Buell Ulysses 2006, Service Manual, Page: 207 / 638

2006 Buell Ulysses: Chassis 2-83
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ASSEMBLY/INSTALLATION
Exhaust Header
1. See Figure 2-116. Install exhaust ring (4), retaining ring
(5) and new port gasket (6).
2. Install exhaust header (2). Tighten mounting fasteners
(3) to 72-96 in-lbs (8-11 Nm).
NOTES
● The front header fasteners must be torqued first.
● Tighten header nuts gradually, alternating between studs
to insure that exhaust rings are flush with engine.
3. Install oxygen sensor. See 4.33 OXYGEN SENSOR .
4. Rotate engine up. See 3.3 ENGINE ROTATION FOR
SERVICE .
Rear Muffler Bracket
1. See Figure 2-115. Slide rear muffler bracket over oil feed
line.
2. Install rear muffler bracket fasteners and tighten to 32-
36 ft-lbs (43-49 Nm).
3. Install oil feed line and p-clamp. Tighten p-clamp to 48-72
in-lbs (5.4-8 Nm). See
3.9 OIL HOSE ROUTING AND
OIL RESERVOIR.
4. Fill swingarm/oil tank with 2.5 quarts (3.3 liters) oil. See
Drain Oil in 1.5 ENGINE LUBRICATION SYSTEM .
5. Install muffler.
Front Muffler Mount
1. See Figure 2-115. Install front muffler mount bushings.
2. Install new strap on front muffler mount (5).
3. Install front fastener loosely. Do not tighten.
4. Install muffler.
NOTE
For assembly details of the interactive exhaust system, see
INSTALLATION under 7.6 INTERACTIVE EXHAUST SYS-
TEM.
Figure 2-115. Muffler and Mounting System
b0986x3c
1. Clamp, Torca
2. Muffler
3. Muffler strap, front
4. Front muffler strap fastener
5. Front muffler mount
6. Rear muffler bracket
7. Rear muffler strap fastener
8. Muffler strap, rear (2)
9. Jacking point symbol
10. Symbol location
4
6
5
2
3
7
8
1
9
10
10