Frame Pucks - Buell Ulysses 2006 Service Manual

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FRAME PUCKS

REMOVAL
11 1
WARNING
The aluminum frame of this motorcycle is the fuel tank.
Drilling, welding, cutting, grinding, sanding, polishing or
other modifications to this frame can weaken it or cause
a fire, which could result in death or serious injury.
(00126b)
1. To break the adhesive bond, apply isopropyl alcohol
along the perimeter edge of the puck at the upper or
lower rear corner. Wipe off excess alcohol.
2. Fit fingers under the corner edge and pry to loosen puck.
NOTE
If the puck fit prevents getting finger tips under puck, cover
the blade of a putty knife or similar tool with duct tape, to pre-
vent scraping the frame, and pry up one corner of the puck.
3. Slip fingers under the loose corner and slowly pull the
puck away from the frame. Apply isopropyl alcohol as
needed to loosen remaining adhesive bond.
4. Clean adhesive from painted finish with isopropyl alco-
hol. Wipe up excess alcohol with cloth.
INSTALLATION
1. Using isopropyl alcohol, clean the frame for the new
puck. Wait a minimum of 5 minutes for the alcohol to
evaporate.
NOTE
Do not sand or scuff the surface where the puck will be
installed.
2. See Figure 2-91. Identify the left and right side pucks by
forward facing directional point.
3. With the adhesive backing in place, locate the puck on
the frame making contact all around its perimeter and fit-
ting the horizontal crease and V-shaped edge.
4. See Figure 2-92. With a pencil, outline the upper rear
and lower rear corners on the frame.
NOTE
The puck can only be applied once. If the puck is peeled off, it
will have reduced adhesive strength when it is re-applied to
the frame.
5. Starting from the edge and working toward the center,
carefully peel off the adhesive backing from the puck.
NOTE
Peeling away the backing may loosen the adhesive in the
center of the puck. This will not affect the final seal.
6. Align the corners with the pencil marks and tack the puck
to the frame at the corners.
7. From the tacked corners, pivot the puck onto the frame
keeping the directional point aligned with the horizontal
crease.
2-64 2006 Buell Ulysses: Chassis
WARNING
8. See Figure 2-93. For 60 seconds, press evenly around
the perimeter to firmly seal the puck. Allow the puck to
cure for at least one hour before riding.
9. Erase the pencil marks.
11111
Figure 2-91. Left Side Puck
8456
Figure 2-92. Outlining Puck Corner
8456
Figure 2-93. Pressing Puck to Frame
2.22