Buell Ulysses 2006, Service Manual, Page: 173 / 638

2006 Buell Ulysses: Chassis 2-49
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10. See Figure 2-72. Over drain pan, remove spring collar
(15), spring (16) and drain fork oil.
11. Drain remaining fork oil by pumping the damping rod (11)
approximately 8 to 10 times or until damping rod moves
freely.
12. Clamp fork upside down in the FORK TUBE HOLDER
TOOL (Part No. HD-41177) over drain pan allowing fork
oil to drain.
NOTE
Be careful not to drop damping rod assembly into oil pan
when removing center bolt.
13. Remove center bolt (14) to release damping rod assem-
bly (11).
14. Remove centering plate (12) from dampening rod (11).
1 1
WARNING
1
WARNING
Be careful not to scratch the slider fork or the outer tube.
Improperly operating forks may lead to a loss of control
which could result in death or serious injury.
15. Remove dust seal (26) to access oil seal stopper
ring (25).
16. Release the oil seal stopper ring (25) out from the outer
tube with a small pry tool.
17. Using a slide hammer action, remove the slider fork (27)
from the outer tube (18).
18. Remove the slide bushing (21) from slider fork by prying
the slide bushing at the split.
NOTE
Careful not to over expand slide bushing.
19. Remove guide bushing (22), seal spacer (23), oil seal
(24), stopper ring (25) and dust seal (26).
Damper Rod Disassembly
NOTES
●
See Figure 2-72. Disassembly of damper rod is not
required unless damper locknut (10) has been moved. If
damper rod needs servicing refer to the Parts Catalog for
kit information.
●
If damper locknut has been moved, proceed with the fol-
lowing disassembly and assembly procedures for setting
the correct range of motion.
1. See Figure 2-72. Lightly turn the rebound adjuster screw
on top of the rebound adjuster assembly (9) counter
clockwise till it stops.
2. Holding the damper locknut (10), unscrew the rebound
adjuster assembly (9) and remove from damper rod
assembly (11).
3. Remove damper locknut (10) from damper rod assembly
(11).
CLEANING AND INSPECTION
1. Thoroughly clean and inspect all parts. Replace any
parts that are bent, broken or damaged.
2. See Figure 2-72. Check the slider fork (27) and outer
tube (18) for score marks, scratches and excessive or
abnormal wear. Replace if worn or damaged.
3. Check the slide bushing (21) and the guide bushing (22)
for excessive wear or scratches. Replace if damaged or
worn.
4. Replace the stopper ring (19) if distorted.
5. Measure spring (16) free length. Replace springs shorter
than the service wear limit of 18.77 in. (476.7 mm).
6. See Figure 2-73. Measure slider fork runout. Replace
pipe if runout exceeds the service wear limit of 0.008 in.
(0.2 mm).
Figure 2-73. Slider fork Runout
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