Buell 2007 ULYSSES Service Manual

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2007 BUELL ULYSSES

SERVICE MANUAL

Part Number 99494-07Y

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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Table of Contents

Summary of Contents for Buell 2007 ULYSSES

Page 1 2007 BUELL ULYSSES SERVICE MANUAL Part Number 99494-07Y 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 Part No. HD-33416 Universal Driver Handle HD-28431B h33418 HD-28431-6 Fluorescent Additive 6 1-oz. bottles HD-28431-22 Fluorescent Additive 1 22-oz. container Part No. HD-28431-B Black Light Fluorescent Additive Part No. HD-33418 Universal Puller Forcing Screw (Use with HD-) 2007 Buell Ulysses: Appendix A...
Page 3 Part No. HD34736-B Valve Spring Compressor Part No. HD-35316-C Main Drive Gear Remover/Installer and Main Drive Gear Bearing Installer h35457 h34751 Part No. HD-35457 Black Part No. HD-34751 Nylon Valve Guide Brush k Light Leak Detector 2007 Buell Ulysses: Appendix A...
Page 4 Part No. HD-35758-B Neway Valve Seat Cutter Set Part No. HD-38515-A Clutch Spring Compressor HD-38125-6 h39302 Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-39302 Steering Head Bearing Race Installer (Sealed) (Used with B-45521) 2007 Buell Ulysses: Appendix A...
Page 5 Part No. HD-39965 Deutsch Terminal Crimp Tool HD-39969 h39782 Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-39782-A Cylinder Head Support Stand HD39978 h39786 Part No. HD-39978 Fluke 78 Multimeter (DVOM)F Part No. HD-39786 Cylinder Head Holding Fixture 2007 Buell Ulysses: Appendix A...
Page 6 Part No. HD-41137 Two-Way Hose Clamp Pliers h41354 HD41155-2 Part No. HD-41354 Speedometer Tester Part No. HD-41155 VHS Tape Storage Rack b41177-94 HD41404 Part No. HD-41177 Fork Tube Holder Part No. HD-41404 Harness Connector Test Kit 2007 Buell Ulysses: Appendix A...
Page 7 Part No. B-41623-B Oil Line Remover HD41675 h41475-100 Part No. HD-41475-100 Deutsch Connector Pick Tool Part No. HD-41675 Oil Pressure Sending Unit Wrench HD41496 h42310a Part No. HD-41496 Main Drive Gear Seal Installer Part No. HD-42310 Engine Transmission Stand 2007 Buell Ulysses: Appendix A...
Page 8 Part No. HD-42376 Battery Load Tester h42320a b42887 Part No. HD-42320-A Piston Pin Extractor Part No. B-42887 Brake Caliper Piston Remover h42322 h43646a Part No. HD-42322 Piston Support Plate Part No HD-43646-A Rolling Engine Stand 2007 Buell Ulysses: Appendix A...
Page 9 Part No. B-43721 Front Fork Seal Driver hd44060 b-43982 Part No. HD-44060 Wheel Bearing Remover/Installer Part No. B43982 Transmission Locking Tool hd44067b hd43984 Part No. HD-44067-A Oil Filter Wrench Part No. HD-43984 Crankshaft Locking Tool 2007 Buell Ulysses: Appendix A...
Page 10 Part No. HD-44567 7" Universal Driver Handle h44687 b45521 Part No HD-44687 Ignition Coil Test Adapter Part No. B-45521 Steering Head Bearing Remover/Installer B-45522a HD44720a Part No. HD-44720 TSSM Adapter Cable Part No. B-45522 Fuel Pressure Gauge Adapter 2007 Buell Ulysses: Appendix A...
Page 11 Part No. B-45524 Valve Guide Installer Part No. HD-45830 Techlink Kit HD45835a B-45525 Part No. B-45525 Valve Guide Hone Part No. HD-45835 Road Test Kit b45657 B43983 Part No. B-45657 Fuel Pump Puller Part No. B-45847 Cross Plate A-10 2007 Buell Ulysses: Appendix A...
Page 12 Part No. B-45926 Clutch Shell Bearing Remover Part No. B-46279 7/8" Axle Wrench (Hex) HD45928 HD-46283 Part No. HD-45928 Terminal Crimper Part No. HD-46283 Primary Drive Locking Tool HD4529 HD-46285 Part No. HD-45929 Terminal Remover Part No.HD-46285 Transmission Assembly Fixture 2007 Buell Ulysses: Appendix A A-11...
Page 13 Part No. HD-47248 Rocker Housing Wrench HD-47184 HD-47250 Part No. HD-47184 Leak Detector Flashlight Part No. HD-47250 Intake Manifold Wrench HD-47258 HD-47187 Part No. HD-47258 Rocker Cover Wrench Part No. HD-47187 Technician Pen Light A-12 2007 Buell Ulysses: Appendix A...
Page 14 Part No. HD-48053 Advanced Battery Conductance Part No. HD-94804-57 Rocker Arm Bushing Reamer and Electrical System Analyzer HD-95635-46 J-5586A Part No. HD-95635-46 All-Purpose Claw Puller Part No. J-5586 Transmission Shaft (use with HD-95637-46A) Retaining Ring Pliers 2007 Buell Ulysses: Appendix A A-13...
Page 15 (HD-95770-69) and 8 (HD-95771-69) are optional. 96796-47 h95952-33C Part No. HD-95952-33C Connecting Rod Clamping Tool Part No. HD-96796 Valve Spring Test Fixture h95920-32D h96921-52C Part No. HD-95970-32D Piston Pin Bushing Tool Part No. HD-96921-52B A-14 2007 Buell Ulysses: Appendix A...
Page 16 HOME h97081a Part No. HD97097-65B Hose Clamp Pliers HD99500-80a Part No. HD-99500-80 Wheel Truing & Balancing Stand 2007 Buell Ulysses: Appendix A A-15...
Page 17 HOME NOTES A-16 2007 Buell Ulysses: Appendix A...
Page 18: 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 2007 Buell Ulysses: Appendix B...
Page 19 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. 2007 Buell Ulysses: Appendix B...
Page 20 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 2007 Buell Ulysses: Appendix B...
Page 21 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 2007 Buell Ulysses: Appendix B...
Page 22: 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. 2007 Buell Ulysses: Appendix B...
Page 23 (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. 2007 Buell Ulysses: Appendix B...
Page 24 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. 2007 Buell Ulysses: Appendix B...
Page 25 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2007 Buell Ulysses: Appendix B...
Page 26 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 2007 Buell Ulysses: Appendix B...
Page 27 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 2007 Buell Ulysses: Appendix B...
Page 28 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. 2007 Buell Ulysses: Appendix B B-11...
Page 29 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 2007 Buell Ulysses: Appendix B...
Page 30 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 2007 Buell Ulysses: Appendix B B-13...
Page 31: 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 32: Main Harness
3-place Deutsch under seat main harness [178] Active intake system to solenoid 2-place Deutsch under airbox cover [179] Active intake system to ECM 2-place Deutsch under seat [180] Rear auxiliary power outlet 2-place Sumitomo 2007 Buell Ulysses: Appendix B B-15...
Page 33: Table Of Contents
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 2007 Buell Ulysses: Appendix B...
Page 34 R/BK SPEEDOMETER LT.GN/R [91A] [39A] R/BK LH TURN SIGNAL GN/Y [95B] R/BK OIL PRESSURE SW [120B] [31B] CLUTCH SW GN/Y 12V AUX. R/BK [160B] [120A] 12V AUX. MALE [180] FEMALE 2007 Ulysses Model Main Harness 2007 Buell Ulysses: Electrical B-17...
Page 35 HOME 2007 Ulysses Model Main Harness 2007 Ulysses Model Main Harness B-18 2007 Buell Ulysses: Electrical...
Page 36: Engine Management Circuit
ASSEMBLY [134B] LT.GN/GY W/BK BK/W GN/W GN/W W/BK BK/W BK/W BANK ANGLE SENSOR [14B] [14A] GY/O GY/O DATA LINK SPEEDOMETER LT.GN/R [95B] [39A] [91A] CLUTCH SW R/BK R/BK R/BK 2007 Ulysses Model Engine Management Circuit 2007 Buell Ulysses: Electrical B-19...
Page 37 HOME 2007 Ulysses Model Engine Management Circuit 2007 Ulysses Model Engine Management Circuit B-20 2007 Buell Ulysses: Electrical...
Page 38: Lighting Circuit
15 AMP [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 2007 Ulysses Model Lighting Circuit 2007 Buell Ulysses: Electrical B-21...
Page 39 HOME 2007 Ulysses Model Lighting Circuit 2007 Ulysses Model Lighting Circuit B-22 2007 Buell Ulysses: Electrical...
Page 40: Horn And Instruments Circuit
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 [120B] OIL PRESSURE SW R/BK GN/Y [120A] R/BK 2007 Ulysses Model Horn & Instruments Circuit 2007 Buell Ulysses: Electrical B-23...
Page 41 HOME 2007 Ulysses Model Horn & Instruments Circuit 2007 Ulysses Model Horn & Instruments Circuit B-24 2007 Buell Ulysses: Electrical...
Page 42: Starting Circuit
15 AMP R/BK GY/O 15 AMP KEY SWITCH NEUTRAL SW TN/Y [131A] [131B] [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 2007 Ulysses Model Starting Circuit 2007 Buell Ulysses: Electrical B-25...
Page 43 HOME 2007 Ulysses Model Starting Circuit 2007 Ulysses Model Starting Circuit B-26 2007 Buell Ulysses: Electrical...
Page 44: Charging Circuits
HOME bs0021au BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] FUSE/RELAY ASSEMBLY [61B] BATTERY, 30A TO VOLTAGE REGULATOR [77A] [77B] VOLTAGE REGULATOR STATOR (HD 3-PHASE) [46B] [46A] 2007 Ulysses Model Charging Circuit 2007 Buell Ulysses: Electrical B-27...
Page 45 HOME 2007 Ulysses Model Charging Circuit 2007 Ulysses Model Charging Circuit B-28 2007 Buell Ulysses: Electrical...
Page 46: Component Circuits
Front Auxilary [85B] Outlet ENGINE TEMP SENSOR Outlet PK/Y [90B] [90A] FUEL PUMP MAIN HARNESS BANK ANGLE SENSOR [89A] BN/Y INTAKE AIR TEMP [86B] LT.GN/GY [89B] FUEL BK/W SENSOR [134B] [134A] 2007 Ulysses Model Component Circuits 2007 Buell Ulysses: Electrical B-29...
Page 47 HOME 2007 Ulysses Model Component Circuits 2007 Ulysses Model Component Circuits B-30 2007 Buell Ulysses: Electrical...
Page 48 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 2007 Buell Ulysses: Appendix C...
Page 49 (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.) 2007 Buell Ulysses: Appendix C...
Page 50 HOME HOSE AND WIRE ROUTING b1114absxu Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 51 HOME b1115acsxu Figure D-2. Rear Brake Systems, Top View...
Page 52 HOME b1116adsxu Figure D-3. Rear Brake Systems, Left Side View...
Page 53 HOME b1117acsxu Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 54 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 55 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 56 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 57 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 58 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 59 HOME b1123absxu Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 60 HOME b1124absx Exhaust valve actuator Mufﬂer valve Figure D-11. Clutch Cable and Exhaust Valve Actuator, Right Side View...
Page 61 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 62 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 64 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. 2007 Buell Ulysses: Appendix E...
Page 65 (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 2007 Buell Ulysses: Appendix E...
Page 66 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 2007 Buell Ulysses: Appendix E...
Page 67 Adjust stop screw, while reading the TPS on Digital 1.14 AIR 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 2007 Buell Ulysses: Appendix E...
Page 68 HOME Active Intake Solenoid Figure E-4. Active Intake System 2007 Buell Ulysses: Appendix E...
Page 69 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. 2007 Buell Ulysses: Appendix E...
Page 70 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. 2007 Buell Ulysses: Appendix E...
Page 71 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 2007 Buell Ulysses: Appendix E...
Page 72 MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 74: General
If all is correct, the vehicle is ready to go back to the All special tools and torque values are noted at the point of customer. use. All required parts or materials can be found in the appropriate PARTS CATALOG. 2007 Buell Ulysses: Maintenance...
Page 75: Hardware And Threaded Parts
Part Replacement Always use the proper tools and ﬁxtures for removing and Always replace worn or damaged parts with new parts. installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary. 2007 Buell Ulysses: Maintenance...
Page 76: 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. 2007 Buell Ulysses: Maintenance...
Page 77: 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. 2007 Buell Ulysses: Maintenance...
Page 78: 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 79: 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. 2007 Buell Ulysses: Maintenance...
Page 80 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 Intake cover assembly Air intake cover screw torque 12-36 in-lbs (1.3-4 Nm) 2007 Buell Ulysses: Maintenance...
Page 81 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) 2007 Buell Ulysses: Maintenance...
Page 82: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Voltmeter Test Buell motorcycle batteries are permanently sealed, mainte- 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 83 Inspect the battery case for cracks or leaks. 100 % at 77 ° F 75 % 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 2007 Buell Ulysses: Maintenance...
Page 84 (00068a) CAUTION Do not over-tighten bolts on battery terminals. Use rec- ommended torque values. Over-tightening battery termi- nal bolts could result in damage to battery terminals. (00216a) 2007 Buell Ulysses: Maintenance 1-11...
Page 85: Engine Lubrication System
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. Insert dipstick into oil tank ﬁller hole, screwing dipstick in completely. DO NOT OVER TIGHTEN. 1-12 2007 Buell Ulysses: Maintenance...
Page 86: 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 8418 Figure 1-7. Oil Filter 2007 Buell Ulysses: Maintenance 1-13...
Page 87 ° H.D. Multi-Grade SAE 20W50 HD 360 Above 40 (4°C) Good ° H.D. Regular Heavy SAE 50 HD 360 Above 60 (16°C) Poor ° H.D. Extra Heavy SAE 60 HD 360 Above 80 (27°C) Poor 1-14 2007 Buell Ulysses: Maintenance...
Page 88: 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. 2007 Buell Ulysses: Maintenance 1-15...
Page 89 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 2007 Buell Ulysses: Maintenance...
Page 90 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 1-10. Reservoir Fluid Level Indicator 2007 Buell Ulysses: Maintenance 1-17...
Page 91 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 2007 Buell Ulysses: Maintenance...
Page 92 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 1-14. Rear Brake Pedal Pushrod Adjustment 2007 Buell Ulysses: Maintenance 1-19...
Page 93: Brake Pads
2.12 FRONT BRAKE CALIPER 2.15 REAR BRAKE CALIPER for rotor replacement procedure. Whenever rotor is replaced, replace rotor drive bushings, fasteners, washers and springs. Figure 1-16. Front Brake Rotor 8347 11141 Figure 1-17. Rear Brake Rotor 1-20 2007 Buell Ulysses: Maintenance...
Page 94: Brake Pad Replacement
Avoid making hard stops for the ﬁrst 100 miles (160 km) to Rear caliper pin plug allow new brake pads to “wear in” properly with the rotor. Rear caliper pin hanger Figure 1-19. Rear Brake Caliper 2007 Buell Ulysses: Maintenance 1-21...
Page 95 “wear in” properly with the rotor. Rear caliper mounting fasteners Retainer Rear caliper pin hanger Rear caliper pin plug Figure 1-21. Rear Brake Caliper 6487 Figure 1-22. Rear Brake Pad Spring Installed 1-22 2007 Buell Ulysses: Maintenance...
Page 96: Tires And Wheels
TIRES AND WHEELS TIRE INFLATION 12380 WARNING WARNING Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stabil- ity, which could result in death or serious injury. (00133a) Do not inﬂate tire beyond maximum pressure as speciﬁed on sidewall.
Page 97: Clutch
84-108 in-lbs (10- Clutch diaphragm spring 12 Nm). Clutch adjusting screw Clean up any ﬂuid that may have spilled on mufﬂer. Primary cover Correct chaincase lubricant level Figure 1-26. Fluid Level 1-24 2007 Buell Ulysses: Maintenance...
Page 98 Adjuster adjusting screw clockwise until it aligns. Figure 1-27. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-28. Clutch Adjustment (Typical 2007 Buell Ulysses: Maintenance 1-25...
Page 99 Each time the clutch inspection cover is removed the gasket must be replaced. Figure 1-24. Install clutch inspection cover and new Figure 1-29. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). 1-26 2007 Buell Ulysses: Maintenance...
Page 100 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. 2007 Buell Ulysses: Maintenance 1-27...
Page 101 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 2007 Buell Ulysses: Maintenance...
Page 102 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 2007 Buell Ulysses: Maintenance 1-29...
Page 103 HOME NOTES 1-30 2007 Buell Ulysses: Maintenance...
Page 104: 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) 2007 Buell Uylsses: Maintenance 1-31...
Page 105 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 1-33. Chain Tension Adjusting Fastener 1-32 2007 Buell Uylsses: Maintenance...
Page 106: 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 107 * 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 2007 Buell Uylsses: Maintenance...
Page 108 Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. Figure 1-35. Front Fork Compression Damping Adjuster 2007 Buell Uylsses: Maintenance 1-35...
Page 109 Then turn the dial counterclockwise the number of turns recommended in Table 1-10. 11958 Figure 1-38. Rear Shock Compression Adjuster Figure 1-36. Rear Shock Preload Adjuster 11121 Figure 1-37. Rear Shock Rebound Adjustment Dial 1-36 2007 Buell Uylsses: Maintenance...
Page 110: 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 111: 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 2007 Buell Uylsses: Maintenance...
Page 112 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. 2007 Buell Uylsses: Maintenance 1-39...
Page 113: Air Cleaner Filter
Thoroughly clean baseplate and inside of air cleaner cover. Figure 1-42. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). 1-40 2007 Buell Uylsses: Maintenance...
Page 114 INSTALLATION Figure 1-44. 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. 2007 Buell Uylsses: Maintenance 1-41...
Page 115: Throttle Cable And Idle Speed Adjustment
10. Install left air scoop. See 2.40 AIR SCOOPS. 11. If it was necessary to remove airbox, baseplate and intake cover assembly, install at this time. See 4.44 AIR CLEANER ASSEMBLY. 12. Recheck engine slow idle speed; adjust if required. 1-42 2007 Buell Uylsses: Maintenance...
Page 116: 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. 2007 Buell Uylsses: Maintenance 1-43...
Page 117 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 ASSEMBLY. 1-44 2007 Buell Uylsses: Maintenance...
Page 118: Ignition Timing
Gently bump ﬂywheel forward in tiny increments. Figure 1-51. 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 1-51. Correct Timing 2007 Buell Uylsses: Maintenance 1-45...
Page 119 Tighten sensor assembly fasteners to 15-30 in-lbs (1.7- 3.4 Nm). Recheck timing. Figure 1-54. Advanced Timing 12136a b1248x1x Figure 1-55. Retard Timing Figure 1-52. Timer Cover 8391a Figure 1-53. Cam Position Sensor 1-46 2007 Buell Uylsses: Maintenance...
Page 120: Headlights
Check that the correct pattern of light is a circular Low beam pattern and is centered on the horizontal line as shown in Figure 1-56. Figure 1-57. Headlight Switch Adjust headlight alignment. See ADJUSTMENT section. 2007 Buell Uylsses: Maintenance 1-47...
Page 121 48-72 in-lbs (5-8 Nm). b1213x1x Figure 1-59. The vertical headlight adjustment screw is located under the front upper fender. 11792 11793 Figure 1-60. Front Fender Assembly Vertical Headlight Adjustment Screw Figure 1-58. Horizontal Headlight Adjustment 1-48 2007 Buell Uylsses: Maintenance...
Page 122: Throttle Position Sensor (Tps)
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 1-61. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 123: 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 2007 Buell Uylsses: Maintenance...
Page 124: 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. 2007 Buell Uylsses: Maintenance 1-51...
Page 125: 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 2007 Buell Uylsses: Maintenance...
Page 126 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. 2007 Buell Uylsses: Maintenance 1-53...
Page 127 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 2007 Buell Uylsses: Maintenance...
Page 128 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 130: 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) 15.35 0.45 ounces Transmission 1.0 quart 0.95 2007 Buell Ulysses: Chassis...
Page 131 9.5-12.2 Nm Tighten in a crosswise pattern, page 2-72 teners Deﬂector fasteners 24-36 in-lbs 2.7-4.1 Nm page 2-68 Deﬂector jam nuts 39-48 in-lbs 4.4-5.4 Nm page 2-68 Deﬂector pivot shaft riser 43-49 in-lbs 4.8-5.5 Nm page 2-68 2007 Buell Ulysses: Chassis...
Page 132 Negative battery cable at bat- 72-96 in-lbs 8-11 Nm page 2-72 tery terminal Nuts, license plate light 12-36 in-lbs 1.4-4 Nm page 2-107 Oil cooler air scoop 48-72 in-lbs 5.4-8.0 Nm LOCTITE 271 (red), page 2-92 2007 Buell Ulysses: Chassis...
Page 133 Tail sections to tail loop 20-22 ft-lbs 27-30 Nm page 2-97 Torca clamp 28-30 ft-lbs 38-40.6 Nm page 2-84 Triple tail plastic collar screw 36-48 in-lbs 4.0-5.4 Nm page 2-107 Upper front fender fasteners 36-48 in-lbs 4-5.4 Nm page 2-88 2007 Buell Ulysses: Chassis...
Page 134 NOTES Upper module fasteners 36-60 in-lbs 4.1-6.8 Nm page 2-77 Valve stem nut 40-44 in-lbs 4.5-4.9 Nm page 2-23 Windscreen fasteners 10-12 in-lbs 1.1-1.4 Nm page 2-100 Wire cover screws 36-48 in-lbs 4.0-5.4 Nm page 2-107 2007 Buell Ulysses: Chassis...
Page 135: 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 136: Vehicle Identification Number
(V.I.N.) is stamped on the right side of the steering head and on a label located on the left side of the steering head. 4MZ KP 01 D 3 7 3 0 00456 Figure 2-2. Typical Buell Identiﬁcation Number Table 2-8. Buell 2007 XB Models V.I.N. Description ITEM DESCRIPTION POSSIBLE VALUES...
Page 137: 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. 2007 Buell Ulysses: Chassis...
Page 138 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 139: Front Wheel
Figure 2-5. 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 2-5. Front Wheel Removal 2-10 2007 Buell Ulysses: Chassis...
Page 140 Forcing screw Figure 2-8. Expand the Collet Figure 2-9. 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. 2007 Buell Ulysses: Chassis 2-11...
Page 141 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 FRONT BRAKE CALIPER. 2-12 2007 Buell Ulysses: Chassis...
Page 142: Bearing Installation
Backing plate Remove the nut, bearing, washer, FRONT BEARING Forcing screw INSTALLER (Part No. B-43993-9) and forcing screw. Figure 2-12. Install the Backing Plate (B-43993-12) and Forcing Screw 2007 Buell Ulysses: Chassis 2-13...
Page 143 (6) until the bearing contacts the spacer. 15. Remove the nut, bearing, washer, FRONT BEARING INSTALLER (Part No. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION under 2.5 FRONT WHEEL. Forcing screw Spacer Figure 2-15. Install the Spacer 2-14 2007 Buell Ulysses: Chassis...
Page 144 (8) toward center of wheel. Align reference dot on front rotor with the valve stem. CAUTION Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 2007 Buell Ulysses: Chassis 2-15...
Page 145 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 2-19. Front Wheel Mounting 2-16 2007 Buell Ulysses: Chassis...
Page 146: Rear Wheel
1.6 BRAKE SYSTEM MAINTENANCE 2.15 REAR BRAKE CALIPER. Figure 2-20. Rear Brake Caliper Carrier Fasteners Remove rear axle. 6.6 DRIVE BELT SYSTEM for proper handling. Slide drive belt out of the way and remove rear wheel. 2007 Buell Ulysses: Chassis 2-17...
Page 147 BEARING REMOVER AND INSTALLER (Part No. HD- 44060). WHEEL. Remove rear wheel spacer (4). b0936x2x Rotor mounting fastener (6) Brake rotor Wheel bearing (2) Wheel spacer Wheel Sprocket Sprocket fastener (6) Axle Figure 2-22. Rear Wheel Assembly 2-18 2007 Buell Ulysses: Chassis...
Page 148 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). 2007 Buell Ulysses: Chassis 2-19...
Page 149 After repairing the brake system, test brakes at low 11169 speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Figure 2-26. Rear Brake Caliper Carrier Fasteners 2-20 2007 Buell Ulysses: Chassis...
Page 150: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-10. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-28. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2007 Buell Ulysses: Chassis 2-21...
Page 151: 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 152 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 2-32. Starting Bead on Rim (Typical) changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 153 Figure 2-33. Checking Tire Lateral Runout Install tire and again check tire radial runout. Table 2-11. Tire Runout b0088x2x RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 Gauge Figure 2-34. Checking Tire Radial Runout 2-24 2007 Buell Ulysses: Chassis...
Page 154: 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. 2007 Buell Ulysses: Chassis 2-25...
Page 155: 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 2-37. Brake Pedal Assembly Figure 2-36. Brake Pedal 2-26 2007 Buell Ulysses: Chassis...
Page 156: 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 2-38. Front Brake Hand Lever Assembly 2007 Buell Ulysses: Chassis 2-27...
Page 157: 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 2-39. Piston Assembly in Master Cylinder 2-28 2007 Buell Ulysses: Chassis...
Page 158 (15) and banjo bolt (13) (metric) and tighten to 16-20 ft-lbs (22-27 Nm). Ridge on rubber boot Circlip Groove on piston Primary seal of piston Spring Figure 2-40. Front Master Cylinder Piston Assembly 2007 Buell Ulysses: Chassis 2-29...
Page 159 11. Turn ignition key switch to ON. Apply brake hand lever to test brake lamp operation. Turn ignition key switch to OFF. 12. Install right deﬂector. See 2.25 DEFLECTORS/HANDLE- BARS. Figure 2-43. Reservoir Brake Fluid Level 2-30 2007 Buell Ulysses: Chassis...
Page 160: Front Brake Line
P-clamp (behind front module) P-clamp on fork tube Brake line Right lower fender fasteners Front brake caliper Figure 2-45. Front Brake Line Bleeder valve Banjo bolt Copper washers Figure 2-44. Bleeder Valve and Banjo Bolt (Caliper) 2007 Buell Ulysses: Chassis 2-31...
Page 161 Install brake line to caliper. OFF. Figure 2-44. 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 2007 Buell Ulysses: Chassis...
Page 162: Front Brake Caliper
11116 Pin hanger set Caliper pad spring Caliper fasteners Bleeder valve Figure 2-47. Pad Spring (Typical) 6495 Brake line Banjo bolt (metric) Mounting fasteners (2) Figure 2-46. Front Brake Caliper Figure 2-48. Removing Pistons (B-42887) 2007 Buell Ulysses: Chassis 2-33...
Page 163 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 2007 Buell Ulysses: Chassis...
Page 164 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 2-49. Front Caliper Assembly 2007 Buell Ulysses: Chassis 2-35...
Page 165: Rear Brake Master Cylinder
Figure 2-50. Brake Bleeder Valve, Rear Caliper PEDAL. Remove seat. See 2.45 SEAT. Figure 2-52. Disconnect brake light connector 11127 located under the seat. Reservoir hose Cotter pin Banjo bolt (metric) Fasteners (2) Figure 2-51. Rear Master Cylinder 2-36 2007 Buell Ulysses: Chassis...
Page 166 Pedal bearing Sleeve Brake pedal fastener Brake pedal 10. Cotter pin 11. Rear master cylinder mount screw (2) Figure 2-54. Rear Master Cylinder Assembly Reservoir Clamp Fastener and washer Remote reservoir hose Figure 2-53. Remote Reservoir 2007 Buell Ulysses: Chassis 2-37...
Page 167 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 2007 Buell Ulysses: Chassis...
Page 168 Attach hose (3) to rear brake reservoir using clamp. 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. 2007 Buell Ulysses: Chassis 2-39...
Page 169: 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 2007 Buell Ulysses: Chassis...
Page 170 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. 2007 Buell Ulysses: Chassis 2-41...
Page 171: Rear Brake Caliper
Figure 2-61. Removing Rear Brake Caliper Piston Figure 2-61. 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 2007 Buell Ulysses: Chassis...
Page 172 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. 2007 Buell Ulysses: Chassis 2-43...
Page 173 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 2007 Buell Ulysses: Chassis...
Page 174: 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 2-64. Upper and Lower Fork Clamp Assembly b0992x2x Figure 2-65. Stopper Ring 2007 Buell Ulysses: Chassis 2-45...
Page 175 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 2-68. Removing Fork Cap From Outer Tube Figure 2-68. Remove fork cap from outer tube. 2-46 2007 Buell Ulysses: Chassis...
Page 176 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 2-69. Expand fork and remove from FORK When using the FORK SPRING COMPRESSING TOOL SPRING COMPRESSION TOOL.
Page 177 24. Oil seal Inner slider piston o-ring 16. Spring joint 25. Oil seal stopper ring Snap ring 17. Spring 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-71. Front Fork Assembly 2-48 2007 Buell Ulysses: Chassis...
Page 178 (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). 2007 Buell Ulysses: Chassis 2-49...
Page 179: Fork Assembly
(11) and insert the damper assembly into the slider fork (27). 11. See Figure 2-71. Replace the sealing washer (13) and center bolt (14) (metric). Install the center bolt and tighten to 22-30 ft-lbs (30-40 Nm). 2-50 2007 Buell Ulysses: Chassis...
Page 180 Thread fork cap (3) into fork tube (18) and tighten to 22-30 ft-lbs (29.8-40.6 Nm). 24. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (1). 25. Install snap ring (8). 2007 Buell Ulysses: Chassis 2-51...
Page 181 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 2007 Buell Ulysses: Chassis...
Page 182: 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 2-77. Steering Stem Assembly 2007 Buell Ulysses: Chassis 2-53...
Page 183 2.30 HANDLEBARS. 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 271 (red) and tightening to 20-22 ft-lbs (27-29.8 Nm). 2-54 2007 Buell Ulysses: Chassis...
Page 184: 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 2-79. Steering Head Bearings Installation Tools 2007 Buell Ulysses: Chassis 2-55...
Page 185 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 2007 Buell Ulysses: Chassis...
Page 186 14. Install headlight assembly and support bracket. See 2.28 HEADLIGHTS AND SUPPORT BRACKET. 15. Install front brake lever housing. See 2.10 FRONT BRAKE MASTER CYLINDER AND HAND LEVER. 16. Install front modules. See 2.29 FRONT MODULES. Figure 2-82. Install Bearings 2007 Buell Ulysses: Chassis 2-57...
Page 187: 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 2-84. Belt Guard Assembly 2-58 2007 Buell Ulysses: Chassis...
Page 188 1.5 ENGINE LUBRICA- TION SYSTEM. Remove rear fender. See 2.36 FENDERS. Remove drive belt. See 6.6 DRIVE BELT SYSTEM. Remove rear wheel. See 2.6 REAR WHEEL. Remove p-clamp fasteners that secure oil lines to swing- arm. 2007 Buell Ulysses: Chassis 2-59...
Page 189 29 ft-lbs (35-36 Nm). mine air ﬂow rates. (00061a) Thoroughly clean all components in solvent. Blow dry with compressed air. 11963a 11972 Return. Vent Feed Figure 2-86. Jiffy Tite, Quick Disconnect Oil Lines and Fittings 2-60 2007 Buell Ulysses: Chassis...
Page 190 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 132-144 in-lbs (15-16.2 Nm). See 2.34 HEEL GUARD AND FOOTPEG MOUNTS. 2007 Buell Ulysses: Chassis 2-61...
Page 191: Front And Rear Isolator
Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). NOTE Hold wire form while tightening to prevent it from twisting. Figure 2-87. Install clutch cable wire form. Tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). NOTE 2-62 2007 Buell Ulysses: Chassis...
Page 192: 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. 2007 Buell Ulysses: Chassis 2-63...
Page 193: Frame Pucks
Align the corners with the pencil marks and tack the puck to the frame at the corners. Figure 2-92. 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 2007 Buell Ulysses: Chassis...
Page 194: 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 2-93. Rear Shock Absorber Assembly 2007 Buell Ulysses: Chassis 2-65...
Page 195 (00070a) NOTE 12. Install seat. See 2.45 SEAT. Rear brake switch wiring is routed over the remote reservoir. 2-66 2007 Buell Ulysses: Chassis...
Page 196: 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. 2007 Buell Ulysses: Chassis 2-67...
Page 197: 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 2-97. Deﬂectors 2-68 2007 Buell Ulysses: Chassis...
Page 198: Clutch Control/Cable
Hand lever clamp Cable adjuster Wind deﬂector standoff Jam nut Clutch hand lever Cable end Clutch adjuster Clutch cable adjuster boot Figure 2-98. Clutch Cable Adjuster Mechanism Clutch cable ferrule Figure 2-100. Clutch Hand Control Assembly 2007 Buell Ulysses: Chassis 2-69...
Page 199 Sleeve, shift lever Shift linkage assembly 10. Bearings, shift lever Figure 2-101. Shifter Linkage 8413 11168 Outer ramp and hook Coupling Cable end Figure 2-102. Clutch Release Mechanism (Typical) Figure 2-103. Clutch Cable and Fitting 2-70 2007 Buell Ulysses: Chassis...
Page 200 Loctite 271 to fasteners and tighten to 36-60 in-lbs (4-6.8 Nm). Adjust to rider comfort. NOTE D.1 HOSE AND WIRE ROUTING in Appendix D. Route clutch cable through clutch cable wire form and upper triple clamp. 2007 Buell Ulysses: Chassis 2-71...
Page 201 13. Install new clutch cover gasket. 14. See Figure 2-101. 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 2007 Buell Ulysses: Chassis...
Page 202: 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 2-106. Headlight Grille 2007 Buell Ulysses: Chassis 2-73...
Page 203: 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 2-107. Headlight and Support Bracket 2-74 2007 Buell Ulysses: Chassis...
Page 204 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 2-108. Headlight Assembly 2007 Buell Ulysses: Chassis 2-75...
Page 205 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 2-109. Headlight and Support Bracket 2-76 2007 Buell Ulysses: Chassis...
Page 206: Front Modules
(00070a) clamp. 11. See Figure 2-111. Remove the left front module. 12. Install seat. See 2.45 SEAT. 12. See Figure 2-110. Remove the ﬁnal fastener and the right front module. 2007 Buell Ulysses: Chassis 2-77...
Page 207 Figure 2-110. 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 2-111. Front Module 2-78 2007 Buell Ulysses: Chassis...
Page 208: Handlebars
Place the upper handlebar clamp in position and thread the four screws in place after applying LOC- TITE 271 (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). 2007 Buell Ulysses: Chassis 2-79...
Page 209 HOME b1209x1x Endcap (2) Handlebar Handlebar clamp Clamp fasteners (4) Left hand grip Harness retainer (4) Figure 2-112. Handlebar Assembly 2-80 2007 Buell Ulysses: Chassis...
Page 210: 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 2-113. Mirrors and Mounting Hardware 2007 Buell Ulysses: Chassis 2-81...
Page 211: Exhaust System
SERVICE. Remove oxygen sensor. See 4.33 OXYGEN SENSOR. Figure 2-115. Remove exhaust header (2) by removing mounting fasteners (3). Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2-82 2007 Buell Ulysses: Chassis...
Page 212 3.3 ENGINE ROTATION FOR NOTE SERVICE. For assembly details of the interactive exhaust system, see Rear Mufﬂer Bracket INSTALLATION under 7.6 INTERACTIVE EXHAUST SYS- TEM. Figure 2-114. Slide rear mufﬂer bracket over oil feed line. 2007 Buell Ulysses: Chassis 2-83...
Page 213 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 214: 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 2-116. Rider Footpeg, Mount and Heel Guard Assembly 2007 Buell Ulysses: Chassis 2-85...
Page 215: Heel Guard And Footpeg Mounts
Position footpeg mount (1). Install footpeg mount fasteners (2), and tighten to 132- 144 in-lbs (15-16 Nm). Install brake pedal fastener. See 2.9 BRAKE PEDAL. Figure 2-118. Heel Guard 12076 Figure 2-119. Rear Brake Master Cylinder Location 2-86 2007 Buell Ulysses: Chassis...
Page 216: Sprocket Cover
36 in-lbs (1-4 Nm). Install chin fairing. See 2.38 CHIN FAIRING. Figure 2-120. Chin Fairing Assembly, Right Rear Fasteners b1187x2x Long fastener and washer Sprocket cover Short fastener and washer (2) Figure 2-121. Sprocket Cover 2007 Buell Ulysses: Chassis 2-87...
Page 217: Fenders
Align rear fender (10) to swingarm 10. Rear fender and brake line. 11. Rear fender fastener (5) Install rear fender (10) with fasteners and washers (11). Tighten to 12-36 in-lbs (1-4 Nm). Figure 2-122. Front and Rear Fenders 2-88 2007 Buell Ulysses: Chassis...
Page 218: Belt Guard
Once the lower belt guard has been removed, remove the metal stone guard (5). b1229a1x Rear fender/upper belt guard Lower belt guard fasteners (2) Rear fender/belt guard fasteners (2) Fasteners, stone guard Lower belt guard Stone guard Figure 2-123. Belt Guard Assembly 2007 Buell Ulysses: Chassis 2-89...
Page 219: Chin Fairing
Figure 2-124. 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 2007 Buell Ulysses: Chassis...
Page 220: Intake Cover Assembly
(00070a) cover. Install seat. See 2.45 SEAT. NOTE Front screws go in at a slight angle. b1222x2x b0981x2x Intake cover assembly Intake cover fasteners Intake air inlet Figure 2-125. Intake Cover Assembly 2007 Buell Ulysses: Chassis 2-91...
Page 221: 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 2-126. RAM Air Scoop, Engine Shroud, Oil Cooler 2-92 2007 Buell Ulysses: Chassis...
Page 222: 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. 2007 Buell Ulysses: Chassis 2-93...
Page 223 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 2-127. Main Harness and Electrical Components Under Seat 2-94 2007 Buell Ulysses: Chassis...
Page 224 Install main harness and plastic grommet (7) into battery pan. Install bank angle sensor (2), connect and tighten fastener to 12-36 in-lbs (1.3-4 Nm). Connect rear brake light switch connector [121]. Install ECM and tighten fasteners to 36-60 in-lbs (4- 6.7 Nm). 2007 Buell Ulysses: Chassis 2-95...
Page 225 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 2-128. Tail Frame and Trunk Pan Assembly 2-96 2007 Buell Ulysses: Chassis...
Page 226: Center Tail Loop
Left turn signal connector [19]. Tail loop License plate bracket License plate lamp connector [45] Wire cover Tail light connectors [93]. Auxiliary power outlet [180] Figure 2-129. Wire Cover/Tail Loop/License Plate Bracket Install cable strap. 2007 Buell Ulysses: Chassis 2-97...
Page 227: 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 2007 Buell Ulysses: Chassis...
Page 228 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. 2007 Buell Ulysses: Chassis 2-99...
Page 229: 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 2-133. Windshield and Windscreen 2-100 2007 Buell Ulysses: Chassis...
Page 230: 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. 11788 Front tab Seat hook Seat lock latch Figure 2-134. Seat Attachments 2007 Buell Ulysses: Chassis 2-101...
Page 231: 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 2007 Buell Ulysses: Chassis...
Page 232 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 2-135. Seat Lock Assembly 2007 Buell Ulysses: Chassis 2-103...
Page 233: Sidestand
Figure 2-137. Sidestand Assembly (Extended) Remove sidestand spring (2) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot pin circlip (7) and remove sidestand pivot pin (3). Extend sidestand leg and remove. 2-104 2007 Buell Ulysses: Chassis...
Page 234 Install mufﬂer. See Mufﬂer and Straps 2.32 EXHAUST SYSTEM. Install chin fairing fasteners. See 2.38 CHIN FAIRING. Extend and retract sidestand leg to check for proper operation Figure 2-139. Lubricating Points (Shaded Areas) 2007 Buell Ulysses: Chassis 2-105...
Page 235: Triple Tail
Hold the RH grab handle and using a Snap-on seal and bushing driver, tap in the bearing. Hold the LH grab handle to assemble the detent and pin. Using a Snap-on seal and bushing driver, tap in the bear- ing. 2-106 2007 Buell Ulysses: Chassis...
Page 236 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 2-141. Triple Tail, Passenger Backrest and Luggage Rack 2007 Buell Ulysses: Chassis 2-107...
Page 237 HOME NOTES 2-108 2007 Buell Ulysses: Chassis...
Page 238 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 240 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 2007 Buell Ulysses: Engine...
Page 241 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 2007 Buell Ulysses: Engine...
Page 242 31.7398 mm (min) Outer race diameter in right 39.7408-39.7561 1.5646-1.5652 in. 1.5672 in. (max) 39.8069 mm (max) crankcase Bearing running clearance 0.00305-0.02235 0.00012-0.00088 in. Fit in cover bushing (loose) 0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm 2007 Buell Ulysses: Engine...
Page 243 271 (red), page 3-92 Piston jet TORX screws 25-35 in-lbs 2.8-4 Nm Loctite 222 (purple), page 3-95 Pushrod cover screws 30-40 in-lbs 3-5 Nm page 3-88 Rear isolator assembly fasten- 25-27 ft-lbs 33.9-36.6 Nm page 3-29 2007 Buell Ulysses: Engine...
Page 244 LOCTITE 271 (red), page 3-30 bolt Swingarm pivot shaft 24-26 ft-lbs 32.5-35.2 Nm page 3-30 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-14, 3-32 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-35 2007 Buell Ulysses: Engine...
Page 245 “oxygenate” the gas. Your sion, it indicates the piston rings need replacing. Low motorcycle will run normally using this type of gas. Buell compression by itself, however, may indicate improperly recommends you use it when possible, as an aid to seated valves, in addition to or in lieu of worn piston rings.
Page 246: 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. 2007 Buell Ulysses: Engine...
Page 247: Engine Rotation For Service
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) 2007 Buell Ulysses: Engine...
Page 248 Figure 3-2. Electrical Connections and Throttle Cables (Typical) 10. See Figure 3-2. Disconnect the ignition coil connector (2) [83] and remove ignition coil (1). 11. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 2007 Buell Ulysses: Engine...
Page 249 14. See Figure 3-3. Remove mufﬂer. See 2.32 EXHAUST 2.40 AIR SCOOPS. SYSTEM. 13. 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 2007 Buell Ulysses: Engine...
Page 250 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 2007 Buell Ulysses: Engine 3-11...
Page 251 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 2007 Buell Ulysses: Engine...
Page 252 Figure 3-7. Front Isolator and Tie Bar Assemblies 21. Loosen rear isolator bolt (1). DO NOT REMOVE. 22. See Figure 3-7. Remove front isolator bolt (1). 23. Remove front isolator mount (2) from engine. 24. Rotate engine down. 2007 Buell Ulysses: Engine 3-13...
Page 253 120-144 in-lbs (13.6-16.3 Nm). Figure 3-8. Install front tie-bar (4) to “V” bracket and tighten to 25-27 ft-lbs (33.9-36.6 Nm). Attach regulator wiring harness to bracket nylon cable straps. Remove scissors jack. 3-14 2007 Buell Ulysses: Engine...
Page 254 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 to Clutch Cable 2007 Buell Ulysses: Engine 3-15...
Page 255 11. Connect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 12. See Figure 3-11. Install the ignition coil (1) and connect (2) [83] and tighten fasteners to 120-144 in-lbs (13.6- 16.3 Nm). 3-16 2007 Buell Ulysses: Engine...
Page 256 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. See 4.39 FUEL PUMP. 2007 Buell Ulysses: Engine 3-17...
Page 257: 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 3-13. Fuel Line and DDFI Electrical Connections (Typical) 3-18 2007 Buell Ulysses: Engine...
Page 258 Figure 3-14. Disconnect the ignition coil connector (2) [83] and remove the ignition coil (1). 10. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 11. Disconnect throttle cables from induction module/throttle body. 2007 Buell Ulysses: Engine 3-19...
Page 259 13. Remove chin fairing. See 2.38 CHIN FAIRING. 14. Remove rear belt and idler pulley. See 6.6 DRIVE BELT 16. See Figure 3-15. Remove mufﬂer. See 2.32 EXHAUST SYSTEM. SYSTEM. 15. Remove transmission sprocket. See 6.16 TRANSMIS- SION SPROCKET. 3-20 2007 Buell Ulysses: Engine...
Page 260 Figure 3-16. 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. 2007 Buell Ulysses: Engine 3-21...
Page 261 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 3-17. Engine Mounting System 3-22 2007 Buell Ulysses: Engine...
Page 262 (1) [77]. Disconnect oil cooler lines at oil cooler. Remove front tie-bar (7) from “V” bracket. Remove front tie-bar (7) from engine. Unbolt “V” bracket from main frame and remove “V” bracket. 2007 Buell Ulysses: Engine 3-23...
Page 263 Disconnect oil return line (4) at oil pump (14) and remove. 10502 28. Remove front and rear mufﬂer brackets. Wire form retainer Clutch cable adjuster boot Lower retaining clamp Figure 3-20. Clutch Cable Wire Form Retainer, Retaining Clamp and Adjuster Boot 3-24 2007 Buell Ulysses: Engine...
Page 264 Remove clutch cable ferrule from hand lever. 30. See Figure 3-21. Remove two fasteners (2) and remove sidestand assembly. 31. Support engine with wide scissors jack. Sidestand assembly b0946c2x Bracket fasteners (2) Figure 3-21. Sidestand Assembly (Extended) 2007 Buell Ulysses: Engine 3-25...
Page 265 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 3-23. Supporting the Swingarm (Typical) 3-26 2007 Buell Ulysses: Engine...
Page 266 Aluminum bushings from front exhaust mount. Figure 3-28. Front Exhaust Mount Bushings (2 piece) Timer cover. Figure 3-29. Wire guard located under the sprocket cover. 12367 8724 12369a 8729 Figure 3-29. Wire Guard Figure 3-27. Removing Threaded Insert 2007 Buell Ulysses: Engine 3-27...
Page 267 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. 3-28 2007 Buell Ulysses: Engine...
Page 268: Engine Installation
Hand thread pivot shaft into crankcase prior to installing the threaded insert. Remove pivot shaft after installing the threaded insert. Figure 3-36. Front Exhaust Mount Bushings (2 piece) Figure 3-35. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. 2007 Buell Ulysses: Engine 3-29...
Page 269 Using the overhead hoist to align the (32.5-35.2 Nm). frame to the rear isolator, install rear isolator bolt and Apply LOCTITE 271 (red) and tighten swingarm pivot leave loose at this time. shaft pinch bolt to 17-19 ft-lbs (23-25.8 Nm). 3-30 2007 Buell Ulysses: Engine...
Page 270 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 3-42. Engine Mounting System 2007 Buell Ulysses: Engine 3-31...
Page 271 27 ft-lbs (33.9-36.6 Nm). Attach remote idle adjustment cable “V” to bracket using nylon cable straps. Attach regulator wiring harness to clutch cable below clutch cable lower retaining clamp using a nylon cable strap. 18. Remove scissors jack. 3-32 2007 Buell Ulysses: Engine...
Page 272 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. 2007 Buell Ulysses: Engine 3-33...
Page 273 The feed oil line (3) is routed through the right side of the rear vehicle. Leave all oil line ﬁttings loose at the engine at mufﬂer bracket (10). this time. See 3.10 OIL LINE FITTINGS. 3-34 2007 Buell Ulysses: Engine...
Page 274 27. Tighten the vent oil line (1) at the gearcase cover to 12- return oil line (4) in front of starter motor and tighten to 13 ft-lbs (16.3-17.6 Nm). 40-50 in-lbs (5-5.5 Nm). 28. Install the vent oil line protective cover. 2007 Buell Ulysses: Engine 3-35...
Page 275 1/4 (3.175-6.35 mm) clearance speciﬁed between the line ﬁtting with a wrench to maintain proper orientation and prevent damage to the oil line ﬁtting. feed oil line and the clutch cable at the front of the crank- case. 3-36 2007 Buell Ulysses: Engine...
Page 276 (1-4 Nm). b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 6 o’clock Figure 3-49. Oil Cooler Feed and Return Oil Lines Location and Orientation 2007 Buell Ulysses: Engine 3-37...
Page 277 7.26 SPROCKET COVER WIRING before connect- ing the following electrical components: Neutral switch [131]. Speedometer sensor [65]. Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. 3-38 2007 Buell Ulysses: Engine...
Page 278 See CLUTCH. Install wire form retainer and tighten fastener to 84- 92 in lbs (9.5-10.4 Nm). 35. Install sidestand assembly. See 2.47 SIDESTAND. Figure 3-51. Correct Routing of Wiring Harnesses and Interactive Mufﬂer Cable 2007 Buell Ulysses: Engine 3-39...
Page 279 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 3-53. Mufﬂer and Mounting System 3-40 2007 Buell Ulysses: Engine...
Page 280 [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 3-54. Electrical Connections and Throttle Cables (Typical) 2007 Buell Ulysses: Engine 3-41...
Page 281 (00070a) 48. Install rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. 54. Install seat. See 2.45 SEAT. 3-42 2007 Buell Ulysses: Engine...
Page 282: 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) b1266x3x Figure 3-56. Rocker Arm and Pushrod Cover Assemblies 2007 Buell Ulysses: Engine 3-43...
Page 283 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 3-58. Removing Rocker Arm Shafts 3-44 2007 Buell Ulysses: Engine...
Page 284 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-59. Head Screw Loosening/Tightening Sequence 8684 Figure 3-60. Valve Spring Compressor (Part No. HD-34736B) 2007 Buell Ulysses: Engine 3-45...
Page 285 11. Cylinder o-ring (2) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-61. Cylinder Head, Cylinder and Piston Assembly 3-46 2007 Buell Ulysses: Engine...
Page 286 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. 2007 Buell Ulysses: Engine 3-47...
Page 287 Figure 3-64. 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). 3-48 2007 Buell Ulysses: Engine...
Page 288: 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. 2007 Buell Ulysses: Engine 3-49...
Page 289 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 3-69. Replacing Rocker Arm Bushings 3-50 2007 Buell Ulysses: Engine...
Page 290 Figure 3-71. 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 3-71. Cleaning Valve Guides 2007 Buell Ulysses: Engine 3-51...
Page 291 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. 3-52 2007 Buell Ulysses: Engine...
Page 292 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 3-73. Valve and Seat Dimensions 2007 Buell Ulysses: Engine 3-53...
Page 293 11. Cylinder o-ring (2) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-74. Cylinder Head, Cylinder and Piston Assembly 3-54 2007 Buell Ulysses: Engine...
Page 294 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. 2007 Buell Ulysses: Engine 3-55...
Page 295 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. 3-56 2007 Buell Ulysses: Engine...
Page 296 1 Band-Orange 17909-02 (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. 2007 Buell Ulysses: Engine 3-57...
Page 297 Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-82. Tightening Head Screws Figure 3-82. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all screws an additional 85 -95 . 3-58 2007 Buell Ulysses: Engine...
Page 298 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) b1266x3x Figure 3-83. Rocker Arm and Push Rod Cover Assemblies 2007 Buell Ulysses: Engine 3-59...
Page 299 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 120-168 in- lbs (13.6-18.9 Nm). 3-60 2007 Buell Ulysses: Engine...
Page 300: 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 3-85. Cylinder and Piston 2007 Buell Ulysses: Engine 3-61...
Page 301 Figure 3-88. Removing Piston Rings Remove circlip from claw and discard. Figure 3-88. To remove piston rings spread outward until they clear grooves in piston and lift off. 3-62 2007 Buell Ulysses: Engine...
Page 302 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. 2007 Buell Ulysses: Engine 3-63...
Page 303: 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. 3-64 2007 Buell Ulysses: Engine...
Page 304 If re-using pis- ton, replace piston rings and hone the cylinder walls with a No. 240 grit ﬂexible hone to facilitate ring seating. Piston ring sets must be properly ﬁtted to piston and cyl- inder. 2007 Buell Ulysses: Engine 3-65...
Page 305 Figure 3-94. Ring End Gap Position Figure 3-94. 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. 3-66 2007 Buell Ulysses: Engine...
Page 306 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. 2007 Buell Ulysses: Engine 3-67...
Page 307 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. 3-68 2007 Buell Ulysses: Engine...
Page 308 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. 2007 Buell Ulysses: Engine 3-69...
Page 309 HOME NOTES 3-70 2007 Buell Ulysses: Engine...
Page 310: Lubrication System
2500 mile (4000 km) intervals. Reﬁll with fresh oil. Always change oil ﬁlter when changing engine oil. NOTE 1.5 ENGINE LUBRICATION SYSTEM for more informa- tion on checking oil level and changing oil and ﬁlter. 2007 Buell Ulysses: Engine 3-71...
Page 311 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 3-106. Oil Lines and Connections 3-72 2007 Buell Ulysses: Engine...
Page 312: Oil Line Fittings
Repeat to remove the remaining oil lines. Remove oil line ﬁttings and plug the holes until they can Figure 3-107. Oil Line Remover (B-41623-B) be replaced. 10369 Figure 3-108. Oil Line Fitting with Spring Clip 2007 Buell Ulysses: Engine 3-73...
Page 313 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 3-109. Flanged Oil Line 3-74 2007 Buell Ulysses: Engine...
Page 314: Oil Cooler
Oil cooler feed line Screws with washers (2) Oil cooler return line Stabilizer bracket Clamp, oil line Screw with washer (1) Screw with nut Oil cooler scoop Oil cooler 10. Screws with washers (2) Figure 3-110. Oil Cooler 2007 Buell Ulysses: Engine 3-75...
Page 315 Verify that the clutch cable and feed Check the oil cooler for dirt and debris. line have a clearance of 1/8-1/4 in. (3.175-6.35 mm) between them. Install oil line clamp and tighten to 12-36 in-lbs (1.3-4 Nm). 3-76 2007 Buell Ulysses: Engine...
Page 316 1/8-1/4 in. (3.175-6.35 mm) clearance Feed oil line to oil cooler Feed oil line Return oil line from oil cooler Figure 3-111. Oil Cooler Feed Oil Line Orientation (Approximately 2 O’Clock) and Oil LIne Clearances 2007 Buell Ulysses: Engine 3-77...
Page 317: Oil Pressure Indicator Switch
Burned-out signal bulb. Figure 3-113. Install OIL PRESSURE GAUGE (prior to oper- Dead battery (see NOTE). ADAPTER (Part No. HD-96925-58) (2) in oil pressure ating engine). indicator lamp switch mounting hole. Tighten adapter snugly. DO NOT OVERTIGHTEN. 3-78 2007 Buell Ulysses: Engine...
Page 318 10. Check oil level in oil tank. See 1.5 ENGINE LUBRICA- TION SYSTEM. Top off oil level if necessary. 11. Start engine and test oil pressure switch for proper oper- ation. Check oil pressure switch for leaks. 2007 Buell Ulysses: Engine 3-79...
Page 319: 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 3-115. Crankcase Breathing System, 3-80 2007 Buell Ulysses: Engine...
Page 320 (3). b1033x3x Reed valve fastener Reed valve Reed valve stop Reed block Figure 3-116. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-117. Reed Valve Stop and Reed Valve 2007 Buell Ulysses: Engine 3-81...
Page 321: 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. 3-82 2007 Buell Ulysses: Engine...
Page 322: 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 3-118. Oil Pump 2007 Buell Ulysses: Engine 3-83...
Page 323 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 3-119. Oil Pump Hardware 3-84 2007 Buell Ulysses: Engine...
Page 324 ﬁtting with a wrench to maintain proper orientation and prevent damage to the oil line ﬁtting. Liberally coat all moving parts with clean engine oil to ensure easy assembly and smooth operation at start-up. 2007 Buell Ulysses: Engine 3-85...
Page 325: Oil Filter Mount
ﬁlter adapter which is installed into ﬁlter mount. Do not apply LOCTITE to adapter Spring threads on ﬁlter element side. Check ball Filter adapter Figure 3-122. Oil Filter Mount Assembly 3-86 2007 Buell Ulysses: Engine...
Page 326: Hydraulic Lifters
Figure 3-123. 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. 2007 Buell Ulysses: Engine 3-87...
Page 327 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. 3-88 2007 Buell Ulysses: Engine...
Page 328: 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 3-126. Gearcase Cover & Cam Assembly 2007 Buell Ulysses: Engine 3-89...
Page 329 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 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-90 2007 Buell Ulysses: Engine...
Page 330 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. 2007 Buell Ulysses: Engine 3-91...
Page 331 Figure 3-126. Install a new seal and new dry gear cover gasket on crankcase. Figure 3-130. Crankshaft Locking Tool (Part No. HD-43984) 3-92 2007 Buell Ulysses: Engine...
Page 332 3.6 CYLINDER HEAD. Install cam position sensor and rotor in gearcase cover. 4.31 CAM POSITION SENSOR AND ROTOR. 10. Install any components removed to gain access to gear- case. Figure 3-132. Checking Cam Gear End Play 2007 Buell Ulysses: Engine 3-93...
Page 333 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. 3-94 2007 Buell Ulysses: Engine...
Page 334 Tighten nuts against each other. Placing wrench on ﬁrst (lower) nut installed, unscrew Figure 3-135. Piston Oil Jet Assemblies stud from cylinder deck. Remove piston jet gaskets from right crankcase. Loosen nuts and remove from cylinder base stud. 2007 Buell Ulysses: Engine 3-95...
Page 335 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 3-137. Crankcase and Flywheel Assembly 3-96 2007 Buell Ulysses: Engine...
Page 336 Figure 3-139. Sprocket Shaft Seal Retaining Ring Figure 3-139. Remove sprocket shaft oil seal retain- ing ring. Figure 3-137. Remove sprocket shaft oil seal (3) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) 2007 Buell Ulysses: Engine 3-97...
Page 337 (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. 3-98 2007 Buell Ulysses: Engine...
Page 338 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. 2007 Buell Ulysses: Engine 3-99...
Page 339 1.2514 1.2516 1.2518 1.2502 1.2504 1.2508 1.2510 1.2512 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 3-100 2007 Buell Ulysses: Engine...
Page 340 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. 2007 Buell Ulysses: Engine 3-101...
Page 341 1.2499 in. (31.747 mm) OD inner race, a blue bear- ing is required. Table 3-34. Pinion Inner Race Speciﬁcations Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-102 2007 Buell Ulysses: Engine...
Page 342 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 3-149. Checking Connecting Rod Side Play 2007 Buell Ulysses: Engine 3-103...
Page 343 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 3-150. Sprocket Shaft Bearing Assembly 3-104 2007 Buell Ulysses: Engine...
Page 344 CRANKSHAFT GUIDE (Part No. HD-42326) 8789 a0120x3x Figure 3-153. Pinion Shaft Bearing 8762 Shoulder for bearing to press against Crankcase bearing remover/installer tool (Part No. B-45655, HD-42720-2 and HD-46663) Bearing retaining ring Figure 3-151. Sprocket Shaft Bearing Installation 2007 Buell Ulysses: Engine 3-105...
Page 345 Slide outer race in right crankcase over pinion shaft and bearing assembly. Apply LOCTITE 271 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. 3-106 2007 Buell Ulysses: Engine...
Page 346 Install the stud in the crankcase with the shoulder end down. Use an air gun to drive the stud until the shoulder reaches the crankcase. Remove air gun. Use a torque wrench to tighten stud to 10-20 ft-lbs (14-27 Nm). 2007 Buell Ulysses: Engine 3-107...
Page 347 HOME NOTES 3-108 2007 Buell Ulysses: Engine...
Page 348 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 349 4.38 Cooling Fan ..........4-106 4.39 Fuel Pump .
Page 350: Fuel System
10-13.6 Nm page 4-121 tener Oxygen sensor 40-45 ft-lbs 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 2007 Buell Ulysses: Fuel System...
Page 351 HOME ITEM TORQUE NOTES Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-102 2007 Buell Ulysses: Fuel System...
Page 352: Dynamic Digital Fuel Injection
DYNAMIC DIGITAL FUEL INJECTION (DDFI) INTRODUCTION GENERAL The Buell DDFII operates both as an open and closed loop The Buell Dynamic Digital Fuel Injection (DDFII) System pro- system which allows it to adjust for all possible operating con- vides microprocessor-based electronic engine management ditions.
Page 353 BE/O IGN Coil Throttle To cooling Position Cooling BK/O fan fuse Sensor BK/W TN/V BE/O BK/W LT GN/Y Sensor [165] Ground Interactive mufﬂer control To Brake/horn/ mufﬂer fuse Figure 4-1. Buell Dynamic Digital Fuel Injection 2007 Buell Ulysses: Fuel System...
Page 354: 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. 2007 Buell Ulysses: Fuel System...
Page 355: 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 2007 Buell Ulysses: Fuel System...
Page 356 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. 2007 Buell Ulysses: Fuel System...
Page 357: 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. 2007 Buell Ulysses: Fuel System...
Page 358 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- tion. Let it run for at least 30 seconds. Turn the engine off. 2007 Buell Ulysses: Fuel System...
Page 359: 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 2007 Buell Ulysses: Fuel System...
Page 360: 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. 2007 Buell Ulysses: Fuel System 4-11...
Page 361: Initial Diagnostic Check
AND IDLE SPEED Compare engine behavior to tables. ADJUSTMENT. Starts hard. Refer to Table 4-4. EVAP hose disconnected Connect. Hesitates, stumbles, surges, misﬁres and/or slug- from induction module (CA) gish performance. Refer to Table 4-5. 4-12 2007 Buell Ulysses: Fuel System...
Page 362 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 2007 Buell Ulysses: Fuel System 4-13...
Page 363 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 2007 Buell Ulysses: Fuel System...
Page 364 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). 2007 Buell Ulysses: Fuel System 4-15...
Page 365 DATA LINK TERMINAL 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. 4-16 2007 Buell Ulysses: Fuel System...
Page 366: 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 2007 Buell Ulysses: Fuel System 4-17...
Page 367 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 2007 Buell Ulysses: Fuel System...
Page 368 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]. Replace Instrument module. See 7.19 INSTRUMENT MODULE Replace bulb. 2007 Buell Ulysses: Fuel System 4-19...
Page 369: 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 2007 Buell Ulysses: Fuel System...
Page 370 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 2007 Buell Ulysses: Fuel System 4-21...
Page 371 Replace ECM. See Replace Instrument Repair short to ground function OK. Check for 4.30 ELECTRONIC Module on BK/Y wire between trouble codes. See CONTROL MODULE. connector [39] and CHECKING FOR connector [10]. TROUBLE CODES. 4-22 2007 Buell Ulysses: Fuel System...
Page 372: 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. 2007 Buell Ulysses: Fuel System 4-23...
Page 373 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 2007 Buell Ulysses: Fuel System...
Page 374 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 2007 Buell Ulysses: Fuel System 4-25...
Page 375 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. 4-26 2007 Buell Ulysses: Fuel System...
Page 376 (Part 3 of 3). Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Replace Replace ignition coil. spark plugs Repair open circuit. Repair short Replace ECM. See to ground. 4.30 ELECTRONIC CONTROL MODULE. 2007 Buell Ulysses: Fuel System 4-27...
Page 377 Replace cam Replace cam position Mechanical failure. position sensor. See 4.31 sensor. See 4.31 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion gear key. 4-28 2007 Buell Ulysses: Fuel System...
Page 378: 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. 2007 Buell Ulysses: Fuel System 4-29...
Page 379 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 2007 Buell Ulysses: Fuel System...
Page 380 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. 2007 Buell Ulysses: Fuel System 4-31...
Page 381: 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 2007 Buell Ulysses: Fuel System...
Page 382 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) 2007 Buell Ulysses: Fuel System 4-33...
Page 383 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 2007 Buell Ulysses: Fuel System...
Page 384 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. 2007 Buell Ulysses: Fuel System 4-35...
Page 385 [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 2007 Buell Ulysses: Fuel System...
Page 386: 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. 2007 Buell Ulysses: Fuel System 4-37...
Page 387: 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 2007 Buell Ulysses: Fuel System...
Page 388 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 2007 Buell Ulysses: Fuel System 4-39...
Page 389 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 2007 Buell Ulysses: Fuel System...
Page 390 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. 2007 Buell Ulysses: Fuel System 4-41...
Page 391 HOME NOTES 4-42 2007 Buell Ulysses: Fuel System...
Page 392: Trouble Code 11
The reference numbers below correlate with the circled num- bers on the Code 11 ﬂow charts. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2007 Buell Ulysses: Fuel System 4-43...
Page 393 [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo under seat 4-44 2007 Buell Ulysses: Fuel System...
Page 394 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Ulysses: Fuel System 4-45...
Page 395 [14]. Measure resistance Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 4-46 2007 Buell Ulysses: Fuel System...
Page 396: 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. 2007 Buell Ulysses: Fuel System 4-47...
Page 397 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 2007 Buell Ulysses: Fuel System...
Page 398 4.30 ELECTRONIC 4.30 ELECTRONIC voltage and repair. V/GY wire. CONTROL MODULE. CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Ulysses: Fuel System 4-49...
Page 399 Repair. Fuel injectors may be dirty. See Fuel Injectors 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 2007 Buell Ulysses: Fuel System...
Page 400 ECM (4.30 now OK. ELECTRONIC CONTROL MODULE). Road test again to verify. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Ulysses: Fuel System 4-51...
Page 401: 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 2007 Buell Ulysses: Fuel System...
Page 402 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 air cleaner baseplate 2007 Buell Ulysses: Fuel System 4-53...
Page 403 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 2007 Buell Ulysses: Fuel System...
Page 404 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Ulysses: Fuel System 4-55...
Page 405: 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 2007 Buell Ulysses: Fuel System...
Page 406 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 air cleaner baseplate 2007 Buell Ulysses: Fuel System 4-57...
Page 407 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 2007 Buell Ulysses: Fuel System...
Page 408 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Ulysses: Fuel System 4-59...
Page 409: Trouble Code 16
A high voltage condition is usually caused by a faulty voltage regulator. 12038a Figure 4-40. Fuse Block and Electrical Relays 4-60 2007 Buell Ulysses: Fuel System...
Page 410 [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 2007 Buell Ulysses: Fuel System 4-61...
Page 411 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 2007 Buell Ulysses: Fuel System...
Page 412 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). 2007 Buell Ulysses: Fuel System 4-63...
Page 413: 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 2007 Buell Ulysses: Fuel System...
Page 414 [ 1 2 1 A ] [ 1 2 1 B ] Y / B K Ground Brake/Horn/Muffler 1 2 3 4 5 6 7 8 LH Controls R/BK Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-43. Interactive Exhaust Circuit 2007 Buell Ulysses: Fuel System 4-65...
Page 415 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 2007 Buell Ulysses: Fuel System...
Page 416: 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). 2007 Buell Ulysses: Fuel System 4-67...
Page 417 Figure 4-46. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch beneath intake cover assembly [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath air cleaner baseplate 4-68 2007 Buell Ulysses: Fuel System...
Page 418 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). 2007 Buell Ulysses: Fuel System 4-69...
Page 419 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 2007 Buell Ulysses: Fuel System...
Page 420 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 2007 Buell Ulysses: Fuel System 4-71...
Page 421 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 air cleaner baseplate 4-72 2007 Buell Ulysses: Fuel System...
Page 422 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). 2007 Buell Ulysses: Fuel System 4-73...
Page 423: 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 2007 Buell Ulysses: Fuel System...
Page 424 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 2007 Buell Ulysses: Fuel System 4-75...
Page 425 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 2007 Buell Ulysses: Fuel System...
Page 426: 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. 11990a Figure 4-53. Instrument Module Connector [39] Breakout box Figure 4-52. Installed Breakout Box 2007 Buell Ulysses: Fuel System 4-77...
Page 427 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 2007 Buell Ulysses: Fuel System...
Page 428 TEST. Intermit- TROL MODULE. tents found? 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 MODULE 2007 Buell Ulysses: Fuel System 4-79...
Page 429: 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 2007 Buell Ulysses: Fuel System...
Page 430 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 2007 Buell Ulysses: Fuel System 4-81...
Page 431 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 2007 Buell Ulysses: Fuel System...
Page 432 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. 2007 Buell Ulysses: Fuel System 4-83...
Page 433: 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 2007 Buell Ulysses: Fuel System...
Page 434 [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo under seat 2007 Buell Ulysses: Fuel System 4-85...
Page 435 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 2007 Buell Ulysses: Fuel System...
Page 436 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). 2007 Buell Ulysses: Fuel System 4-87...
Page 437: 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 2007 Buell Ulysses: Fuel System...
Page 438 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 2007 Buell Ulysses: Fuel System 4-89...
Page 439 [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo under seat 4-90 2007 Buell Ulysses: Fuel System...
Page 440 [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). 2007 Buell Ulysses: Fuel System 4-91...
Page 441 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 2007 Buell Ulysses: Fuel System...
Page 442: Electronic Control Module
(00068a) Install battery by threading positive cable (red) into threaded hole ﬁrst tightening to 72-96 in-lbs (8-11 Nm). 1.4 BATTERY MAINTENANCE. Connect negative battery cable. Zero TPS. See 4.37 THROTTLE POSITION SENSOR. 2007 Buell Ulysses: Fuel System 4-93...
Page 443 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 2007 Buell Ulysses: Fuel System...
Page 444: Cam Position Sensor And Rotor
Remove timer plate studs (4). Carefully remove cam position sensor. Remove bolt (17) and trig- ger rotor (16). 10. Carefully remove camshaft oil seal (15) if damaged or if there is any evidence of oil leakage past the seal. 2007 Buell Ulysses: Fuel System 4-95...
Page 445 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 2007 Buell Ulysses: Fuel System...
Page 446 HOME bs0017au Figure 4-68. Ignition System Circuit 2007 Buell Ulysses: Fuel System 4-97...
Page 447 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Install sprocket cover. See 2.35 SPROCKET COVER. 12. Connect negative battery cable. 4-98 2007 Buell Ulysses: Fuel System...
Page 448: Ignition Coil
Install intake cover assembly. See 2.39 INTAKE COVER Rear Cylinder Post ASSEMBLY. Coil Pin A (rear cylinder) Connect negative battery cable. Coil Pin B (12 VDC) Coil Pin C (front cylinder) Front Cylinder Post Figure 4-71. Ignition Coil 2007 Buell Ulysses: Fuel System 4-99...
Page 449 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 4-100 2007 Buell Ulysses: Fuel System...
Page 450: 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 ASSEMBLY. Connect negative battery cable. 2007 Buell Ulysses: Fuel System 4-101...
Page 451: Engine Temperature Sensor
While riding, a loose seat can Figure 4-75. Engine Temperature Sensor Location (rear shift causing loss of control, which could result in death cylinder) or serious injury. (00070a) Install seat. See 2.45 SEAT. 4-102 2007 Buell Ulysses: Fuel System...
Page 452: 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. 2007 Buell Ulysses: Fuel System 4-103...
Page 453: Intake Air Temperature Sensor
INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner cover base from beneath. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install negative battery cable. 4-104 2007 Buell Ulysses: Fuel System...
Page 454: Throttle Position Sensor
Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-80. Throttle Position Sensor 12501 Figure 4-79. Throttle Position Sensor Location b0651x4x Figure 4-81. Tabs on TP Sensor Connector [88A] 2007 Buell Ulysses: Fuel System 4-105...
Page 455: 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 2007 Buell Ulysses: Fuel System...
Page 456: 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). 2007 Buell Ulysses: Fuel System 4-107...
Page 457 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 2007 Buell Ulysses: Fuel System...
Page 458 (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 2007 Buell Ulysses: Fuel System 4-109...
Page 459 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 2007 Buell Ulysses: Fuel System...
Page 460 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) 2007 Buell Ulysses: Fuel System 4-111...
Page 461 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 2007 Buell Ulysses: Fuel System...
Page 462 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 2007 Buell Ulysses: Fuel System 4-113...
Page 463 Connect fuel pump connector [86] (1) and push cable strap tab into hole in frame. Install swingarm. See 2.19 SWINGARM AND BRACE. 10. Install rider footpeg mounts. See 2.33 RIDER AND PAS- SENGER FOOTPEGS. 4-114 2007 Buell Ulysses: Fuel System...
Page 464: 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) 2007 Buell Ulysses: Fuel System 4-115...
Page 465: 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 2007 Buell Ulysses: Fuel System...
Page 466: Throttle Body
Remove fuel rail fastener (1) that holds the fuel rail to the throttle body and manifold. 10. Remove fastener connecting thottle body to cylinder brace 11. Disconnect TPS connector [88] and injector connectors [84] and [85]. 2007 Buell Ulysses: Fuel System 4-117...
Page 467 10. Throttle position sensor 21. Bolt (2) 11. Clamp, wire spring 22. Mounting ﬂange, intake (1 front, 1 rear) 12. Velocity stack 23. Seal, intake manifold (2) Figure 4-99. One Piece Throttle Body/Intake Manifold Assembly 4-118 2007 Buell Ulysses: Fuel System...
Page 468: Fuel Injectors
Intake ﬂange fastener (2) Front and rear fuel injectors are not interchangeable. Figure 4-102. Intake Manifold Fasteners (gearcase cover side) 8750a Manifold to cylinder brace fastener Intake ﬂange fastener (2) Figure 4-100. Intake Manifold (Primary Side) 2007 Buell Ulysses: Fuel System 4-119...
Page 469 Snap the injector clips (4) over the ﬂange on the fuel rail outlet and into the top grove in the injector. Fuel rail fastener Rear fuel injector Fuel rail assembly Clip (2) Front fuel injector Figure 4-104. Fuel Injectors 4-120 2007 Buell Ulysses: Fuel System...
Page 470 11. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. 12. Check throttle cable adjustment. See 2.24 THROTTLE CONTROL. 13. Install air scoops. See 2.40 AIR SCOOPS. 14. Verify engine speed. See 1.19 THROTTLE POSITION SENSOR (TPS). 2007 Buell Ulysses: Fuel System 4-121...
Page 471 Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.39 INTAKE COVER ASSEMBLY. Fuel rail fastener Rear fuel injector Fuel rail assembly Clip (2) Front fuel injector Figure 4-107. Fuel Injectors 4-122 2007 Buell Ulysses: Fuel System...
Page 472: Intake Leak Test
Nozzle Figure 4-108. 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 4-109. Leak Tester 2007 Buell Ulysses: Fuel System 4-123...
Page 473 Figure 4-110. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Figure 4-109. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 4-124 2007 Buell Ulysses: Fuel System...
Page 474: Air Cleaner Assembly
If torn or damaged, replace. Inspect IAT sensor and replace if faulty. See 4.36 INTAKE AIR TEMPERATURE SENSOR Figure 4-112. Inspect breather hoses, intake air temperature sensor grommet and baseplate gasket (3). Replace as necessary. 2007 Buell Ulysses: Fuel System 4-125...
Page 475 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. 4-126 2007 Buell Ulysses: Fuel System...
Page 476 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 4-113. Air Cleaner Assembly with Interactive Exhaust Components 2007 Buell Ulysses: Fuel System 4-127...
Page 477 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 478 The barb is the larger outside diameter portion (bump) on the fuel ﬁtting. Figure 4-114. Connect two hoses to the canister. Make sure to push hoses all the way on to carbon canis- ter ﬁttings. Figure 4-116. Canister Mounting Bracket 2007 Buell Ulysses: Fuel System 4-129...
Page 479 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 4-117. Emissions Hose Attachment, California Models Only 4-130 2007 Buell Ulysses: Fuel System...
Page 480 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 482 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 2007 Buell Ulysses: Starter...
Page 483: Electric Starter System
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). 2007 Buell Ulysses: Starter...
Page 484 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 2007 Buell Ulysses: Starter...
Page 485: 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. right handlebar starter relay. switchgear. 5832 5818 2007 Buell Ulysses: Starter...
Page 486 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 2007 Buell Ulysses: Starter...
Page 487 (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 2007 Buell Ulysses: Starter...
Page 488 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 2007 Buell Ulysses: Starter...
Page 489: 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. 2007 Buell Ulysses: Starter...
Page 490 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. 2007 Buell Ulysses: Starter...
Page 491 5-10 2007 Buell Ulysses: Starter...
Page 492: Starter System Testing
Brake/horn/interactive exhaust (10 Amp) 12. Diode 13. Key switch relay Accessory (10 Amp) 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 2007 Buell Ulysses: Starter 5-11...
Page 493 180 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 2007 Buell Ulysses: Starter...
Page 494 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) 2007 Buell Ulysses: Starter 5-13...
Page 495: 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 2007 Buell Ulysses: Starter...
Page 496 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 2007 Buell Ulysses: Starter 5-15...
Page 497 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 2007 Buell Ulysses: Starter...
Page 498 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 2007 Buell Ulysses: Starter 5-17...
Page 499 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 2007 Buell Ulysses: Starter...
Page 500 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 2007 Buell Ulysses: Starter 5-19...
Page 501 While riding, a loose seat can Mounting bolts and washers shift causing loss of control, which could result in death Starter or serious injury. (00070a) Figure 5-26. Starter Mounting Install seat. See 2.45 SEAT. 5-20 2007 Buell Ulysses: Starter...
Page 502 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 2007 Buell Ulysses: Starter 5-21...
Page 503 Replace wire connection hardware as necessary. Figure 5-28. Starter Solenoid 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 2007 Buell Ulysses: Starter...
Page 504 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 506 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) 2007 Buell Ulysses: Drive/Transmission...
Page 507 LOCTITE 271 (red), page 6-6 Special proce- LOCTITE 271 (red), left hand threads, special Transmission sprocket nut dure torque turn method, page 6-54 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-54 2007 Buell Ulysses: Drive/Transmission...
Page 508 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. 2007 Buell Ulysses: Drive/Transmission...
Page 509 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 22. Rubber washer Figure 6-3. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2007 Buell Ulysses: Drive/Transmission...
Page 510 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. 2007 Buell Ulysses: Drive/Transmission...
Page 511 22-24 ft-lbs (30-32.5Nm). 13. Install rubber washer and engine shift lever assembly (1). 14. After applying LOCTITE 271 (red), install ﬂange bolt (5) and shift pedal to shifter bracket, and tighten to 22-24 ft- lbs (30-32.5 Nm). 2007 Buell Ulysses: Drive/Transmission...
Page 512: 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 2007 Buell Ulysses: Drive/Transmission...
Page 513 After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) Install seat. See 2.45 SEAT. 2007 Buell Ulysses: Drive/Transmission...
Page 514 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. 2007 Buell Ulysses: Drive/Transmission...
Page 515 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 2007 Buell Ulysses: Drive/Transmission...
Page 516 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. 2007 Buell Ulysses: Drive/Transmission 6-11...
Page 517 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 2007 Buell Ulysses: Drive/Transmission...
Page 518 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. 2007 Buell Ulysses: Drive/Transmission 6-13...
Page 519: Assembly And Installation
ﬂats to prevent the forcing screw from turning. Figure 6-21. Spring Seat Installation Turn compressing tool handle clockwise until dia- phragm spring compresses just enough to install new retaining ring into the groove in clutch hub prongs. 6-14 2007 Buell Ulysses: Drive/Transmission...
Page 520 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 2007 Buell Ulysses: Drive/Transmission 6-15...
Page 521 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 2007 Buell Ulysses: Drive/Transmission...
Page 522 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 2007 Buell Ulysses: Drive/Transmission 6-17...
Page 523 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 2007 Buell Ulysses: Drive/Transmission...
Page 524 Install engine sprocket nut. Tighten to 240-260 ft-lbs (325.4-352.5 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 2007 Buell Ulysses: Drive/Transmission 6-19...
Page 525 (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 2007 Buell Ulysses: Drive/Transmission...
Page 526: 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 2007 Buell Ulysses: Drive/Transmission 6-21...
Page 527 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 2007 Buell Ulysses: Drive/Transmission...
Page 528: 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 2007 Buell Ulysses: Drive/Transmission 6-23...
Page 529 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 2007 Buell Ulysses: Drive/Transmission...
Page 530 1st Gear Neutral Countershaft Countershaft Mainshaft Mainshaft 2nd Gear 3rd Gear Countershaft Countershaft Mainshaft Mainshaft 4th Gear 5th Gear Countershaft Countershaft - IN - SLIDING MEMBER - POWER FLOW - OUT Figure 6-45. Transmission Power Flow 2007 Buell Ulysses: Drive/Transmission 6-25...
Page 531: Case Disassembly For Transmission Removal
Figure 6-48. With transmission still in neutral, scribe a line on the end of the shifter drum at the 12 o’clock Figure 6-46. Place transmission in 1st gear. Remove position for later reference. hex fastener. 6-26 2007 Buell Ulysses: Drive/Transmission...
Page 532 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). 2007 Buell Ulysses: Drive/Transmission 6-27...
Page 533 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 2007 Buell Ulysses: Drive/Transmission...
Page 534: 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 2007 Buell Ulysses: Drive/Transmission 6-29...
Page 535 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 2007 Buell Ulysses: Drive/Transmission...
Page 536 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 2007 Buell Ulysses: Drive/Transmission 6-31...
Page 537 30. Retaining ring 15. Mainshaft 2nd gear 31. Countershaft retaining screw 16. Mainshaft bearing Mainshaft 2nd and 3rd gears are integral to the shaft. Countershaft 5th gear is integral to the shaft. Figure 6-60. Transmission Assembly 6-32 2007 Buell Ulysses: Drive/Transmission...
Page 538 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 6-62. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 2007 Buell Ulysses: Drive/Transmission 6-33...
Page 539 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 6-63. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 6-34 2007 Buell Ulysses: Drive/Transmission...
Page 540: 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 6-64. Transmission Mainshaft Assembly/Reassembly 2007 Buell Ulysses: Drive/Transmission 6-35...
Page 541 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 6-65. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 6-36 2007 Buell Ulysses: Drive/Transmission...
Page 542 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 6-66. Transmission Assembly-Right Crankcase Half 2007 Buell Ulysses: Drive/Transmission 6-37...
Page 543 (7) over end of bolt. Tighten nut until main drive gear is free. 8681 Figure 6-68. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-69. Insert bolt (2) through cross plate (1) and 5th gear (3). NOTE 6-38 2007 Buell Ulysses: Drive/Transmission...
Page 544 Figure 6-70. 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 6-71. Removing Inner Bearing Race From Main Drive Gear 2007 Buell Ulysses: Drive/Transmission 6-39...
Page 545 Figure 6-73. 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 6-72. Pressing Inner Needle Bearing Assembly into Main Drive Gear 6-40 2007 Buell Ulysses: Drive/Transmission...
Page 546 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 6-75. Installing Main Drive Gear Bearing 2007 Buell Ulysses: Drive/Transmission 6-41...
Page 547: Main Drive Gear
0.060-0.030 in. (1.524- 11510 0.762 mm). 8 in. bolt (Part No. HD-35316-4A) Washer (Part No. HD-35316-7) Main drive gear Installer cup (Part No. HD-35316-12) Nice bearing Flat washer Figure 6-77. Installing Main Drive Gear (Typical) 6-42 2007 Buell Ulysses: Drive/Transmission...
Page 548 1) over ADAPTER until cupped end of installer is ﬂat against seal. Figure 6-79. Install Main Drive Gear Seal (Typical) Figure 6-79. Place seal over pilot and position seal squarely in end of crankcase bore. 2007 Buell Ulysses: Drive/Transmission 6-43...
Page 549 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. 6-44 2007 Buell Ulysses: Drive/Transmission...
Page 550: 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 12. Bushing, shifter drum Oil seal Figure 6-84. Transmission Assembly-Right Crankcase Half 2007 Buell Ulysses: Drive/Transmission 6-45...
Page 551: 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. 6-46 2007 Buell Ulysses: Drive/Transmission...
Page 552: 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 6-87. Transmission Assembly in Fixture (Typical) 2007 Buell Ulysses: Drive/Transmission 6-47...
Page 553 Figure 6-90. Installing Shift Fork Shafts NOTE Figure 6-90. 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 6-89. Shifter Forks, Drum and Shafts 6-48 2007 Buell Ulysses: Drive/Transmission...
Page 554 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). 2007 Buell Ulysses: Drive/Transmission 6-49...
Page 555 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-94. Crankcase Fasteners 6-50 2007 Buell Ulysses: Drive/Transmission...
Page 556: 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 6-96. Shifter Shaft Return Spring (Incorrectly Installed) 2007 Buell Ulysses: Drive/Transmission 6-51...
Page 557 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. 6-52 2007 Buell Ulysses: Drive/Transmission...
Page 558: 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 6-102. Removing Transmission Sprocket Locknut 2007 Buell Ulysses: Drive/Transmission 6-53...
Page 559 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. 6-54 2007 Buell Ulysses: Drive/Transmission...
Page 560 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). 2007 Buell Ulysses: Drive/Transmission 6-55...
Page 561 HOME NOTES 6-56 2007 Buell Ulysses: Drive/Transmission...
Page 562 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 564 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 0.74 Y0042.K Marker lamps 1 bulb each) License plate illumination 0.37 53436-97 lamp 2007 Buell Ulysses: Electrical...
Page 565 Spark plugs 12-18 ft-lbs 16-24 Nm page 7-1 T-27 TORX with retaining compound, replace with Stator TORX mounting screws 30-40 in-lbs 3-4 Nm new after each removal, page 7-33 Tail lamp 12-36 in-lbs 1.4-4 Nm page 7-47 2007 Buell Ulysses: Electrical...
Page 566 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 271 (red), page 7-53 Voltage regulator mounting 36-60 in-lbs 4.1-6.8 Nm Use new fasteners, page 7-34 screws 2007 Buell Ulysses: Electrical...
Page 567: 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. 2007 Buell Ulysses: Electrical...
Page 568 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 2007 Buell Ulysses: Electrical...
Page 569 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 2007 Buell Ulysses: Electrical...
Page 570 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 2007 Buell Ulysses: Electrical...
Page 571 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) 2007 Buell Ulysses: Electrical...
Page 572 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 2007 Buell Ulysses: Electrical...
Page 573 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. Install windscreen and tighten fasteners to 10-12 in-lbs (1.1-1.4 Nm). 7-10 2007 Buell Ulysses: Electrical...
Page 574: 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. 2007 Buell Ulysses: Electrical 7-11...
Page 575 Install airbox assembly. See 4.44 AIR CLEANER ASSEMBLY. Figure 7-10. Boot Gap Should Not exceed 1/8 in. (3.2 mm) Install left air scoop. See 2.40 AIR SCOOPS. 7-12 2007 Buell Ulysses: Electrical...
Page 576 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. 2007 Buell Ulysses: Electrical 7-13...
Page 577 Figure 7-11. Diode Polarity b1107c7x RELAY CENTER [95A] [95B] TN/LTGN Clutch Switch Spare Key Sw Lights Spare Diode Battery Bk/Hn/Mflr TN/Y Aux. Acces. Diode [131B] [131A] TN/LTGN Neutral Start Switch Relay Figure 7-13. Diode Wiring 7-14 2007 Buell Ulysses: Electrical...
Page 578 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 2007 Buell Ulysses: Electrical 7-15...
Page 579 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 2007 Buell Ulysses: Electrical...
Page 580 0 ohms or little resistance. Replace the assembly with a new switch if necessary. 2.26 CLUTCH CONTROL/CABLE. Clutch engaged (switch open) Tighten fasteners to 7-10 in-lbs (0.8-1.12 Nm). Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 2007 Buell Ulysses: Electrical 7-17...
Page 581 A 30 Amp battery fuse links the ignition key switch and the battery. The 30 Amp battery fuse is located under the rider’s Battery seat. See 7.23 BATTERY FUSE AND FUSES for more infor- mation. Figure 7-16. Starter Relay Test 7-18 2007 Buell Ulysses: Electrical...
Page 582 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-17. Relay Block b1234x1x Spare Key Sw Lights Spare Bk/Hn/Mflr Battery Aux. Acces. Diode Figure 7-18. Fuse Block 2007 Buell Ulysses: Electrical 7-19...
Page 583 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 2007 Buell Ulysses: Electrical...
Page 584 HOME b0064b Interactive exhaust cable Harness with connector [161B] Interactive exhaust cable bracket Actuator Air cleaner cover Figure 7-20. Interactive Control System (XB12 Models Only) 2007 Buell Ulysses: Electrical 7-21...
Page 585 13. Remove mufﬂer. See 2.32 EXHAUST SYSTEM. 14. Loosen jam nut and remove interactive exhaust cable from bracket on mufﬂer. 15. Remove interactive exhaust cable from cable wheel on mufﬂer. 7-22 2007 Buell Ulysses: Electrical...
Page 586 Figure 7-22. Interactive Exhaust Cable Behind Wire Harness Strap and Guide Install actuator. Tighten fasteners to 36-40 in-lbs (4.1- 4.5 Nm). Attach interactive exhaust cable to cable wheel on actua- tor. Connect interactive exhaust harness to actuator [161B]. 2007 Buell Ulysses: Electrical 7-23...
Page 587 HOME NOTES 7-24 2007 Buell Ulysses: Electrical...
Page 588: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-25. Voltage Regulator Inspection Figure 7-24. Stator Connector [46] Figure 7-24. The plug connector to stator must be clean and tight. 2007 Buell Ulysses: Electrical 7-25...
Page 589 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 2007 Buell Ulysses: Electrical...
Page 590 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. 2007 Buell Ulysses: Electrical 7-27...
Page 591 HOME bs0021ax [128A] Battery [GRD2] Battery Fuse [61B] [77A] [77B] [46B] [46A] Figure 7-25. Charging System Circuit 7-28 2007 Buell Ulysses: Electrical...
Page 592 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. 2007 Buell Ulysses: Electrical 7-29...
Page 593 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 2007 Buell Ulysses: Electrical...
Page 594 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 2007 Buell Ulysses: Electrical 7-31...
Page 595 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 2007 Buell Ulysses: Electrical...
Page 596 Install connector (5) [46] onto the stator wiring (4) using cavities 1, 2, 3 of connector (5) [446]. See DEUTSCH ELECTRICAL CONNECTORS for addi- tional information. NOTE 7.26 SPROCKET COVER WIRINGfor remaining wire routing information. 2007 Buell Ulysses: Electrical 7-33...
Page 597 Stator connector [46] or serious injury. (00070a) Voltage regulator connector [77] Install seat. See 2.45 SEAT. Voltage regulator mount bracket Voltage regulator Test charging system. See 7.7 CHARGING SYSTEM. Fastener (3) Figure 7-37. Voltage Regulator 7-34 2007 Buell Ulysses: Electrical...
Page 598: Battery Cables
Connect positive cable to positive (+) battery termi- nal using fastener. Connect negative cable to negative (-) battery termi- nal using fastener. Tighten terminal fasteners to 72-96 in-lbs (8-11 Nm). 2007 Buell Ulysses: Electrical 7-35...
Page 599 Fastener with washer Red/Yellow wires (14 gauge, to be spliced) Positive battery cable Battery strap Figure 7-40. Positive Battery Cable Figure 7-38. Battery (Protective Boot Not Shown) 11968 Figure 7-39. Negative Battery Cable and Frame Ground 7-36 2007 Buell Ulysses: Electrical...
Page 600 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 601: 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 2007 Buell Ulysses: Electrical...
Page 602: 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. 2007 Buell Ulysses: Electrical 7-39...
Page 603: Battery Charging
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 2007 Buell Ulysses: Electrical...
Page 604 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. 2007 Buell Ulysses: Electrical 7-41...
Page 605 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 2007 Buell Ulysses: Electrical...
Page 606 (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). 2007 Buell Ulysses: Electrical 7-43...
Page 607 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 2007 Buell Ulysses: Electrical...
Page 608 If the rubber boots are not installed correctly the wiring har- nesses can contact the edge of the forward frame mount. The wiring harness guides must be installed at a 20 degree angle. 11. Install seat. See 2.45 SEAT. 2007 Buell Ulysses: Electrical 7-45...
Page 609 HOME 10525 10526 Figure 7-49. Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 7-46 2007 Buell Ulysses: Electrical...
Page 610: 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 2007 Buell Ulysses: Electrical 7-47...
Page 611: License Plate Lamp Assembly
(2) and the Wire cover license plate bracket (4). Front wire cover fasteners Attach the two connectors [45] from license plate lamp to main harness. Figure 7-52. License Plate Lamp 7-48 2007 Buell Ulysses: Electrical...
Page 612: 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). 2007 Buell Ulysses: Electrical 7-49...
Page 613 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 2007 Buell Ulysses: Electrical...
Page 614 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 2007 Buell Ulysses: Electrical 7-51...
Page 615 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 2007 Buell Ulysses: Electrical...
Page 616: 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. 2007 Buell Ulysses: Electrical 7-53...
Page 617: 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 2007 Buell Ulysses: Electrical...
Page 618 (00316a) To stoplight Check handlebar switch for proper operation. If operation [121A] [121B] fails, reread procedure and verify that all steps were per- Brake Switch formed. Figure 7-63. Right Handlebar Switch Connection 2007 Buell Ulysses: Electrical 7-55...
Page 619 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as long as the switch is pressed. Figure 7-64. Left Handlebar Switch Connection Check left and right turn signals. Activate horn by pressing horn switch. 7-56 2007 Buell Ulysses: Electrical...
Page 620 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 2007 Buell Ulysses: Electrical 7-57...
Page 621: 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 2007 Buell Ulysses: Electrical...
Page 622 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 2007 Buell Ulysses: Electrical 7-59...
Page 623: Speedometer Performance Check
CLEAR to cancel and enter the new fre- CAN, JPN quency. Press ENTER to begin and reverify. 80 KPH 1320 NOTE 100 KPH 1650 The speedometer should be accurate within 0-5 MPH (0-8 KPH). 7-60 2007 Buell Ulysses: Electrical...
Page 624 Install a known, good vehicle speed sensor If testing CEN range, press 4 or 6. and test again. If testing HI range, press 7 or 9. b0779x7x Deutsch socket housing (2) Deutsch pin housing Figure 7-74. Test Harness 2007 Buell Ulysses: Electrical 7-61...
Page 625 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 2007 Buell Ulysses: Electrical...
Page 626 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. 2007 Buell Ulysses: Electrical 7-63...
Page 627 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 2007 Buell Ulysses: Electrical...
Page 628 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 2007 Buell Ulysses: Electrical 7-65...
Page 629 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 2007 Buell Ulysses: Electrical...
Page 630: Neutral Indicator Switch
(2) threads. Install washer (3) over neutral indicator switch (2) threads. Install switch in crankcase. Tighten switch to 60-84 in-lbs (6.8-9.4 Nm). Connect wire lead (1) to switch. Install sprocket cover. See 2.35 SPROCKET COVER. 2007 Buell Ulysses: Electrical 7-67...
Page 631 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 and ignition fuses are rated at 15 amps. The ECM, cooling fan, brake/horn/mufﬂer, aux.
Page 632: Main Wire Harness
Unthread fastener and remove battery negative cable (black) from battery negative (-) terminal. Pull back terminal cover boot on battery positive cable (red). Unthread fastener and remove battery positive cable from battery positive (+) terminal. Remove battery. 2007 Buell Ulysses: Electrical 7-69...
Page 633 BAS (bank angle sensor) connector [134]. 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]. Interactive exhaust connector [165B], (under main wiring harness) 7-70 2007 Buell Ulysses: Electrical...
Page 634 Clutch switch [95] from left switch housing. Front brake switch [121] from right switch housing. O2 sensor [137]. Temp sensor [90] Fuel injectors [84] & [85]. Ground fastener at steering head. Intake air temperature sensor [89] throttle position sensor [88]. 2007 Buell Ulysses: Electrical 7-71...
Page 635 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 2007 Buell Ulysses: Electrical...
Page 636 11. Install cable strap loosely around main harness (6) and ignition switch. 12. Connect throttle position sensor [88]. See 4.37 THROT- TLE POSITION SENSOR. 13. Connect intake air temperature sensor [89]. See 4.36 INTAKE AIR TEMPERATURE SENSOR. 2007 Buell Ulysses: Electrical 7-73...
Page 637 30. Verify that front forks can be turned from full left to full or serious injury. (00070a) right lock without wire harness binding or pinching. 35. Install seat. See 2.45 SEAT. 7-74 2007 Buell Ulysses: Electrical...
Page 638: Interactive Exhaust Actuator Harness
For actuator or actuator cable replacement see 7.6 INTER- ACTIVE EXHAUST SYSTEM. ECM connector [10] Exhaust actuator connector [164] ECM connector [11] Negative battery cable Battery ground Actuator ground Figure 7-89. Harness and Cable Routing 2007 Buell Ulysses: Electrical 7-75...
Page 639 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. 7-76 2007 Buell Ulysses: Electrical...
Page 640: Sprocket Cover Wiring
Neutral switch connector Cam position sensor connector [14] Sprocket cover boss Stator connector [46] Vehicle speed sensor connector [65] Oil pressure switch wiring Main harness 10. Interactive exhaust cable Figure 7-91. Sprocket Cover Wiring and Connections 2007 Buell Ulysses: Electrical 7-77...
Page 641 (3-pin black). 11. See Figure 7-93. Using a cable strap, secure the loop of the neutral safety wire to the cam position connector (13) under the attachment clip on the connector. 7-78 2007 Buell Ulysses: Electrical...
Page 642 13. Cable strap securing neutral connector to cam Cable wrap securing Interactive exhaust cable and position sensor connector [14] main harness to oil return line 14. Position of forward cable straps to secure wiring Figure 7-93. Sprocket Cover Wiring and Connections 2007 Buell Ulysses: Electrical 7-79...
Page 643 Figure 7-94. Cable Strap Wire Bundle to Return Oil Line Main harness 2nd Location Cable strap securing main harness wiring to Return Oil Line, Upper Part of Sprocket Cover Figure 7-96. Correct Location for Sprocket Cover Wiring 12369 Figure 7-95. Vehicle Speed Sensor 7-80 2007 Buell Ulysses: Electrical...
Page 644: 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 dislocation. Figure 7-98. Auxiliary Power Outlet (under seat) 2007 Buell Ulysses: Electrical 7-81...
Page 645 HOME NOTES 7-82 2007 Buell Ulysses: Electrical...
Page 646 Table Of Contents SUBJECT PAGE NO. APPENDIX A-TOOLS ..........APPENDIX B-WIRING .

Buell 2007 ULYSSES Service Manual

Index to Wiring Diagrams B.5

Maintenance 1

Chassis 2

Fuel System 4

Quick Links

Chapters

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Summary of Contents for Buell 2007 ULYSSES