount. Do not apply LOCTITE to adapter threads on ﬁlter element side. 3-84 2006 Buell Ulysses: Engine...
Page 319: Hydraulic Lifters
Figure 3-125. Lifter Assembly (Typical) End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2006 Buell Ulysses: Engine 3-85...
Page 320 Tighten screws evenly to 30-40 in-lbs (3-5 Nm). Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. 3-86 2006 Buell Ulysses: Engine...
Page 321: Gearcase Cover And Cam Gears
Gear cover gasket 13. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16. bushing, gear shaft- pinion Figure 3-128. Gearcase Cover & Cam Assembly 2006 Buell Ulysses: Engine 3-87...
Page 322 8662a Front exhaust cam gear Front intake cam gear Rear intake cam gear Rear exhaust cam gear Pinion gear Pinion nut Timing V mark Figure 3-129. Cam and Pinion Gear Location and Timing Mark Indexing 3-88 2006 Buell Ulysses: Engine...
Page 323 Table 3-25. Cam Identiﬁcation Stamp Location/Function Front Exhaust Front Intake Rear Intake Rear Exhaust NOTE Prior to changing any cam gears, check gear shaft ﬁt within corresponding bushings. Worn bushings can cause excessive backlash. 2006 Buell Ulysses: Engine 3-89...
Page 324 Figure 3-128. Install a new seal and new dry gear cover gasket on crankcase. Figure 3-132. Crankshaft Locking Tool (Part No. HD-43984) 3-90 2006 Buell Ulysses: Engine...
Page 325 LIFTERS. 8654 Install cam position sensor and rotor in gearcase cover. See CAM POSITION SENSOR AND ROTOR section. Install any components removed to gain access to gear- case. Figure 3-134. Checking Cam Gear End Play 2006 Buell Ulysses: Engine 3-91...
Page 326 Remove oil pump. See 3.15 OIL PUMP. Remove gearcase components. See 3.18 GEARCASE COVER AND CAM GEARS. Remove primary cover and primary drive/clutch compo- nents. See 6.2 PRIMARY COVER. Remove starter motor. See 5.7 STARTER. 3-92 2006 Buell Ulysses: Engine...
Page 327 (2.8-4.0 Nm). Figure 3-137. Piston Oil Jet Assemblies Figure 3-137. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2006 Buell Ulysses: Engine 3-93...
Page 328 Inner race, sprocket shaft bearing Thrust washer 10. Connecting rod and ﬂywheel assembly 11. Inner race 12. Pinion shaft bearing 13. Retaining ring 14. Outer bearing race 15. Crankshaft case Figure 3-139. Crankcase and Flywheel Assembly 3-94 2006 Buell Ulysses: Engine...
Page 329 Remove sprocket shaft oil seal retain- ing ring. Figure 3-139. Remove sprocket shaft oil seal (3) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) Remove outer thrust washer (4) next to sprocket shaft bearing (6). 2006 Buell Ulysses: Engine 3-95...
Page 330 (ID) of the outer race (crankcase bushing). A running clear- ance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-96 2006 Buell Ulysses: Engine...
Page 331 That is, a replacement crankcase set may have a class 1, 2 or 3 pinion bearing outer race. Replacement ﬂywheel assemblies will have either a class A or B inner race. 2006 Buell Ulysses: Engine 3-97...
Page 332 1.2502 1.2504 1.2508 1.2510 1.2512 1.2514 1.2516 1.2518 31.740 31.745 31.750 31.755 31.760- 31.765 31.770 31.775 31.780 31.786 3.791- 31.745 31.750 31.765 31.796 31.755 31.760 31.770 31.755 31.780 31.786 31.791 FACTORY COLOR CODE Green White 3-98 2006 Buell Ulysses: Engine...
Page 333 The new outer race must be lapped slightly to true and align with left case bearing and to meet the following speciﬁcations in Table 3-33. LAPPING PINION SHAFT BEARING OUTER RACE. 2006 Buell Ulysses: Engine 3-99...
Page 334 1.2499 in. (31.747 mm) OD inner race, a blue bear- Table 3-34. Pinion Inner Race ing is required. Speciﬁcations Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-100 2006 Buell Ulysses: Engine...
Page 335 Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than service wear limit listed below, replace ﬂywheel/connecting rod assembly. Service wear limit, 0.036 in. (0.8 mm) Figure 3-151. Checking Connecting Rod Side Play 2006 Buell Ulysses: Engine 3-101...
Page 336 HD-46663), install sprocket shaft bearing into left crankcase half from the inside. b1046a3x Spacer, sprocket shaft Retaining ring, oil seal Oil seal Thrust washer Crankcase half Bearing Bearing retaining ring Figure 3-152. Sprocket Shaft Bearing Assembly 3-102 2006 Buell Ulysses: Engine...
Page 337 Install pinion shaft bearing. Bearing retaining ring Lubricate pinion shaft bearing with engine oil. Figure 3-153. Sprocket Shaft Bearing Installation Slip bearing on pinion shaft. Install new retaining ring in groove of pinion shaft bearing inner race. 2006 Buell Ulysses: Engine 3-103...
Page 338 Slide outer race in right crankcase over pinion shaft and bearing assembly. Apply LOCTITE 272 to the last few threads and tighten fasteners to 15-19 ft-lbs (20-26 Nm). NOTE According to manufacturing, there is no torque sequence to follow when tightening crankcase fasteners. 3-104 2006 Buell Ulysses: Engine...
Page 339 Be sure to reﬁll transmission to proper level with fresh lubri- cant. See CLUTCH. 20. See 3.6 CYLINDER HEAD and perform the applicable steps. 21. To reinstall engine in frame see 3.5 ENGINE INSTALLA- TION. 2006 Buell Ulysses: Engine 3-105...
Page 340 HOME NOTES 3-106 2006 Buell Ulysses: Engine...
Page 341 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 342 4.38 Cooling Fan ..........4-106 4.39 Fuel Pump .
Page 343: Fuel System
54-61 Nm LOCTITE ANTI-SEIZE, page 4-101 Throttle position sensor 12-15 in-lbs 1.4-1.7 Nm LOCTITE 222 (purple), page 4-105 Timer plate studs 15-30 in-lbs 2-3 Nm page 4-98 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-102 2006 Buell Ulysses: Fuel System...
Page 344 HOME NOTES 2006 Buell Ulysses: Fuel System...
Page 345: Dynamic Digital Fuel Injection
DYNAMIC DIGITAL FUEL INJECTION (DDFI) INTRODUCTION GENERAL The Buell DDFI operates both as an open and closed loop The Buell Dynamic Digital Fuel Injection (DDFI) System pro- system which allows it to adjust for all possible operating con- vides microprocessor-based electronic engine management ditions.
Page 346 BE/O IGN Coil Throttle To cooling Position Cooling BK/O fan fuse Sensor BK/W BE/O TN/V BK/W LT GN/Y Sensor [165] Ground Interactive mufﬂer control To Brake/horn/ mufﬂer fuse Figure 4-1. Buell Dynamic Digital Fuel Injection 2006 Buell Ulysses: Fuel System...
Page 347: Diagnostic Introduction
Correct problems through the replacement and/or repair of the affected components. After repairs are performed, the work must be validated. This involves clearing the trouble codes and conﬁrming proper vehicle operation as indicated by the behavior of the check engine lamp. 2006 Buell Ulysses: Fuel System...
Page 348: Checking For Trouble Codes
Key ON Lamp ON 8 seconds: functional error** 4 Sec. 8 Sec. Lamp OFF 4 Sec. Key ON Lamp remains ON: current trouble code 4 Sec. 4 Sec. Key ON Figure 4-5. Check Engine Lamp Operation 2006 Buell Ulysses: Fuel System...
Page 349 The fuel injection system provides two levels of diagnostics. The most sophisticated mode employs using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). The other mode requires using the check engine lamp. 4.5 CHECK ENGINE LAMP DIAGNOSTICS more information. 2006 Buell Ulysses: Fuel System...
Page 350: Check Engine Lamp Diagnostics
Once all codes have been sent, the data string is repeated. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 2006 Buell Ulysses: Fuel System...
Page 351 50 start and run cycles. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle. over data link connector. Return data link to original posi- Let it run for at least 30 seconds. tion. Turn the engine off. 2006 Buell Ulysses: Fuel System...
Page 352: Breakout Box
Reconnect harness to ECM. See 4.30 ELECTRONIC Breakout box grey and black connections at main CONTROL MODULE. harness Breakout box grey and black connections at ECM Figure 4-9. ECM and Breakout Box with Connections 4-10 2006 Buell Ulysses: Fuel System...
Page 353: Wiggle Test
BOX. Set DVOM to read voltage changes. Start motorcycle engine and run at idle. Shake or wiggle harness to detect intermittents. If inter- mittents are present, radical voltage changes will register on the DVOM. 2006 Buell Ulysses: Fuel System 4-11...
Page 354: General Information
AND IDLE SPEED bers on the diagnostic check ﬂow charts. See Diagnostic ADJUSTMENT. Check (Part 1 of EVAP hose disconnected Connect. Compare engine behavior to tables. from induction module (CA) Starts hard. Refer to Table 4-4. 4-12 2006 Buell Ulysses: Fuel System...
Page 355 Cooling fan 4.26 TROUBLE CODE 36 Bank angle sensor 4.27 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.28 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.29 TROUBLE CODE 56 2006 Buell Ulysses: Fuel System 4-13...
Page 356 Figure 4-11. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat under seat - through V-notch of left side [91A] data link 4-place Deutsch tail section 4-14 2006 Buell Ulysses: Fuel System...
Page 357 Refer to applicable trouble code flow chart. Start with lowest trouble code. All diagnostic Refer to diagnostic codes are listed on page 4-13 in Table 4-7. tips in related trouble code chart (even if no code is set). 2006 Buell Ulysses: Fuel System 4-15...
Page 358 ECM TERMINAL Wire Color Connector Lt. GN/R [11B] [10B] [11B] [10B] Continuity present in all four circumstances? Inspect terminals for damage or repair Replace ECM. See opens as necessary. 4.30 ELECTRONIC CONTROL MODULE. 7120 4-16 2006 Buell Ulysses: Fuel System...
Page 359: Check Engine Lamp Not Illuminated At Key On 4.9
Table 4-9. ECM Connectors DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat under seat - through V-notch of left side [91A] Data link 4-place Deutsch tail section 2006 Buell Ulysses: Fuel System 4-17...
Page 360 Electronic Control Module (ECM) Figure 4-14. Check Engine Lamp Circuit Table 4-10. Wire Harness Connectors in Figure 4-14. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-18 2006 Buell Ulysses: Fuel System...
Page 361 Repair open or Disassemble instrument short to voltage on module. Inspect check BK/Y wire between engine lamp bulb. connector [39] and Bulb failed? connector [10B]. 7145 7151 Replace Instrument module. See 7.19 INSTRUMENT MODULE Replace bulb. 2006 Buell Ulysses: Fuel System 4-19...
Page 362: Check Engine Lamp On Continuously
Test 4.10 ﬂow chart. Figure 4-15. If the lamp goes off when the black 8891 ECM connector [10] is unplugged, the BK/Y wire is not shorted to ground. Figure 4-16. Electronic Control Module 4-20 2006 Buell Ulysses: Fuel System...
Page 363 Electronic Control Module (ECM) Figure 4-17. Check Engine Lamp Circuit Table 4-11. Wire Harness Connectors in Figure 4-17. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 2006 Buell Ulysses: Fuel System 4-21...
Page 364 Repair short to ground on BK/Y wire between connector [39] and connector [10]. 7165 Check engine lamp Replace ECM. See function OK. Check for 4.30 ELECTRONIC trouble codes. See CONTROL MODULE. CHECKING FOR 7150 TROUBLE CODES. 4-22 2006 Buell Ulysses: Fuel System...
Page 365: Engine Cranks But Will Not Start
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00275a) Purge fuel line of high pressure gasoline. See 4.39 FUEL PUMP. 2006 Buell Ulysses: Fuel System 4-23...
Page 366 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [83] ignition coil 3-place Amp beneath airbox base 4-24 2006 Buell Ulysses: Fuel System...
Page 367 Cam Position Sensor Front Rear Injector Injector [84A] [85A] [14A] Ignition Relay A B C [85B] [84B] [14B] Dyno Loop [10B] [11B] [10A] [11A] Connector Connector Electronic Control Module (ECM) Figure 4-20. Ignition Circuit 2006 Buell Ulysses: Fuel System 4-25...
Page 368 49-51 PSI (338-352 kPa). Adequate pressure? Go to Test 4.11 STOP Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 7459 4-26 2006 Buell Ulysses: Fuel System...
Page 369 Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Replace Replace ignition coil. spark plugs 7220 7520 Repair open circuit. 7875 Repair short Replace ECM. See to ground. 4.30 ELECTRONIC CONTROL MODULE. 7853 7870 2006 Buell Ulysses: Fuel System 4-27...
Page 370 Replace cam position Mechanical failure. position sensor. See 4.31 7945 sensor. See 4.31 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion 7952 gear key. 7952 7940 4-28 2006 Buell Ulysses: Fuel System...
Page 371: No Ecm Power
ECM does not appear to be receiving power, check the bers on the Test 4.12 ﬂow chart. ground sources. A blown ignition fuse or ECM fuse can also Connect BREAKOUT BOX (Part No. HD-42682) to ECM. disable the ECM. 4.6 BREAKOUT BOX. 2006 Buell Ulysses: Fuel System 4-29...
Page 372 Table 4-13. Wire Harness Connectors in Figure 4-21. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] right hand controls 4-place Multilock to the right of windscreen [95] clutch switch 2-place Multilock to the left of windscreen 4-30 2006 Buell Ulysses: Fuel System...
Page 373 Check for 12 volts wire between connector on right handlebar con- [22] and ignition relay. nector [22A] W/BK wire. Voltage present? Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 2006 Buell Ulysses: Fuel System 4-31...
Page 374: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-25. Verify that fuel valve (2) and air bleed pet- cock (5) on the gauge are closed. Attach FUEL PRESSURE GAUGE (Part No. HD-41182) (4) to fuel pressure gauge adapter (1). 4-32 2006 Buell Ulysses: Fuel System...
Page 375 Air bleed tube 41404), gray socket probe and patch cord. Fuel pressure gauge (HD-41182) Air bleed petcock Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-25. Fuel Pressure Gauge (Part No. HD-41182) 2006 Buell Ulysses: Fuel System 4-33...
Page 376 Table 4-14. Wire Harness Connectors in Figure 4-26. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen [86] fuel pump 4-place Multilock left side of rear shock absorber 4-34 2006 Buell Ulysses: Fuel System...
Page 377 Measure voltage relay and fuel pump. during first two seconds after key ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. connection between bat- tery and ignition relay. 2006 Buell Ulysses: Fuel System 4-35...
Page 378 [10] (black) Termi- nal 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.39 wiring. FUEL PUMP. Replace ECM. See 4.30 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 4-36 2006 Buell Ulysses: Fuel System...
Page 379: Idle Speed Control
An idle speed too low can cause poor throttle response. An idle speed too high can cause a slow return to idle. 1.15 THROTTLE CABLE AND IDLE SPEED ADJUST- MENT for more information on idle speed adjustment. 2006 Buell Ulysses: Fuel System 4-37...
Page 380: Misfire
7.4 SPARK PLUG CABLES. Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-16. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 4-38 2006 Buell Ulysses: Fuel System...
Page 381 Table 4-17. Wire Harness Connectors in Figure 4-29. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] right hand controls 4-place Multilock beneath windscreen [83] ignition coil 3-place Packard beneath airbox base 2006 Buell Ulysses: Fuel System 4-39...
Page 382 Switch coil with unit Replace known to be good. ignition coil. Perform spark test. Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.15 is faulty. Replace. STOP (Part 2 of 2). 4-40 2006 Buell Ulysses: Fuel System...
Page 383 Replace cam position sensor. 4.31 CAM POSITION Replace cam position Mechanical failure. SENSOR AND ROTOR. sensor. See 4.31 Inspect for loose CAM POSITION SEN- rotor cup and SOR AND ROTOR. sheared pinion gear key. 2006 Buell Ulysses: Fuel System 4-41...
Page 384 HOME NOTES 4-42 2006 Buell Ulysses: Fuel System...
Page 385: Trouble Code 11
TP sensor voltage (when throttle is closed) to greater than 4.0 volts (when throttle is held wide open). As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. 2006 Buell Ulysses: Fuel System 4-43...
Page 386 ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo under seat 4-44 2006 Buell Ulysses: Fuel System...
Page 387 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-45...
Page 388 Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater 7591 than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 7589 7592 4-46 2006 Buell Ulysses: Fuel System...
Page 389: Trouble Code 13
If fresh air enters exhaust system, the O2 sensor will read a lean condition, causing the system to go rich. Diagnostic Notes Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2006 Buell Ulysses: Fuel System 4-47...
Page 390 Electronic Control Module (ECM) Figure 4-35. Oxygen Sensor Circuit Table 4-19. Wire Harness Connectors in Figure 4-35. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 4-48 2006 Buell Ulysses: Fuel System...
Page 391 V/GY wire. CONTROL MODULE. CONTROL MODULE. 7657 7658 7659 7656 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-49...
Page 392 Fuel injectors may be dirty. See Fuel Injectors 7663 under 4.42 THROTTLE BODY. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-50 2006 Buell Ulysses: Fuel System...
Page 393 (4.30 now OK. ELECTRONIC CONTROL 7672 MODULE). Road test again to verify. 7659 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-51...
Page 394: Trouble Code 14
[10]). bers on the Code 14 ﬂow charts. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. 4-52 2006 Buell Ulysses: Fuel System...
Page 395 (ECM) Figure 4-37. Engine Temperature Sensor Circuit Table 4-21. Wire Harness Connectors in Figure 4-37. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [90] engine temperature sensor 1-place bullet beneath airbox base 2006 Buell Ulysses: Fuel System 4-53...
Page 396 Dis- DIGITAL TECHNICIAN (Part No. HD-44750). regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 4-54 2006 Buell Ulysses: Fuel System...
Page 397 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-55...
Page 398: Trouble Code 15
If connections and harness check out OK, check intake air temperature reading while moving related connectors and wiring harness. If the failure is induced, the IAT sen- sor display will change. 4-56 2006 Buell Ulysses: Fuel System...
Page 399 Figure 4-39. Intake Air Temperature Sensor Circuit Table 4-23. Wire Harness Connectors in Figure 4-39. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [89] intake air temperature sensor 2-place Amp in airbox base 2006 Buell Ulysses: Fuel System 4-57...
Page 400 12 volts normal progression through the chart brings you to and repair. this location. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-58 2006 Buell Ulysses: Fuel System...
Page 401 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-59...
Page 402: Trouble Code 16
A high voltage condition is usually caused by a faulty voltage regulator. 12038 Figure 4-40. Fuse Block and Electrical Relays 4-60 2006 Buell Ulysses: Fuel System...
Page 403 [10B] [11B] Connector Connector Electronic Control Module (ECM) [10A] [11A] Figure 4-41. Battery Voltage Circuit Table 4-24. Wire Harness Connectors in Figure 4-41. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat 2006 Buell Ulysses: Fuel System 4-61...
Page 404 Replace ignition relay. STOP Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-62 2006 Buell Ulysses: Fuel System...
Page 405 Is voltage drop greater than 0.5 volt? Replace R/Y wire between battery fuse and Replace main fuse. battery. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-63...
Page 406: Trouble Code 21
Using TEST CONNECTOR KIT (Part No. HD-41404), attach red probe and patch cord to [164B]. Figure 4-42. Fuses and Diodes Using TEST CONNECTOR KIT (Part No. HD-41404), use gray male pin probe and patch cord. 4-64 2006 Buell Ulysses: Fuel System...
Page 407 HOME b1073a4x INTERACTIVE MUFFLER SUB HARNESS CONTROL ELECTRONICS HORN/BRAKE LIGHT CIRCUITS GROUND [122A] [122B] BRAKE/HORN/MUFFLER R/BK Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-43. Interactive Exhaust Circuit 2006 Buell Ulysses: Fuel System 4-65...
Page 408 Does valve Replace ECM. Replace inter- Locate and repair arm move freely without active motor. short to voltage on binding? TN/Y wire. Replace inter- active muffler actuator. Replace muffler Replace inter- assembly. active muffler cable. 4-66 2006 Buell Ulysses: Fuel System...
Page 409: Trouble Codes 23 And 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- Figure 4-45. Fuel Injector Connector 41404), purple pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use FUEL INJECTOR TEST LAMP (Part No. HD-34730- 2C). 2006 Buell Ulysses: Fuel System 4-67...
Page 410 Figure 4-46. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch under intake cover assembly [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath airbox base 4-68 2006 Buell Ulysses: Fuel System...
Page 411 Replace ECM. See 4.30 Perform 4.7 WIGGLE TEST. ELECTRONIC CONTROL Repair as necessary. MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-69...
Page 412 WIGGLE TEST to locate open wire. intermittents. Repair as necessary. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-70 2006 Buell Ulysses: Fuel System...
Page 413 24 or 25. This condition is normal and does not by itself indicate a malfunction. Codes must be cleared if this condition occurs. Figure 4-48. Testing Ignition Coil Connectors 2006 Buell Ulysses: Fuel System 4-71...
Page 414 Electronic Control Module (ECM) Figure 4-49. Ignition Coil Circuit Table 4-26. Wire Harness Connectors in Figure 4-49. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [83] ignition coil 3-place Packard beneath airbox base 4-72 2006 Buell Ulysses: Fuel System...
Page 415 Repair as Replace ECM. See necessary. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-73...
Page 416: Trouble Code 33
Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), red pin probe and patch cord. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray socket probe and patch cord. 4-74 2006 Buell Ulysses: Fuel System...
Page 417 Table 4-27. Wire Harness Connectors in Figure 4-51. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen [86] fuel pump 4-place Multilock left side of rear shock absorber 2006 Buell Ulysses: Fuel System 4-75...
Page 418 Terminal 87 to Pin D of [86]. Continuity present? Repair open. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-76 2006 Buell Ulysses: Fuel System...
Page 419: Trouble Code 35
Code 35 ﬂow chart. 10654a Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Replace instrument module. See 7.19 INSTRUMENT MODULE. 11990 Figure 4-53. Instrument Module Connector [39] Breakout box Figure 4-52. Installed Breakout Box 2006 Buell Ulysses: Fuel System 4-77...
Page 420 Electronic Control Module [11A] (ECM) Figure 4-54. Tachometer Circuit Table 4-28. Wire Harness Connectors in Figure 4-54. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-78 2006 Buell Ulysses: Fuel System...
Page 421 MODULE. tents found? 7882 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). Repair. Replace instrument module. 7.19 INSTRUMENT 7886 MODULE 7883 2006 Buell Ulysses: Fuel System 4-79...
Page 422: Trouble Code 36
The reference numbers below correlate with the circled num- bers on the Code 36 ﬂow charts. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 4-80 2006 Buell Ulysses: Fuel System...
Page 423 Electronic Control Module (ECM) Figure 4-56. Cooling Fan Circuit Table 4-30. Wire Harness Connectors in Figure 4-56. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [97] cooling fan 2-place Multilock behind rear cylinder 2006 Buell Ulysses: Fuel System 4-81...
Page 424 Disregard the asterisk (but not the instruction box) if your normal pro- gression through the chart brings you to this location. Defective ECM or System ok. ECM connection. 4-82 2006 Buell Ulysses: Fuel System...
Page 425 Place a jumper wire between fan Y/BN wire and battery positive. Place a System ok. jumper between fan BK Replace fan. wire and ground. Does fan run at full speed? Replace fan. System ok. 7879 2006 Buell Ulysses: Fuel System 4-83...
Page 426: Trouble Code 44
Use HARNESS CONNECTOR TEST KIT (Part No. HD- 11968 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-58. Bank Angle Sensor (Under ECM) 4-84 2006 Buell Ulysses: Fuel System...
Page 427 ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo under seat 2006 Buell Ulysses: Fuel System 4-85...
Page 428 Are ferrous metals located within Install properly. See 4.35 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? Replace bank angle sensor. See 4.35 Return to original BANK ANGLE SENSOR. configuration. 4-86 2006 Buell Ulysses: Fuel System...
Page 429 Repair short to ground Replace ECM. See on Lt GN/GY wire. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-87...
Page 430: Trouble Codes 52, 53, 54 And 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
ECM. See 4.30 ELECTRONIC CONTROL MODULE. Code 52 - RAM failure. Code 53 - ROM failure. Code 54 - EE PROM failure. Code 55 - Microprocessor failure. Figure 4-60. Electronic Control Module 4-88 2006 Buell Ulysses: Fuel System...
Page 431 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer plate stud (2) 4.31 CAM POSITION SENSOR AND ROTOR. Sensor wiring Cam position sensor b0313a7x Figure 4-61. Cam Position Sensor 2006 Buell Ulysses: Fuel System 4-89...
Page 432 ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo under seat 4-90 2006 Buell Ulysses: Fuel System...
Page 433 [11] and to ground. to voltage. TRONIC CON- [14]. [14]. TROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Ulysses: Fuel System 4-91...
Page 434 Install original cam System position sensor. Replace ECM. See 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-92 2006 Buell Ulysses: Fuel System...
Page 435: Electronic Control Module
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) 2006 Buell Ulysses: Fuel System 4-93...
Page 436 Rear coil primary Sensor ground 1 Injector rear Vehicle speed sensor Interactive mufﬂer control feedback Engine temperature Bank angle sensor input Intake air temperature System ground B (coil) Serial data receive Tachometer Serial data transmit 4-94 2006 Buell Ulysses: Fuel System...
Page 437: Cam Position Sensor And Rotor
10. Carefully remove camshaft oil seal (15) if damaged or if there is any evidence of oil leakage past the seal. Timer plate stud (2) Sensor wiring Cam position sensor Scribe mark b0313a7x Figure 4-66. Marking Ignition Timing 2006 Buell Ulysses: Fuel System 4-95...
Page 438 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164a4x Figure 4-67. Ignition Components 4-96 2006 Buell Ulysses: Fuel System...
Page 439 HOME bs0017au Figure 4-68. Ignition System Circuit 2006 Buell Ulysses: Fuel System 4-97...
Page 440 Use of regular rivets can damage ignition system components and may allow water to enter the timing compartment. 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Connect negative battery cable. 4-98 2006 Buell Ulysses: Fuel System...
Page 441: Ignition Coil
This is most noticeable in NORMAL wet weather or after the motorcycle has been washed. OHMMETER WINDING RESISTANCE RANGE SCALE (IN OHMS) Primary R x 1 0.5-0.7 Secondary R x 1K 5.5K-7.5K 2006 Buell Ulysses: Fuel System 4-99...
Page 442 Install intake cover assembly. See 2.39 INTAKE COVER. Coil Pin A (rear cylinder) Coil Pin B (12 VDC) Connect negative battery cable. Coil Pin C (front cylinder) Front Cylinder Post Figure 4-72. Ignition Coil 4-100 2006 Buell Ulysses: Fuel System...
Page 443: Oxygen Sensor
Connect 1-place connector [137] (1) to wiring harness. Install cable straps (2). Install air cleaner cover assembly. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.39 INTAKE COVER. Connect negative battery cable. 2006 Buell Ulysses: Fuel System 4-101...
Page 444: Engine Temperature Sensor
While riding, a loose seat can shift causing loss of control, which could result in death Figure 4-75. Engine Temperature Sensor Location (rear or serious injury. (00070a) cylinder) Install seat. See 2.45 SEAT. 4-102 2006 Buell Ulysses: Fuel System...
Page 445: Bank Angle Sensor
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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Fuel System 4-103...
Page 446: Intake Air Temperature Sensor
INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner cover base from underneath. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install negative battery cable. 4-104 2006 Buell Ulysses: Fuel System...
Page 447: Throttle Position Sensor
[88A]. NOTE Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-80. Throttle Position Sensor b0651x4x Figure 4-81. Tabs on TP Sensor Connector [88A] 2006 Buell Ulysses: Fuel System 4-105...
Page 448: Cooling Fan
Install fan and rotate counterclockwise into position. Install cooling fan fasteners. Tighten to 12-36 in-lbs (1.4- 4.1 Nm). Install shock absorber. See 2.23 REAR SHOCK ABSORBER. Connect negative battery cable. 4-106 2006 Buell Ulysses: Fuel System...
Page 449: Fuel Pump
(00002a) Remove drain plug (4) and drain fuel into appropriate container. Discard plug. When fuel tank is empty, replace with new drain plug. Tighten to 84-108 in-lbs (9.5-12.2 Nm). 2006 Buell Ulysses: Fuel System 4-107...
Page 450 10. Place wrench onto nut and another wrench onto the bolt. Figure 4-86. Fuel Pump Removal Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 4-108 2006 Buell Ulysses: Fuel System...
Page 451 (3) in place. Spread the four clips and detach regulator (3) from regulator housing (4). 10937a Plastic retaining ring Fuel pressure regulator Plastic retainers Fuel pressure regulator housing Figure 4-87. Fuel Pressure Regulator 2006 Buell Ulysses: Fuel System 4-109...
Page 452 10935a Fuel supply stud Fuel pump connectors Fuel pump assembly Low fuel level sensor O-rings Fastener Fuel screen Fuel pressure regulator Fuel pump 10. Low fuel level sensor connector Figure 4-88. Fuel Pump Assembly 4-110 2006 Buell Ulysses: Fuel System...
Page 453 10. Overﬂow hose Low fuel level sensor 11. Fuel pump housing Fuel pump connectors 12. Ground fastener Low fuel level sensor connector Pressure regulator E-clip (1) Figure 4-89. Fuel Pump Assembly (Left and Right Sides) 2006 Buell Ulysses: Fuel System 4-111...
Page 454 Plastic retaining ring, pressure regulator Fuel pump Fuel ﬁlter Low fuel level sensor E-clip Fuel pressure regulator housing Connectors, fuel pump Fuel pressure regulator 10. Fuel pump wiring harness Figure 4-90. Fuel Pump Assembly 4-112 2006 Buell Ulysses: Fuel System...
Page 455 11. Connect fuel pump connectors (5). Connectors are two different sizes. Figure 4-92. Wire Harness Removal Direction 12. Install fuel pump assembly. See INSTALLATION in this section. b1043x4x Safety pin Fuel pump connector Clips Figure 4-93. Fuel Pump Connector Disassembly 2006 Buell Ulysses: Fuel System 4-113...
Page 456 (3). Install new fastener. Tighten to 84-108 in-lbs (9.5-12.2 Nm). Fill tank with a small amount of fuel. Check for leaks. Connect fuel pump connector [86] (1) and push cable strap tab into hole in frame. 4-114 2006 Buell Ulysses: Fuel System...
Page 457: Fuel Tank Vent Valve
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) 10. Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Fuel System 4-115...
Page 458: Fuel Cap Retaining Ring
Insert fuel cap retaining ring into fuel ﬁller neck. Fuel cap retaining ring Install fasteners (4). Tighten to 62-71 in-lbs (7-8 Nm). Fastener (5) Install fuel ﬁller cap. Figure 4-96. Fuel Cap Retaining Ring 4-116 2006 Buell Ulysses: Fuel System...
Page 459: Throttle Body
On California models, pull EVAP hose from ﬁtting (1). Remove left and right air scoops. See 2.40 AIR SCOOPS. Remove air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Remove ignition coil. See 4.32 IGNITION COIL. 2006 Buell Ulysses: Fuel System 4-117...
Page 460 10. Throttle position sensor 21. Bolt (2) 11. Clamp, wire spring, 49mm 22. Mounting ﬂange, intake (1 front, 1 rear) 12. Velocity stack, 49mm 23. Seal, intake manifold (2) Figure 4-98. One Piece Throttle Body/Intake Manifold Assembly 4-118 2006 Buell Ulysses: Fuel System...
Page 461: Fuel Injectors
Remove fuel injectors (2, 5) from manifold by gently rock- ing and pulling it away from the manifold. NOTE Front and rear fuel injectors are not interchangeable. Manifold to engine mount fastener Intake ﬂange fastener (2) Figure 4-100. Intake Manifold (Primary Side) 2006 Buell Ulysses: Fuel System 4-119...
Page 462 Open throttle, replace fuel injectors if there is any Front fuel injector evidence of raw fuel in throttle body manifold. Figure 4-102. Fuel Injectors Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.39 INTAKE COVER. 4-120 2006 Buell Ulysses: Fuel System...
Page 463 Connect EVAP hose to port at bottom of throttle body (California models only). Calibrate throttle position sensor if removed or replaced. 4.37 THROTTLE POSITION SENSOR. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Check throttle cable adjustment. See 2.24 THROTTLE CONTROL. 2006 Buell Ulysses: Fuel System 4-121...
Page 464: Intake Leak Test
Nozzle Figure 4-104. Flatten one end of copper tube to form Copper tube a nozzle. Hose Valve Insert round side of copper tube into end of tubing. Knob Propane bottle Figure 4-105. Leak Tester 4-122 2006 Buell Ulysses: Fuel System...
Page 465 Figure 4-106. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Figure 4-105. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 2006 Buell Ulysses: Fuel System 4-123...
Page 466: Air Cleaner Assembly
If torn or damaged, replace. Inspect IAT sensor and replace if faulty. See 4.36 INTAKE AIR TEMPERATURE SENSOR Figure 4-108. Inspect breather hoses, intake air temperature sensor grommet and baseplate gasket (3). Replace as necessary. 4-124 2006 Buell Ulysses: Fuel System...
Page 467 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) 12. Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Fuel System 4-125...
Page 468 Interactive exhaust cable Mounting fasteners (4) Cover, air cleaner Filter element Air cleaner seal Shoulder screw (4) 10. Baseplate assembly 11. Breather hoses, front and rear Figure 4-109. Air Cleaner Assembly with Interactive Exhaust Components 4-126 2006 Buell Ulysses: Fuel System...
Page 469 4.45 GENERAL 8915 Buell motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. The EVAP system prevents fuel hydrocarbon vapors from escap- ing into the atmosphere and is designed to meet the Califor- nia Air Resource Board (CARB) regulations in effect at the time of manufacture.
Page 470 The barb is the larger outside diameter portion (bump) on the fuel ﬁtting. Figure 4-110. Connect two hoses to the canister. Make sure to push hoses all the way on to carbon canis- ter ﬁttings. Figure 4-112. Canister Mounting Bracket 4-128 2006 Buell Ulysses: Fuel System...
Page 471 ﬁtting and not on the ﬁtting barb. Failure to comply may result in fuel leakage which could result in death or seri- ous injury. Figure 4-113. Emissions Hose Attachment, California Models Only 2006 Buell Ulysses: Fuel System 4-129...
Page 472 HOME NOTES 4-130 2006 Buell Ulysses: Fuel System...
Page 473 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 475 8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm page 5-20 Starter battery positive cable 60-85 in-lbs 7-10 Nm page 5-20 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-20 2006 Buell Ulysses: Starter...
Page 476: Wiring Diagrams
The solenoid plunger (7) is returned to its original 7.5 STARTER INTERLOCK for operation and trouble- position by the return spring, which causes the pinion gear (1) shooting information. to disengage from the clutch ring gear (13). 2006 Buell Ulysses: Starter...
Page 477 Pinion gear Idler gear Field winding Armature Brush Ball bearing Solenoid plunger Main solenoid contacts Battery 10. Pull-in winding Starting circuit-see 11. Hold-in winding wiring diagram 12. Overrunning clutch 13. Clutch ring gear Figure 5-1. Starter Operation 2006 Buell Ulysses: Starter...
Page 478: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. starter relay. right handlebar switchgear. 5832 5818 2006 Buell Ulysses: Starter...
Page 479 Terminal 30 Replace grounds. Replace or Terminal 87 when starter on starter relay. solenoid. repair starter motor. button is pressed? 5827 5860 5817 Repair open on Replace GN wire between relay starter relay. and solenoid. 5832 5827 2006 Buell Ulysses: Starter...
Page 480 (W/BK wire at connector [22]). Interlock Circuit relay. button to relay. Battery voltage present? or Correct 5832 Relay Ground. 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2006 Buell Ulysses: Starter...
Page 481 Are test results within range? Remove spark plugs while in Test starter motor for 5th gear. Rotate rear wheel. opens, shorts or grounds. Check for engine, primary Replace or repair starter and/or crankshaft bind. motor. 5817 Use appropriate code 2006 Buell Ulysses: Starter...
Page 482: Starter Activation Circuits
10. Start relay Main fuse (30 A) purposes only) 11. Solenoid Key switch fuse Ignition fuse 12. Starter Key switch Key switch relay Run/Stop switch Start switch Figure 5-3. Typical Circuity. Refer to wiring diagrams for more information. 2006 Buell Ulysses: Starter...
Page 483 However, when sufﬁ- entire difference in potential displayed on the meter. cient current is passed through, the resistance caused by the powdered paint will cause a voltage drop or potential difference in the ground circuit. 2006 Buell Ulysses: Starter...
Page 484 HOME bd0023au IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK LOCK RH CONTROLS [33A] STARTER SOLENOID WIRE COLOR R/BK R/GY [22A] WIRE SECT mm [128A] [33B] CONNECTING BATTERY USER + BATTERY USER + [GRD2] [128B] GROUND [61B] FUSE & DIODE ASSY BATTERY 30 AMP DIODE TN/Y...
Page 485: Starter System Testing
Brake/horn/interactive exhaust (10 Amp) 12. Diode Accessory (10 Amp) 13. Key switch relay Ignition (15 Amp) 14. Ignition relay Key switch (15 Amp) 15. AUX relay Lamps (15 Amp) 16. Start relay Figure 5-5. Fuses, Relays and Diode 2006 Buell Ulysses: Starter 5-11...
Page 486 180 amperes. Induction If starter current draw exceeds 180 amperes, then Ammeter the problem may be in the starter or starter drive. Remove starter for further tests. See STARTER. Battery Figure 5-7. Starter Draw Test 5-12 2006 Buell Ulysses: Starter...
Page 487 Remove positive battery cable ring terminal (2). Detach solenoid wire (3). Remove starter and gasket from the gearcase cover side. Fastener with washer (metric) Positive battery cable ring terminal Solenoid wire Figure 5-9. Starter Wires (Protective Boot Not Shown) 2006 Buell Ulysses: Starter 5-13...
Page 488: Testing Assembled Starter
Solenoid motor terminal to negative battery post. Solenoid relay terminal to positive battery post. Observe starter pinion. If starter pinion pulls in strongly, solenoid is working properly. If starter pinion does not pull in, replace the sole- noid. 5-14 2006 Buell Ulysses: Starter...
Page 489 If starter pinion returns to its original position, sole- Motor terminal noid is working properly. Relay terminal If starter pinion does not return to its original posi- tion, replace the solenoid. Battery Figure 5-13. Return Test 2006 Buell Ulysses: Starter 5-15...
Page 490 1/32 in. (0.794 mm) deep. The slots should then be cleaned to remove any dirt or cop- per dust. Field frame Brush holder Brush spring (4) Armature Solenoid housing Figure 5-16. Starter Components 5-16 2006 Buell Ulysses: Starter...
Page 491 Mica must not be left with a thin edge next to segments Mica Segments WRONG Mica must be cut away clean between segments Mica Undercutting mica with Segments piece of hacksaw blade RIGHT WAY Figure 5-17. Undercutting Mica Separators 2006 Buell Ulysses: Starter 5-17...
Page 492 There should be continuity (0 ohms) at all test points. No continuity at any test point indicates armature is open and must be replaced. Figure 5-19. Grounded Armature Test 6012a Figure 5-20. Open Armature Test 5-18 2006 Buell Ulysses: Starter...
Page 493 16. Remove drive (1), idler gear (2), idler gear bearing (3), and o-ring (4) from drive housing (o-ring is located in Figure 5-22. Open Field Test drive housing groove). s0164x5x Figure 5-23. Brush Holder Insulation Test 2006 Buell Ulysses: Starter 5-19...
Page 494 While riding, a loose seat can shift causing loss of control, which could result in death Figure 5-26. Starter Mounting or serious injury. (00070a) Install seat. See 2.45 SEAT. 5-20 2006 Buell Ulysses: Starter...
Page 495 Bearing cage 16. O-ring 17. Return spring 18. Ball 19. Gasket 20. Washer (2) 21. Mounting bolt (2) 22. Field wire 23. O-ring (2) 24. Field wire nut with washer (metric) Figure 5-27. Starter Assembly 2006 Buell Ulysses: Starter 5-21...
Page 496 Replace wire connection hardware as Figure 5-28. Starter Solenoid necessary. Install plunger (5) in solenoid housing (6). Install new gasket (4) onto cover (3). Position cover with gasket onto solenoid housing. Install clip (2) and screws (1). 5-22 2006 Buell Ulysses: Starter...
Page 497 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 499 ITEM NEW COMPONENTS SERVICE WEAR LIMITS Friction plate (ﬁber) (in.) 0.0866 + 0.0031 in. (2.200 + 0.079 mm) Steel plate 0.0629 + 0.0020 in. (1.598 + 0.051 mm) Clutch pack (in.) 0.661 in. (16.789 mm) (minimum) 2006 Buell Ulysses: Drive/Transmission...
Page 500 30-32.5 Nm LOCTITE 272 (red), page 6-6 LOCTITE 272 (red), left hand threads, special torque Special Transmission sprocket nut procedure turn method, page 6-53 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-53 2006 Buell Ulysses: Drive/Transmission...
Page 501 Add free play to clutch cable. See ADJUSTMENT under 1.8 CLUTCH. Figure 6-1. Loosen locknut (7). Turn chain adjuster screw (6) counterclockwise to remove tension on primary chain. 10. Remove three TORX screws with washers and clutch inspection cover. 2006 Buell Ulysses: Drive/Transmission...
Page 502 18. Oil seal Rubber shift lever pad 19. Sems screw (14) Linkage assembly 20. O-ring 10. Shifter linkage assembly bolt 21. Drain plug 11. Flange head bolt Figure 6-3. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2006 Buell Ulysses: Drive/Transmission...
Page 503 1.8 CLUTCH. screw with nylon sealing surface toward cover. A 1/4-inch allen wrench may be inserted into end of adjuster screw Adjust primary chain tension. See 1.10 PRIMARY to hold it while threading locknut. CHAIN. 2006 Buell Ulysses: Drive/Transmission...
Page 504 22-24 ft-lbs (30-32.5Nm). 13. Install rubber washer and engine shift lever assembly (1). 14. After applying LOCTITE 272 (red), install ﬂange bolt (5) and shift pedal to shifter bracket, and tighten to 22-24 ft- lbs (30-32.5 Nm). 2006 Buell Ulysses: Drive/Transmission...
Page 505: Clutch Release Mechanism
(7). As the adjusting screw is turned, b1057b6x TORX screw with washers (3) Ramp assembly Clutch inspection cover Adjusting screw assembly Clutch cover gasket Primary cover Spring 10. Coupling Lockplate 11. Drain plug and o-ring Figure 6-9. Clutch Release Mechanism 2006 Buell Ulysses: Drive/Transmission...
Page 506 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) Install seat. See 2.45 SEAT. 2006 Buell Ulysses: Drive/Transmission...
Page 507 Replace release ramps and/or balls. Clutch drags. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 2006 Buell Ulysses: Drive/Transmission...
Page 508 29. Clutch shell and sprocket Retaining ring 19. Steel plate (7) 30. Outer thrust washer Retaining ring 20. Friction plate, narrow 10. Spring seat 21. Damper spring 11. Diaphragm spring 22. Damper spring seat Figure 6-12. Clutch Assembly 6-10 2006 Buell Ulysses: Drive/Transmission...
Page 509 Thread the CLUTCH SPRING FORCING SCREW (Part No. HD-38515-91) onto the clutch adjusting screw. Place the bridge of SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring. Install bearing and washer. Thread the tool handle onto end of forcing screw. 2006 Buell Ulysses: Drive/Transmission 6-11...
Page 510 Install adjusting screw assembly into pressure plate. Align two tabs on perimeter of release plate with cor- responding recesses in pressure plate. Secure the adjusting screw assembly with new retaining ring. 6-12 2006 Buell Ulysses: Drive/Transmission...
Page 511 See 6.5 PRIMARY CHAIN. Inspect slots that mate with the clutch plates on both clutch shell and hub. If slots are worn or damaged, replace shell and/or hub. See 6.5 PRIMARY CHAIN. 2006 Buell Ulysses: Drive/Transmission 6-13...
Page 512: Assembly And Installation
Place a wrench on the clutch spring forcing screw Adjusting screw assembly ﬂats to prevent the forcing screw from turning. Spring seat Turn compressing tool handle clockwise until dia- phragm spring compresses just enough to install Figure 6-21. Spring Seat Installation 6-14 2006 Buell Ulysses: Drive/Transmission...
Page 513 11. Install seat. See 2.45 SEAT. Diaphragm spring Snap ring Pressure plate Spring seat Figure 6-22. Pressure Plate Assembly 8815 Adjusting screw assembly Retaining ring Tab recesses Figure 6-23. Clutch Adjusting Screw Assembly and Retaining Ring 2006 Buell Ulysses: Drive/Transmission 6-15...
Page 514 TWO CLAW PULLER (Part No. HD-97292-61) and two bolts to loosen the engine sprocket. Figure 6-16. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-16 2006 Buell Ulysses: Drive/Transmission...
Page 515 If the inner race shows any of these signs the complete 8804 hub assembly must be replaced. 11. Replace damaged parts as necessary. Figure 6-28. Clutch Hub Bearing Race 2006 Buell Ulysses: Drive/Transmission 6-17...
Page 516 Installation end of bearing tool Bearing guide, installer Figure 6-29. Clutch Shell Bearing Remover/Installer (Part No. B-45926) 8812 Figure 6-32. Installing Clutch Shell Needle Bearing Clutch Shell Bearing Remover/Installer (Part No. B-45926) Figure 6-30. Removing Clutch Shell Needle Bearing 6-18 2006 Buell Ulysses: Drive/Transmission...
Page 517 Install engine sprocket nut. Tighten to 190-210 ft-lbs (257.6-284.7 Nm). b1061x6x Mainshaft nut Washer Clutch hub Figure 6-35. Mainshaft Nut and Washer Clutch hub Needle bearing Clutch shell Thrust washer, outer Figure 6-33. Clutch Hub and Shell Assembly 2006 Buell Ulysses: Drive/Transmission 6-19...
Page 518 (00070a) 14. Install seat. See 2.45 SEAT. Adjusting screw assembly Retaining ring Tab recesses Figure 6-37. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2006 Buell Ulysses: Drive/Transmission...
Page 519: Drive Belt System
Mishandling drive belt will result in premature failure. For maximum strength, integrity and longevity, avoid over bending (A and B), twisting (C), crimping, pinching or kink- ing (D), and prying (E). Figure 6-38. Proper Drive Belt Handling 2006 Buell Ulysses: Drive/Transmission 6-21...
Page 520 Right section fastener and washer (3) 11. Slide belt from sprocket and remove. Figure 6-39. Chin Fairing Assembly Remove right rear chin fairing fasteners. See 2.38 CHIN FAIRING. b0943a2x Sprocket cover fastener and washers Sprocket cover Figure 6-40. Sprocket Cover 6-22 2006 Buell Ulysses: Drive/Transmission...
Page 521: Drive Belt Installation
12. Remove scissor jack from motorcycle. Drive belt not fully seated in rear sprocket Squeezing drive belt in order to seat in pulleys Drive belt fully seated in rear sprocket Figure 6-42. Seating Drive Belt Into Pulley Teeth 2006 Buell Ulysses: Drive/Transmission 6-23...
Page 522 The pulley wheel bearings can not be replaced separately. b1106x6x 8420 Axle Pinch bolt fastener Wheel Wheel nut Figure 6-43. Rear Wheel Mounting, Right Side Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 6-44. Idler Pulley Assembly 6-24 2006 Buell Ulysses: Drive/Transmission...
Page 523 1st Gear Neutral Countershaft Countershaft Mainshaft Mainshaft 2nd Gear 3rd Gear Countershaft Countershaft Mainshaft Mainshaft 5th Gear 4th Gear Countershaft Countershaft - IN - SLIDING MEMBER - POWER FLOW - OUT Figure 6-45. Transmission Power Flow 2006 Buell Ulysses: Drive/Transmission 6-25...
Page 524: Case Disassembly For Transmission Removal
Figure 6-48. With transmission still in neutral, scribe Figure 6-46. Place transmission in 1st gear. Remove a line on the end of the shifter drum at the 12 o’clock position for later reference. hex fastener. 6-26 2006 Buell Ulysses: Drive/Transmission...
Page 525 Figure 6-49. Remove shifter shaft assembly. Figure 6-51. Rear Isolator Assembly 14. See Figure 6-51. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2006 Buell Ulysses: Drive/Transmission 6-27...
Page 526 No tools are required for this operation. 8621 8636 Figure 6-53. Separating Crankcase Halves Figure 6-54. Removing Flywheels from Left Case Half 16. See Figure 6-53. Separate crankcase halves. 17. See Figure 6-54. Remove the ﬂywheel assembly from left crankcase half. 6-28 2006 Buell Ulysses: Drive/Transmission...
Page 527: Transmission Disassembly
Slots for removing the shifter fork shafts Figure 6-56. Removing Shifter Fork Shafts Mainshaft 11349 Left Right Shifter drum Shifter fork (3) Mainshaft Mainshaft 2nd gear Countershaft Countershaft Figure 6-55. Shifter Forks, Drum and Shafts Figure 6-57. Transmission Assembly 2006 Buell Ulysses: Drive/Transmission 6-29...
Page 528 10. Spring, shifter return 23. Bolt, shift lever 11. Spring, extension 24. Pad, rubber, shift lever 12. Shifter lever assembly 25. Linkage assembly, shifter 13. Oil seal 26. Bolt, linkage assembly Figure 6-58. Shifter Mechanism 6-30 2006 Buell Ulysses: Drive/Transmission...
Page 529 SION REMOVER (2) (Part No. B-43895-1) to remove transmission assembly from crankcase half. Remove crankcase from press. Arbor press Transmission remover (Part No. B-43985-1) Crankcase Transmission assembly Parallel Supports Figure 6-59. Removing Transmission Assembly from Left Case Half 2006 Buell Ulysses: Drive/Transmission 6-31...
Page 530 Split bearing Retaining ring Mainshaft Thrust washer Mainshaft 3rd gear Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 2nd and 3rd gears are integral to the shaft. Figure 6-61. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 6-32 2006 Buell Ulysses: Drive/Transmission...
Page 531 Thrust washer 12. Countershaft 3rd gear 19. Spacer Retaining ring 13. Thrust washer Dog ring 14. Retaining ring Countershaft 5th gear is integral to the shaft. Figure 6-62. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 2006 Buell Ulysses: Drive/Transmission 6-33...
Page 532: Transmission Assembly
Left Crankcase Mainshaft 1st gear Split bearing Retaining ring Mainshaft Thrust washer Mainshaft 3rd gear Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 2nd and 3rd gears are integral to the shaft. Figure 6-63. Transmission Mainshaft Assembly/Reassembly 6-34 2006 Buell Ulysses: Drive/Transmission...
Page 533 Thrust washer 12. Countershaft 3rd gear 19. Spacer Retaining ring 13. Thrust washer Dog ring 14. Retaining ring Countershaft 5th gear is integral to the shaft. Figure 6-64. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 2006 Buell Ulysses: Drive/Transmission 6-35...
Page 534: Main Drive Gear And Bearing
Fifth gear mainshaft Bearing (Outer) O-ring Oil seal Right crankcase half Ball bearing with spacer Retaining ring 10. Oil seal 11. Bearing, (closed end) countershaft 12. Bushing, shifter drum Figure 6-65. Transmission Assembly-Right Crankcase Half 6-36 2006 Buell Ulysses: Drive/Transmission...
Page 535 (2). Install and tighten nut (6) until 5th gear (3) is free. 8681 Figure 6-67. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-67. Place cross plate on crankcase as shown. 2006 Buell Ulysses: Drive/Transmission 6-37...
Page 536 Figure 6-69. Removing Main Drive Gear Bearing (Typical) Main drive gear Inner bearing race (not visible in this photo) Bearing race puller (Part no. HD-95637-46A) Press ram Figure 6-70. Removing Inner Bearing Race From Main Drive Gear 6-38 2006 Buell Ulysses: Drive/Transmission...
Page 537 Figure 6-72. Pressing Outer Needle Bearing Assembly into Main Drive Gear Press ram Needle bearing installation tool (Part No. HD-47855) Needle bearing Main drive gear Figure 6-71. Pressing Inner Needle Bearing Assembly into Main Drive Gear 2006 Buell Ulysses: Drive/Transmission 6-39...
Page 538 AND PRIMARY CHAINCASE LUBRICANT (Part No. Cross plate (Part No. B-45847) 99851-05). 8 in. bolt (Part No. HD-35316-4A) Main drive gear bearing Bearing driver (Part No. HD-35316-8) Nice bearing Flat washer Figure 6-74. Installing Main Drive Gear Bearing 6-40 2006 Buell Ulysses: Drive/Transmission...
Page 539: Main Drive Gear
AND PRI- Flat washer MARY CHAINCASE LUBRICANT. NOTE Figure 6-76. Installing Main Drive Gear (Typical) Figure 6-83. Make sure to install new o-ring (5) onto main drive gear before installing main drive gear into crank- case. 2006 Buell Ulysses: Drive/Transmission 6-41...
Page 540 1) over ADAPTER until cupped end of installer is ﬂat against seal. Figure 6-78. Install Main Drive Gear Seal (Typical) Figure 6-78. Place seal over pilot and position seal squarely in end of crankcase bore. 6-42 2006 Buell Ulysses: Drive/Transmission...
Page 541 ﬂush with outer edge of crank- case bore. NOTE It is acceptable to recess seal to about 0.030 in. (0.762 mm) below outer edge of bore. Seal will be controlled by tool. Remove nut, installer, adapter and pilot. 2006 Buell Ulysses: Drive/Transmission 6-43...
Page 542: Transmission Right Case Bearings
Right crankcase half Bearing (Inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (Outer) 10. Oil seal O-ring 11. Bearing, (closed end) countershaft Oil seal 12. Bushing, shifter drum Figure 6-83. Transmission Assembly-Right Crankcase Half 6-44 2006 Buell Ulysses: Drive/Transmission...
Page 543: Transmission Left Case Bearings
If using a pressing tool larger than diam- eter of bushing, the pressing tool will bottom against crankcase when bushing is ﬂush with top surface. 2006 Buell Ulysses: Drive/Transmission 6-45...
Page 544: Transmission Installation
Remove transmission assembly and left crankcase half from ﬁxture. Re-install transmission assembly and left crankcase half in engine stand. Arbor press Guide tool (Part No. B-43985-4) Transmission assembly Transmission Remover/Installer ﬁxture (Part No. HD-46285) Figure 6-86. Transmission Assembly in Fixture (Typical) 6-46 2006 Buell Ulysses: Drive/Transmission...
Page 545 Figure 6-89. Installing Shift Fork Shafts NOTE Figure 6-89. Install shifter fork shafts in the left case half by lightly tapping on the end with a brass hammer until seated in bore. Countershaft Figure 6-88. Shifter Forks, Drum and Shafts 2006 Buell Ulysses: Drive/Transmission 6-47...
Page 546 No. B-45520) until it has bottomed in right case half. Place transmission in the 1st gear position. Lubricate main drive gear needle bearing assemblies, the mating surface of the mainshaft and countershaft with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (Part No. 99857-97). 6-48 2006 Buell Ulysses: Drive/Transmission...
Page 547 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-93. Crankcase Fasteners 2006 Buell Ulysses: Drive/Transmission 6-49...
Page 548: Shifter Shaft
The shifter shaft return spring can be installed incorrectly and then assembled in the left crankcase half. Failure to install the spring properly will result in improper shifting. b0951x6x Figure 6-95. Shifter Shaft Return Spring (Incorrectly Installed) 6-50 2006 Buell Ulysses: Drive/Transmission...
Page 549 3.19 CRANKCASE/ ASSEMBLY, 3.6 CYLINDER HEAD 3.7 CYLINDER AND PISTON/ ASSEMBLY/INSTALLATION. Install primary chain and engine sprocket, clutch assem- bly and primary cover. See 6.5 PRIMARY CHAIN. Install engine in chassis. See 3.5 ENGINE INSTALLA- TION. 2006 Buell Ulysses: Drive/Transmission 6-51...
Page 550: Transmission Sprocket
Replace with new pulley wheel (1). Transmission sprocket holding tool Mainshaft locknut wrench NOTE Breaker bar The pulley wheel bearings can not be replaced separately. A new pulley wheel must be installed. Figure 6-101. Removing Transmission Sprocket Locknut 6-52 2006 Buell Ulysses: Drive/Transmission...
Page 551 Since this compound remains effective for about three removal/installation cycles, the original screws may be reused up to three times. After the third removal/installation cycle, replace both screws with new screws identical to the original. 2006 Buell Ulysses: Drive/Transmission 6-53...
Page 552 Tighten rear axle (1) to 23-27 ft-lbs (31.2-36.6 Nm), back off two full turns and then retighten to 48-52 ft-lbs (65.1-70.5 Nm). 13. Tighten pinch fastener (2) on right side of swingarm to 40-45 ft-lbs (54-61 Nm). 6-54 2006 Buell Ulysses: Drive/Transmission...
Page 553 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 555 Position lamp 0.37 53436-97 (European models only) Y0401.1AKC Tail/Stop Lamp Replace taillight assembly if lamp fails. Turn signal lamp (front and rear 10.0 0.84 Y0042.K Marker lamps 1 bulb each) License plate illumination 0.37 53436-97 lamp 2006 Buell Ulysses: Electrical...
Page 556 Spark plugs 11-18 ft-lbs 15-24 Nm page 7-1 T-27 TORX with retaining compound, replace Stator TORX mounting screws 30-40 in-lbs 3-4 Nm with new after each removal, page 7-33 Tail lamp 12-36 in-lbs 1.4-4 Nm page 7-47 2006 Buell Ulysses: Electrical...
Page 557 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-52 Turn signal ﬂasher fastener 48-72 in-lbs 3-4 Nm LOCTITE 272 (red), page 7-53 Voltage regulator mounting screws 36-60 in-lbs 4.1-6.8 Nm Use new fasteners, page 7-34 2006 Buell Ulysses: Electrical...
Page 558: Ignition System
As See Section 4 Fuel System for troubleshooting information. the vehicle warms up to operating temperature the fuel mix- ture will lean and the spark advance will decrease. 2006 Buell Ulysses: Electrical...
Page 559 10. Rear spark plug cable 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164b4x Figure 7-1. Ignition Components 2006 Buell Ulysses: Electrical...
Page 560: Ignition/Headlight Key Switch
Front and rear turn signals can be activated cannot be Horn can be activated activated AUX power outlets ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Figure 7-2. Ignition/Headlight Key Switch 2006 Buell Ulysses: Electrical...
Page 561 Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-3. Electrical Connectors Behind Windscreen 2006 Buell Ulysses: Electrical...
Page 562 10. Slide the ignition switch assembly out to your left (the right side of the vehicle). 8904 8902 Socket head fastener (1) (spacer behind switch) Tamper-resistant Torx fasteners (2) Throttle cables Ignition switch as positioned on vehicle Fork stop pin (retracted) Figure 7-4. Ignition Switch (Typical) 2006 Buell Ulysses: Electrical...
Page 563 Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-6. Electrical Connectors Behind Windscreen 2006 Buell Ulysses: Electrical...
Page 564 While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.45 SEAT. 11. Install windscreen and tighten fasteners to 10-12 in-lbs (1.1-1.4 Nm). 7-10 2006 Buell Ulysses: Electrical...
Page 565: Spark Plug Cables
Remove airbox assembly. See 4.44 AIR CLEANER ASSEMBLY. Remove air scoop left side. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 2006 Buell Ulysses: Electrical 7-11...
Page 566 Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install airbox assembly. See 4.44 AIR CLEANER ASSEMBLY. Figure 7-10. Boot Gap Should Not exceed 1/8 in. (3.2 mm) 7-12 2006 Buell Ulysses: Electrical...
Page 567 Place vehicle in neutral. Clutch lever not disengaged. Pull in clutch lever. Starter relay problems. Listen for starter relay “click”. If click is not heard, perform starter relay tests. Follow starter troubleshooting in Section 5. 2006 Buell Ulysses: Electrical 7-13...
Page 568 Figure 7-11. Diode Polarity b1107c7x RELAY CENTER [95A] [95B] TN/LTGN Clutch Switch Spare Key Sw Lights Spare Diode Bk/Hn/Mflr Battery TN/Y Aux. Acces. Diode [131B] [131A] TN/LTGN Neutral Start Switch Relay Figure 7-13. Diode Wiring 7-14 2006 Buell Ulysses: Electrical...
Page 569 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN/Y Diode installed backwards. Replace Replace neutral wire between neutral Reverse polarity. diode. switch. switch and Diode. 5064 5061 5062 5063 2006 Buell Ulysses: Electrical 7-15...
Page 570 Check for ground on BK Repair open on TN/ wire of connector [95]. LTGN wire between Ground present? connector [95] and starter relay. 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 7-16 2006 Buell Ulysses: Electrical...
Page 571 With clutch disengaged (2) (switch closed), the switch should show 0 ohms or little resistance. Replace the assembly with a new switch if necessary. 2.26 CLUTCH CONTROL/CABLE. Clutch engaged (switch open) Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 2006 Buell Ulysses: Electrical 7-17...
Page 572 A 30 Amp battery fuse links the ignition key switch and the battery. The 30 Amp battery fuse is located under the rider’s seat. See 7.23 BATTERY FUSE AND FUSES for more infor- mation. Battery Figure 7-16. Starter Relay Test 7-18 2006 Buell Ulysses: Electrical...
Page 573 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-17. Fuse Block (contains diode) b1234x1x Spare Key Sw Lights Spare Battery Bk/Hn/Mflr Aux. Acces. Diode Figure 7-18. Fuse Block 2006 Buell Ulysses: Electrical 7-19...
Page 574 Exhaust valve Exhaust in Valve open (exhaust ﬂow - chamber C) Valve closed (exhaust ﬂow - chamber A to B to C) Chamber A Chamber B Chamber C Exhaust exit Figure 7-19. Interactive Exhaust System Mufﬂer 7-20 2006 Buell Ulysses: Electrical...
Page 575 HOME 8899 Interactive exhaust cable Harness with connector [161B] Interactive exhaust cable bracket Actuator Air cleaner cover Figure 7-20. Interactive Control System (XB12 Models Only) 2006 Buell Ulysses: Electrical 7-21...
Page 576 (Part No. HS0020.02A8) to aid in removal and installation. 15. Remove interactive cable from vehicle. Slip end of hose over upper end of cable and attach with tape. Gently pull cable assembly down and out. Remove hose from interactive cable assembly. 7-22 2006 Buell Ulysses: Electrical...
Page 577 Connect interactive exhaust harness to actuator [161B]. Route fuel vent line and install. Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust. See 1.16 INTERACTIVE EXHAUST CABLE. Install intake cover. See 2.39 INTAKE COVER. 2006 Buell Ulysses: Electrical 7-23...
Page 578 HOME NOTES 7-24 2006 Buell Ulysses: Electrical...
Page 579: Charging System
Figure 7-24. Stator Connector [46] Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-25. Voltage Regulator Inspection Figure 7-24. The plug connector to stator must be clean and tight. 2006 Buell Ulysses: Electrical 7-25...
Page 580 STOP 5310 Go to Test 7.7 (Part 2 of 2). NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 7-26 2006 Buell Ulysses: Electrical...
Page 581 System Damaged or Replace Replace slipping rotor. stator. rotor. 5319 5314 5319 NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 2006 Buell Ulysses: Electrical 7-27...
Page 582 HOME bs0021ax [128A] [GRD2] Battery Fuse [61B] [35A] [35B] [77A] [77B] [46A] [46B] Figure 7-25. Charging System Circuit 7-28 2006 Buell Ulysses: Electrical...
Page 583 Reconnect regulator after testing. SPROCKET COVER WIRING. Start the motorcycle and run the engine at 3000 RPM. With ignition and all continuously running lights and accessories turned on (headlight on high beam), read the total current draw. 2006 Buell Ulysses: Electrical 7-29...
Page 584 If the resistance is lower, the stator is damaged and must be replaced. NOTE Verify that meter reads 0 ohms when probes are shorted together. If not, subtract lowest value to resistance value of stator. 7-30 2006 Buell Ulysses: Electrical...
Page 585 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST page 7-30. b1235x1x Figure 7-30. Check for Stator Resistance b1236x1x Figure 7-31. Check Stator AC Voltage Output 2006 Buell Ulysses: Electrical 7-31...
Page 586 Remove stator wiring grommet (3) from left crankcase half. Withdraw stator wiring (4) from grommet hole in left crankcase half. Remove stator. Stator fastener (4) Stator Grommet Stator wiring Connector [46] Figure 7-34. Stator Assembly 7-32 2006 Buell Ulysses: Electrical...
Page 587 TORX screws (1). Tighten TORX screws to 30-40 in-lbs (3-4 Nm). Route stator wiring (4) behind rear cylinder and in front of transmission breather hose. See 7.26 SPROCKET COVER WIRING for remaining wire routing information. 2006 Buell Ulysses: Electrical 7-33...
Page 588: Voltage Regulator
Voltage regulator mount bracket shift causing loss of control, which could result in death Voltage regulator or serious injury. (00070a) Fastener (3) Install seat. See 2.45 SEAT. Figure 7-37. Voltage Regulator Test charging system. See 7.7 CHARGING SYSTEM. 7-34 2006 Buell Ulysses: Electrical...
Page 589: Battery Cables
(00068a) CAUTION Connect the cables to the correct battery terminals. Fail- ure to do so could result in damage to the motorcycle electrical system. (00215a) Figure 7-39. Negative Battery Cable 2006 Buell Ulysses: Electrical 7-35...
Page 590 Attach negative cable to frame. Tighten to 72-96 in-lbs (8.1-10.8 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Protective boot, positive battery cable Positive battery cable Figure 7-40. Positive Battery Cable 7-36 2006 Buell Ulysses: Electrical...
Page 591 HOME BATTERY 7.11 GENERAL f1730x8x All Buell 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.
Page 592: Battery Testing
After dis- connecting the battery cables from the battery, retest the 12.7 100% battery using the out-of-vehicle test before replacing. 12.6 12.3 12.0 x0661x3x 11.8 Figure 7-43. Battery Test Results–Printout 7-38 2006 Buell Ulysses: Electrical...
Page 593: Disconnection And Removal
Load battery at 50% of CCA rating using battery has been frozen, overheated or overcharged. the load tester. Voltage reading after 15 seconds should be 9.6 V or more at 70° F. (21° C). Inspect the battery case for cracks or leaks. 2006 Buell Ulysses: Electrical 7-39...
Page 594: Safety Precautions
Perform a voltmeter test to determine the state of charge. BATTERY TESTING. If battery needs to be charged, proceed to step 2. CAUTION Remove battery from motorcycle before charging. Elec- trolyte leakage will damage motorcycle parts. (00213a) 7-40 2006 Buell Ulysses: Electrical...
Page 595 If a constant current charger is the only type available, do not exceed the charge times listed above and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes. 2006 Buell Ulysses: Electrical 7-41...
Page 596 Insert fastener through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten fastener to 72-96 in-lbs (8-11 Nm). Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals. 7-42 2006 Buell Ulysses: Electrical...
Page 597 (not freezing), dry place. See Fig- ure 7-46. 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). 2006 Buell Ulysses: Electrical 7-43...
Page 598 8917 Headlight Bulb holder (2) High beam connection [38] (left side) with ground Low beam connection [38] (right side) with ground Headlight bulbs Figure 7-47. Headlight Assembly/Rear View 7-44 2006 Buell Ulysses: Electrical...
Page 599 If the rubber boots are not installed correctly the wiring har- Install seat. See 2.45 SEAT. nesses can contact the edge of the forward frame mount. The wiring harness guides must be installed at a 20 degree angle. 2006 Buell Ulysses: Electrical 7-45...
Page 600 HOME 10525 10526 Figure 7-49. Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 7-46 2006 Buell Ulysses: Electrical...
Page 601: Tail Lamp
Install seat. See 2.45 SEAT. before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) b1139x7x Center tail section Nuts and washers (2) Tail lamp Figure 7-50. Tail Lamp Assembly 2006 Buell Ulysses: Electrical 7-47...
Page 602: License Plate Lamp Assembly
Insert license plate lamp wiring harness through hole and route into the center tail section (2) and the license plate bracket (4). Attach lamp (3) to tail section using washers and jam nuts (1) and tighten to 12-36 in-lbs (1.4-4.1 Nm). 7-48 2006 Buell Ulysses: Electrical...
Page 603: Turn Signals
Figure 7-54. Remove jam nut and lockwasher (2) Figure 7-53. Front Turn Signal Connections from inside of front module (3). Pull bullet connectors and wiring through hole in front module (3) and remove turn signal (1). 2006 Buell Ulysses: Electrical 7-49...
Page 604 HOME Turn signal (2) b1198x7x Jam nut and lockwasher (2) Front module, left and right Windshield Windscreen Figure 7-54. Front Turn Signals 7-50 2006 Buell Ulysses: Electrical...
Page 605 Tail lamp [18A] [18A] [18A] [18A] Right turn signal Figure 7-55. Rear Turn Signal Connections b1199x7x Turn signal (2) Turn signal bulb Reﬂector Jam nut and lockwasher (2) License plate bracket Figure 7-56. Rear Turn Signals 2006 Buell Ulysses: Electrical 7-51...
Page 606 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) Install seat. See 2.45 SEAT. 7-52 2006 Buell Ulysses: Electrical...
Page 607: Turn Signal Flasher
Left turn signal dlebar. Front and rear right turn signals must ﬂash. Right turn signal Turn ignition key switch to OFF. Figure 7-60. Turn Signal Controls Install windscreen and windshield. See 2.44 WIND- SHIELD AND WINDSCREEN. 2006 Buell Ulysses: Electrical 7-53...
Page 608: Handlebar Switches
To headlight Light power High beam Horn Y/BK Y/BK From ﬂasher BE/W V/BN Left turn Right turn Horn power To interlock circuit TN/LTGN To ground [95B] [95A] Clutch Switch Figure 7-62. Left Handlebar Switch Connection 7-54 2006 Buell Ulysses: Electrical...
Page 609 (00316a) [121A] [121B] Check handlebar switch for proper operation. If operation Brake Switch fails, reread procedure and verify that all steps were per- formed. Figure 7-63. Right Handlebar Switch Connection 2006 Buell Ulysses: Electrical 7-55...
Page 610 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as Figure 7-64. Left Handlebar Switch Connection long as the switch is pressed. Check left and right turn signals. Activate horn by pressing horn switch. 7-56 2006 Buell Ulysses: Electrical...
Page 611 Top View R/BK Switch GY/O Relay R/BK Vehicle Speed Sensor Connector Vehicle Speed Sensor [39A] [39B] BK/W [65A] [65B] [10B] [11B] Connector Connector Electronic Control Module (ECM) [10A] [11B] Figure 7-66. Vehicle Speed Sensor Wiring 2006 Buell Ulysses: Electrical 7-57...
Page 612: Bulb Replacement
Remove the nine fasteners securing the back of the module housing to the display and remove back cover. NOTE Do not turn display over. Speedometer and Tachometer will fall out possibly causing damage to instruments. 7-58 2006 Buell Ulysses: Electrical...
Page 613 Install seat. See 2.45 SEAT. 11930b Instrument module Fairing support, center Grommet (3) Washer (2) Fastener (3) Front support module, left and right Instrument module connector [39] Figure 7-70. Instrument Module Connector [39] Figure 7-71. Instrument Module 2006 Buell Ulysses: Electrical 7-59...
Page 614: Speedometer Performance Check
CLEAR to cancel and enter the new fre- 40 MPH 1062 quency. Press ENTER to begin and reverify. 60 MPH 1593 NOTE 80 MPH 2124 The speedometer should be accurate within 0-5 MPH (0-8 KPH). 7-60 2006 Buell Ulysses: Electrical...
Page 615 If testing LO range, press 1 or 3. If testing CEN range, press 4 or 6. If testing HI range, press 7 or 9. Deutsch socket housing (2) Deutsch pin housing Figure 7-74. Test Harness 2006 Buell Ulysses: Electrical 7-61...
Page 616 Are correct 6020 numbers displayed? Replace instrument module. Press reset for 5 sec- onds. Does trip odome- 6020 ter reset to zero? STOP Replace instrument module. 6020 Go to Speedometer Test: Chart 7-62 2006 Buell Ulysses: Electrical...
Page 617 Go to If necessary, remove vehicle speed sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 2006 Buell Ulysses: Electrical 7-63...
Page 618 Does voltage fluctuate? Replace vehicle speed 6022 sensor. 6010 Check speedometer speed Repair as necessary. sensor. Clean or replace sen- sor as required. Retest. 6008 Problem solved? System OK. Replace instrument module. 6029 6024 7-64 2006 Buell Ulysses: Electrical...
Page 619 While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.45 SEAT. Figure 7-76. Left Handlebar Switch Connection 2006 Buell Ulysses: Electrical 7-65...
Page 620 If horn is faulty, replace unit as an assembly. The horn is not repairable. If battery voltage is not present, either horn switch or wiring to horn is faulty. If horn switch is faulty, replace left handlebar switch. See 7.17 HANDLE- SWITCHES. 7-66 2006 Buell Ulysses: Electrical...
Page 621: Neutral Indicator Switch
Neutral indicator switch wire lead threads. Neutral indicator switch Install switch in crankcase. Tighten switch to 60-84 Washer in-lbs (6.8-9.4 Nm). Figure 7-79. Neutral Indicator Switch Connect wire lead (1) to switch. Install sprocket cover. See 2.35 SPROCKET COVER. 2006 Buell Ulysses: Electrical 7-67...
Page 622 HOME BATTERY FUSE AND FUSES 7.23 GENERAL b1166a4x Buell motorcycles feature two components which protect the electrical system. Fuses The covered fuse block is under the seat. Figure 7-80. The lights, key switch, brake/horn and igni- tion fuses are rated at 15 amps. The ECM, cooling fan, aux.
Page 623: Main Wire Harness
Figure 7-82. Positive Battery Cable Pull back terminal cover boot on battery positive cable Figure 7-82. Disconnect positive battery cable from (red). starter. Unthread fastener and remove battery positive cable from battery positive (+) terminal. Remove battery. 2006 Buell Ulysses: Electrical 7-69...
Page 624 Right rear turn signal connector [18]. Left rear turn signal connector [19]. License plate lamp connector [45]. Tail light connectors [93]. Rear auxiliary power outlet [180]. Figure 7-83. Interactive exhaust connector [165B], (under main wiring harness) 7-70 2006 Buell Ulysses: Electrical...
Page 625 Temp sensor [90] Fuel injectors [84] & [85]. Ground fastener at steering head. 17. Disconnect intake air temperature sensor [89]. See 4.36 INTAKE AIR TEMPERATURE SENSOR. 18. Disconnect throttle position sensor [88]. See 4.37 THROTTLE POSITION SENSOR. 2006 Buell Ulysses: Electrical 7-71...
Page 626 Fuel line is installed under engine connector portion of wire harness. 8837a Figure 7-85. Wire Harness Clip Figure 7-85. Install clamp over portion of harness that leads to engine connectors. Install clamp as shown using new plastic tree fastener. 7-72 2006 Buell Ulysses: Electrical...
Page 627 12. Install cable strap loosely around main harness (6) and ignition switch. 13. Connect throttle position sensor [88]. See 4.37 THROT- TLE POSITION SENSOR. 14. Connect intake air temperature sensor [89]. See 4.36 INTAKE AIR TEMPERATURE SENSOR. 2006 Buell Ulysses: Electrical 7-73...
Page 628 Rear auxiliary power outlet [180]. 27. Route main harness and rear auxiliary power outlet wir- ing under seat latch bracket. 28. Tighten fasteners. 29. Install main harness and grommet into battery tray. 30. Install rear wire cover. 7-74 2006 Buell Ulysses: Electrical...
Page 629 Rear cable strap (1) secures conduit to voltage reg- ulator wiring. 32. Verify that front forks can be turned from full left to full right lock without wire harness binding or pinching. 2006 Buell Ulysses: Electrical 7-75...
Page 630: Interactive Exhaust Actuator Harness
See ICM connector [11] INTERACTIVE EXHAUST SYSTEM. Negative battery cable Remove interactive exhaust cable from cable wheel. Battery ground Remove actuator. Actuator ground Figure 7-90. Harness and Cable Routing 7-76 2006 Buell Ulysses: Electrical...
Page 631 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) 11. Install seat. 2006 Buell Ulysses: Electrical 7-77...
Page 632: Sprocket Cover Wiring
Neutral switch connector [131] Cam position sensor connector [14] Neutral switch location Stator connector [46] Vehicle speed sensor connector [65] Oil pressure switch wiring Main harness 10. Interactive exhaust cable Figure 7-93. Sprocket Cover Wiring and Connections 7-78 2006 Buell Ulysses: Electrical...
Page 633 (2-pin) voltage regulator (1). 12010 Reﬂective convolute covering with seam Covering in place on bottom of return line Covering in place on top of return line Sprocket cover boss Figure 7-94. Convoluted Covering for Oil Return Line 2006 Buell Ulysses: Electrical 7-79...
Page 634 Using a cable strap, secure the loop the neutral safety wire makes to the cam position connector under the attachment clip on the connector. Figure 7-96. Cable Strap Locations 12013 Figure 7-97. Cam Position Sensor Connector with Cable Strap 7-80 2006 Buell Ulysses: Electrical...
Page 635 12014 Sprocket cover boss Main harness Cable strap securing main harness wiring Figure 7-101. Correct Location for Sprocket Cover Wiring Figure 7-99. Cable Strap Wire Bundle to Return Oil Line, Upper Part of Sprocket Cover 2006 Buell Ulysses: Electrical 7-81...
Page 636: Auxiliary Power Outlets
Remove the windscreen to access the forward power outlet electrical connector. 12132 2.44 WINDSHIELD AND WINDSCREEN. Remove the seat to access the rearward power outlet electrical connector located in the tailsection. Figure 7-103. Auxiliary Power Outlet (under seat) 7-82 2006 Buell Ulysses: Electrical...
Page 637 Table Of Contents SUBJECT PAGE NO. APPENDIX A-TOOLS ..........APPENDIX B-WIRING .

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