Fork rebuild parts for 06 Uly

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motoguy

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I'm at work an can't get the online parts manuals to open. I need to get parts ordered to rebuild the forks on my 07 Ulysses. I only need fork seals (leaking) but figure I may as well do guides and sliders while I'm at it (40k miles). It looks like I can find the slider PN 46343-06 online (ebay and St Paul), but I don't seem to be having luck with the guide bushing PN 46348-06. The seals themselves seem pretty easy to find.

Do I have these part #'s wrong? If not, are these items getting hard to find, or am I just not looking in the correct places? I need (2) sets for the leaking forks on my 06 and 07 Uly, then I'll need to find the correct parts for the larger forks on the '09 as well. I'm going to continue looking while at work today, but if anyone has a link to a source for them (or correct PN if the ones I have are wrong) I'd certainly appreciate it.

Thanks!
 
Answers for 2005-late 2008 ALL X AND XT MODEL ULYSSES OEM SHOWA FORKS as follows:

FORK SEALS MEASURE 43MM ID X 54MM OD X 11MM HT--available thru HD dealerships as same for all years XR1200
FORK SEALS AND COMPANION DUST BOOTS ALSO AVAILABLE FROM ALL BALLS AND K&L SUPPLY--BOTH EXCELLENT SEALS

GUIDE BUSHING EACH---HD PART # 46343-06...SYSTEM SHOWS 46 SETS STILL AVAILABLE USA DEALERSHIPS
GUIDE BUSHING BUELL PART # J8140.3A8....SYSTEM SHOWS TEMPORARILY NLA

SLIDER BUSHING EACH--HD PART # J8138.3A8---SUFFIX L19E...SYSTEM SHOWS 14 STILL AVAILABLE USA DEALERSHIPS

NEEDED 1 US QUART OF 10W RECOMMENDED FORK OIL TOTAL TO REBUILD BOTH FORKS..DO NOT USE ATF

FORK OIL FLUID CAPACITY VARIES FROM 2006-2007 X MODEL ULYSSES AS PER DANNY'S INFO DIRECT FROM BUELL

2006 FLUID LEVEL--10W FLUID---113MM FROM TOP OF FORK TUBE SPRINGS REMOVED AND FORK FULLY COMPRESSED
2007 FLUID LEVEL--10W---172MM FROM TOP OF FORK TUBE SPRINGS REMOVED AND FORK FULLY COMPRESSED



That help????
 
I had a leaky seal on my XB9s. I was dreading the rebuild process. I bought this tool where you pry down on the dust wiper to get to the actual seal. You slip this tool between the seal and stanchion and rotate it around a couple of times. The thought is that it's not so much that the seal is worn out as it is dirt stuck in the seal causing the leak. Mine was leaking enough to where it was running down the brake caliper mount to the brake caliper. After a couple of hundred miles I have had no more leakage. Tried it on my Suzuki bobber with the same results. Needless to say I was very happy especially since I'm such a lazy bastard. I'd rather ride than wrench.
 
miatamarty said:
I had a leaky seal on my XB9s. I was dreading the rebuild process. I bought this tool where you pry down on the dust wiper to get to the actual seal. You slip this tool between the seal and stanchion and rotate it around a couple of times. The thought is that it's not so much that the seal is worn out as it is dirt stuck in the seal causing the leak. Mine was leaking enough to where it was running down the brake caliper mount to the brake caliper. After a couple of hundred miles I have had no more leakage. Tried it on my Suzuki bobber with the same results. Needless to say I was very happy especially since I'm such a lazy bastard. I'd rather ride than wrench.
Click to expand...

Well that's interesting. I assume you are referring to something like this:

https://sealmate.net/pages/instructions-for-seal-mate


or this:

https://www.amazon.com/Risk-Racing-00-121-millimeters-55-millimeters/dp/B0068G164E/ref=sr_1_6?dib=eyJ2IjoiMSJ9._MHiSGezLipBIE2Nm8izHJqVfyNDLbsq-bs6O8hIXwKS-r2em79VMVRjDZEBw0e3CjV4CS-_0WmLGkpKJkuzLdBc22JcTUkQuz99G_3x2M_WFvpUlk3DEEmepWk5PUN107kbE7LSAGGf8GM7vDN-h-Y34KL96bhdVdVKBDX2T8r4-Fj1nC_WFVaa_pwa0NxKubC_VnCR6X-zc2znSVY_CaX3BXDYXnhXvxR4D_g71N63TtYZMr3xf4ipwcypC9vKevy5IiuiKGf_PAg1nHWuPpT_69skpDXhilo8e_18Kkg.pZ6PDCpl8qJkX_k-M9fjbPNJgHNRu-LoWE0wYfT1qlU&dib_tag=se&keywords=fork%2Bseal%2Bcleaner&qid=1711821312&sr=8-6&th=1

if they actually work, they would be handy to have. Off to Youtube to look for user videos...
 
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The Seal Mate works fine, as is any thin stiff plastic. We used to use a piece of 35mm film before people forgot what that is:upset:. As long as it is indeed a bit of dirt in the seal. Handy to have (especially for dirt bikes), but by far not a cure for forks that need sliders, a re-build, or 5 year old fork oil.
 
Cooter said:
The Seal Mate works fine, as is any thin stiff plastic. We used to use a piece of 35mm film before people forgot what that is:upset:. As long as it is indeed a bit of dirt in the seal. Handy to have (especially for dirt bikes), but by far not a cure for forks that need sliders, a re-build, or 5 year old fork oil.
Click to expand...

I ordered one "just in case". Along with sliders, guides and fork oil for both the 06 and 09. Thanks for the info in the thread fellas.
 
Last edited:
Yep, handy tool to have.When I was riding with the retirees in FL, we'd leave from my place and it seems I used it on other peoples bikes almost weekly before each ride!
 
Cooter said:
Yep, handy tool to have.When I was riding with the retirees in FL, we'd leave from my place and it seems I used it on other peoples bikes almost weekly before each ride!
Click to expand...

Used the Seal Mate on my leaking Uly fork the other day. I've not taken it for a ride yet, but it hasn't leaked a drop in the garage since I used it!
 
motoguy said:
Used the Seal Mate on my leaking Uly fork the other day. I've not taken it for a ride yet, but it hasn't leaked a drop in the garage since I used it!
Click to expand...

Went out for a couple of short rides since then. Still no leak. I'm officially impressed with the SealMate. Of course I now have no idea how much fork oil is in the fork, but that's another issue.
 
Cooter said:
We used to use a piece of 35mm film before people forgot what that is
Click to expand...

One_Hour_Photo_movie.jpg
 

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Barrett said:
2006 FLUID LEVEL--10W FLUID---113MM FROM TOP OF FORK TUBE SPRINGS REMOVED AND FORK FULLY COMPRESSED
2007 FLUID LEVEL--10W---172MM FROM TOP OF FORK TUBE SPRINGS REMOVED AND FORK FULLY COMPRESSED

That help????
Click to expand...

A lot! Thanks! I notice your info says 172mm for 07 forks, and the 07 manual says 192mm. Any idea why the difference?

I pulled the forks again today to fix my “not adjusting” rebound adjustment. While I had it apart I adjusted the fork oil level to 192mm, per the manual.
 
motoguy said:
A lot! Thanks! I notice your info says 172mm for 07 forks, and the 07 manual says 192mm. Any idea why the difference?

I pulled the forks again today to fix my “not adjusting” rebound adjustment. While I had it apart I adjusted the fork oil level to 192mm, per the manual.
Click to expand...


A lot! Thanks! I notice your info says 172mm for 07 forks, and the 07 manual says 192mm. Any idea why the difference?

Why? Because that was the info I received on the subject from the lead Buell engineer when Buell was actually a company.

As per Danny:
Air gap fine tunes the forks
Slightly larger air gap extends fork seal life
Slightly larger air gap slightly softens the compression characteristics
 
Barrett said:
Why? Because that was the info I received on the subject from the lead Buell engineer when Buell was actually a company.

As per Danny:
Air gap fine tunes the forks
Slightly larger air gap extends fork seal life
Slightly larger air gap slightly softens the compression characteristics
Click to expand...

That answers that! Thanks! I knew it would be slightly softer with the larger air gap. I really, really like the suspension on the Uly. It's both comfortable and confidence inspiring. I don't really know how much oil was in it prior to the refresh (leaking fork seal which was fixed with the Seal Mate), so I'll just have to ride it and find out.
 
So far the Seal Mate seems to have fixed the leaks. I still have the fork rebuild parts in my stash, but haven't needed them yet.
 

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