Buell 2007 ULYSSES Service Manual page 297

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CYLINDER HEAD INSTALLATION
NOTES
Short head screws will be installed in the 1 and 2 posi-
tions, and long head screws in the 3 and 4 positions.
Thoroughly clean and lubricate the threads of the cylin-
der head screws before installation. Friction caused by
dirt and grime will result in a false torque indication.
1. Thoroughly clean and dry the gasket surfaces of cylin-
ders and cylinder heads.
2. Install new o-rings over two ring dowels at the top of the
cylinder. Apply a very thin film of clean H-D 20W50
engine oil to o-rings before installation.
NOTE
To ensure proper head gasket alignment, install new o-rings
over cylinder ring dowels before installing the head gasket.
Improper head gasket alignment will cause leaks.
3. Install a new head gasket to cylinder.
4. Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.
5. Lightly coat the threads and bottom face of the cylinder
head screws with clean H-D 20W50 engine oil. Wipe off
any excess oil.
NOTE
The procedure for tightening the head screws is critical to
proper distribution of pressure over gasket area. It prevents
gasket leaks, stud failure, and head and cylinder distortion.
Always tighten in sequence shown.
6. Start the cylinder head screws onto the cylinder studs,
two short screws on the left side of the engine, two long
screws on the right.
7. See Figure 3-81. For each cylinder head, start with
screw numbered one, as shown. In increasing numerical
sequence (i.e. – 1, 2, 3 and 4):
a. Tighten screws to 96-120 in-lbs (11-14 Nm).
b. Tighten screws to 13-15 ft-lbs (18-20 Nm).
c. Loosen all screws.
8. After bolts are loosened from initial torque, tighten head
screws in three stages. Tighten fasteners in increasing
numerical sequence (i.e. – 1, 2, 3 and 4).
a. Tighten each screw to 96-120 in-lbs (11-14 Nm).
b. Tighten each screw to 13-15 ft-lbs (18-20 Nm).
c. See Figure 3-82.
screw shoulder with a line as shown (View A).
d. Turn all screws an additional 85 -95 .
3-58 2007 Buell Ulysses: Engine
Mark cylinder head and head
° °
x0128x3a
Front Cylinder
1st
2nd
Rear Cylinder
2nd
1st
Figure 3-81. Head Screw Loosening/Tightening Sequence
a0089x3x
View
A
Tighten head screws 1/4-turn in
the third stage of installation
Figure 3-82. Tightening Head Screws
3rd
4th
4th
3rd
View
B