Buell Ulysses 2006 Service Manual page 208

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Muffler and Straps
NOTE
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.
1. Install muffler and new Torca clamp onto header.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
2. Install interactive exhaust cable to muffler.
3. See Figure 2-115. Loosely install new front and rear
muffler straps (2, 4).
NOTES
Never re-use front muffler strap. Always replace front
muffler strap with a new strap when removed from sys-
tem.
It is important that the front muffler mount is tightened
last in order to ensure proper alignment of the exhaust
system.
When rear muffler straps have been installed, it is impor-
tant that strap fasteners do not contact idler pulley
bracket.
On the front muffler mount fastener, torque is applied to
the head and not to the nut.
4. Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
a. Front: Tighten around the muffler until snug.
b. Rear: 48-60 in-lbs (5-7 Nm).
c. Front muffler mount: 16-18 ft-lbs (21.7-24.4 Nm).
d. Front: 108-120 in-lbs (12-14 Nm). Back off fastener
two full turns and then retighten to 108-120 in-lbs
(12-14 Nm).
5. See Figure 2-116. Tighten the Torca clamp (1) to 28-
30 ft-lbs (38-40.6 Nm).
6. Tighten the front muffler mount to 16-18 ft-lbs (1.7-24.4
Nm).
7. Install idler pulley. See
DRIVE BELT.
8. Install front sprocket cover. See
COVER.
9. Install chin fairing. See 2.38 CHIN
10. Adjust interactive exhaust cable. See
TIVE EXHAUST CABLE.
2-84 2006 Buell Ulysses: Chassis
DRIVE BELT REMOVAL in
2.35 SPROCKET
FAIRING.
1.16 INTERAC-
b0973a2x
1. Torca clamp
2. Header
3. Header mount fastener
4. Exhaust ring
5. Exhaust retaining ring
6. Exhaust port gasket
Figure 2-116. Exhaust Header
1.9
6
5
4
3
2
1