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Ulysses 2006
Buell Ulysses 2006 User Manual
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2006 Buell Ulysses: Appendix A
A-1
HOME
APPENDIX A–T
OOLS
A.1
Pa
rt
No.
B-41623-B Oil Line Remover
Pa
rt
No.
B-42887 Brake Caliper Piston Remover
Pa
rt
No.
B-43721 Front Fork Seal Driver
Pa
rt
No.
B-46279 7/8" Axle
Wrench (He
x)
Pa
rt
No.
B-43993-7/-8
Wheel Bearing Collets
Pa
rt
No.
B-45521 Steering Head Bearing Remover/
Installer
Pa
rt
No.
HD-39302 Steering Head Bearing Race Installer
(Used with B-45521)
Pa
rt
No.
B-59000B Pro Level Oil Gauge
2
4
Table of Contents
Maintenance 1
67
Amp Multilock Electrical Connectors
13
Deutsch Electrical Connectors
17
Electrical Connectors
26
Table of Contents
67
Safe Operating Maintenance
69
Instruments and Gauges
70
Part Replacement
70
Lip Type Seals
70
Hardware and Threaded Parts
70
Repair and Replacement Procedures
70
Part Protection
71
Cleaning Process
71
Rust or Corrosion Removal
71
Tool Safety
71
Air Tools
71
Ratchets and Handles
71
Storage Units
72
Fuel and Oil
73
Engine Oil
73
Maintenance Schedule
74
Battery Maintenance
77
Cleaning and Inspection
78
Engine Lubrication System
80
Engine Oil Level Check
80
Engine Oil and Filter Change
81
Brake System Maintenance
83
Brake Pads
88
Brake Pad Replacement
89
Tires and Wheels
91
Tire Inflation
91
Tire Replacement
91
Wheel Bearings
91
Transmission Fluid
92
Drive Belt
95
Primary Chain
99
Suspension Damping Adjustments
101
Steering Head Bearings
105
Spark Plugs
106
Air Cleaner Filter
108
Throttle Cable and Idle Speed Adjustment
110
Idle Speed
110
Interactive Exhaust Cable
111
Ignition Timing
113
Removal from Storage
118
Troubleshooting
119
Electrical System
120
Chassis 2
123
Specifications
125
Torque Values
126
Tire Specifications
129
Vehicle Identification Number
130
Wheels
132
Front Wheel
134
Bearing Installation
137
Rear Wheel
141
Checking Cast Rim Runout
145
Tires
146
Wheel Balancing
149
Brake Pedal
150
Front Brake Master Cylinder and Hand Lever 2.10
151
Front Master Cylinder
152
Front Master Cylinder
153
Front Brake Line
155
Front Brake Caliper
157
Rear Brake Master Cylinder
160
Rear Brake Line
164
Rear Brake Caliper
166
Front Fork
169
Fork Assembly
174
Fork Clamps, Upper and Lower
177
Steering Head Bearings
179
Swingarm and Brace
182
Front and Rear Isolator
186
Frame
187
Frame Pucks
188
Rear Shock Absorber
189
Throttle Control
191
Deflectors
192
Clutch Control/Cable
193
Clutch Cable
195
Headlight Grill
197
Headlights and Support Bracket
198
Front Modules
201
Handlebars
203
Mirrors
205
Exhaust System
206
Rider and Passenger Footpegs
209
Heel Guard and Footpeg Mounts
210
Sprocket Cover
211
Fenders
212
Rear Fender
212
Belt Guard
213
Chin Fairing
214
Intake Cover
215
Air Scoops
216
Left Tail Section and Battery Pan
217
Center Tail Loop
221
Right Tail Section
222
Windshield and Windscreen
224
Seat
225
Seat Lock
226
Sidestand
228
Triple Tail
230
Engine 3
233
Diagnosing Smoking Engine or High Oil Consumption
241
Engine Rotation for Service
242
Stripping Motorcycle for Engine Service
253
Engine Installation
264
Cylinder Head
278
Valve Guides
284
Valve Springs
284
Cylinder Head Installation
293
Cylinder and Piston
296
Deglazing Cylinder
299
Lubrication System
305
Oil Hose Routing and Oil Reservoir
306
Oil Line Fittings
307
Oil Cooler
309
Oil Pressure
311
Oil Pressure Indicator Switch
311
Crankcase Breathing System
312
Oiling System
314
Oil Pump
315
Oil Filter Mount
318
Hydraulic Lifters
319
Gearcase Cover and Cam Gears
321
Fuel System 4
341
Fuel System
343
Specifications
343
Dynamic Digital Fuel Injection
345
Diagnostic Introduction
347
Checking for Trouble Codes
348
Check Engine Lamp Diagnostics
350
Breakout Box
352
Wiggle Test
353
General Information
354
Initial Diagnostic Check
354
Check Engine Lamp Not Illuminated at Key on 4.9
359
Check Engine Lamp on Continuously
362
Engine Cranks but will Not Start
365
No ECM Power
371
Fuel Pressure Test
374
Idle Speed Control
379
Misfire
380
Trouble Code 11
385
Trouble Code 13
389
Trouble Code 14
394
Trouble Code 15
398
Trouble Code 16
402
Battery Voltage
402
Trouble Code 21
406
Trouble Codes 23 and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 and
409
Trouble Code 33
416
Trouble Code 35
419
Trouble Code 36
422
Trouble Code 44
426
Trouble Codes 52, 53, 54 and 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
430
Electronic Control Module
435
Cam Position Sensor and Rotor
437
Ignition Coil
441
Oxygen Sensor
443
Engine Temperature Sensor
444
Bank Angle Sensor
445
Intake Air Temperature Sensor
446
Throttle Position Sensor
447
Cooling Fan
448
Fuel Pump
449
Fuel Tank Vent Valve
457
Fuel Cap Retaining Ring
458
Throttle Body
459
Fuel Injectors
461
Intake Leak Test
464
Air Cleaner Assembly
466
Wiring Diagrams
476
Starter Relay
476
Starting System Diagnosis
478
Starter Activation Circuits
482
Starter System Testing
485
Testing Assembled Starter
488
Drive/Transmission 6
497
Clutch Release Mechanism
505
Assembly and Installation
512
Drive Belt System
519
Drive Belt Installation
521
Case Disassembly for Transmission Removal
524
Transmission Disassembly
527
Transmission Assembly
532
Main Drive Gear and Bearing
534
Main Drive Gear
539
Transmission Right Case Bearings
542
Transmission Left Case Bearings
543
Transmission Installation
544
Shifter Shaft
548
Transmission Sprocket
550
Electrical 7
553
Ignition System
558
Ignition/Headlight Key Switch
560
Spark Plug Cables
565
Charging System
579
Voltage Regulator
588
Battery Cables
589
Battery Testing
592
Voltmeter Test
592
Disconnection and Removal
593
Safety Precautions
594
Tail Lamp
601
License Plate Lamp Assembly
602
Turn Signals
603
Turn Signal Flasher
607
Handlebar Switches
608
Bulb Replacement
612
Speedometer Performance Check
614
Neutral Indicator Switch
621
Main Wire Harness
623
Interactive Exhaust Actuator Harness
630
Sprocket Cover Wiring
632
Auxiliary Power Outlets
636
5
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Buell Ulysses 2006 Specifications
General
Brand
Buell
Model
Ulysses 2006
Category
Motorcycle
Language
English
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