Handlebars - Buell Ulysses 2006 Service Manual

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HANDLEBARS

REMOVAL
1. Remove seat. See 2.45
11 1
WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. Remove deflectors. See
BARS.
4. Remove left handlebar switch housing. See
DLEBAR SWITCHES. Cut left handlebar grip and
remove.
5. Detach clutch hand control from handlebars. See
CLUTCH CONTROL/CABLE.
6. Remove front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND
7. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
8. Remove four harness retainers securing switch housing
harnesses to handlebars.
9. See Figure 2-113. Remove the four screws holding
upper handlebar clamp.
NOTE
Right hand control assembly may now be removed from
detached handlebar.
10. Remove handlebars without stretching throttle cables.
11. See Figure 2-113. Remove endcaps.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
THROTTLE CONTROL.
2. See Figure 2-113. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying LOC-
TITE 272 (red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-16
Nm).
SEAT.
WARNING
2.25 DEFLECTORS/HANDLE-
7.17 HAN-
2.10 FRONT
LEVER.
3. Install clutch hand control. See
TROL/CABLE.
4. Install left switch housing. See
SWITCHES.
5. Check control wire routing. See
ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower
clamp and fork tube.
c. Install harness retainers.
6. Install a new left hand grip.
7. Install front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND LEVER.
8. Install deflectors. See
2.26
BARS.
9. Check steering motion range to both fork stops.
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
10. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.4 BATTERY
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)
2.24
11. Install seat. See
2.26 CLUTCH CON-
7.17 HANDLEBAR
HOSE AND WIRE
2.10 FRONT
2.25 DEFLECTORS/HANDLE-
11 1
WARNING WARNING
MAINTENANCE.
11 1
WARNING WARNING
2.45 SEAT.
2006 Buell Ulysses: Chassis
2.30
2-79