Buell Ulysses 2006, Service Manual, Page: 165 / 638

2006 Buell Ulysses: Chassis 2-41
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INSTALLATION
1. Route the brake line. See HOSE AND WIRE ROUTING
for brake line routing.
2. See Figure 2-59. Install brake line switch/banjo bolt with
new copper washers to the master cylinder. Tighten to
16-20 ft-lbs (22-27 Nm).
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WARNING
1
WARNING
Use only new copper crush banjo washers (See Parts
Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver banjo washers are not compatible with D.O.T. 4 fluid
and will not seal properly over time. Failure to comply
may adversely affect braking ability and lead to brake
failure which could result in death or serious injury.
3. Install brake line bracket and tighten fasteners to 48-60
in-lbs (5-7 Nm).
4. Install the rider/passenger peg mount to the motorcycle.
5. See Figure 2-57. Connect brake line switch connector
underneath seat.
6. Install brake line switch/banjo bolt and new copper wash-
ers to rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
7. Bleed brakes. See BLEEDING BRAKES in 1.6 BRAKE
SYSTEM MAINTENANCE .
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WARNING
1
WARNING
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)
8. Install negative battery cable and tighten to 72-96 in-lbs
(8-11 Nm). See
1.4 BATTERY MAINTENANCE .
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WARNING
1
WARNING
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)
9. Install seat. See 2.45 SEAT.
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WARNING
1
WARNING
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
result in death or serious injury. (00316a)
10. Turn ignition key ON, depress rear brake pedal and
check for proper brake light operation.
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WARNING
1
WARNING
After repairing the brake system, test brakes at low
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)
11. Test ride motorcycle and check for proper brake opera-
tion.