COMPETITION SERIES ENGINES *NOT EPA COMPLIANT ULTIMA COMPANY LLC
Ultima Company LLC is not a representative of any other motorcycle manufacturer and the parts we sell are not necessarily recommended by any other motorcycle manufacturer. All words used in this catalog denoting any motorcycle manufacturer, models or motorcycle, or part numbers are intended for use as reference only.
ULTIMA® COMPETITION SERIES ENGINES DISTRIBUTED EXCLUSIVELY BY MIDWEST MOTORCYCLE SUPPLY Failure to read and comply with this document completely may Void Warranty.
LONG ROD SERIES ENGINES 130 & 140 CI Ultima’s Complete Assembled, Unassembled and Long Blocks in the Long Rod Series of Engines have no warranty expressed or implied, however, engines that are suspect of being defective may qualify for limited warranty assistance. Due to the nature of these engines ultimate use and performance level we feel it is impossible to express a comprehensive warranty and any claims will be handled strictly at Ultima’s discretion.
General Specifications 80” - 113” 4 Displacement CI Displacement CC/CI 80Ci 1340/81.8 96Ci 1564/95.5 100Ci 1643/100.2 107Ci 1751/106.8 113Ci 1853/113.1 Bore Stroke Compression Valve : Int Valve: Ex Cam Lift: Int Cam Lift: Ex Cam Duration Pushrod Length Piston Cylinder Length Case Deck Height Rod Length Flywheel Case Spigot bore Pump Type Breather Type Cam Cover Type Rocker Box Type Rocker Arm/ Ratio Engine Height Rated power RW Engine Weight 3.498” 4.25” 8.75:1 1.850” 1.625” .490” .
General Specifications Displacement CI Displacement CC/CI 120 Ci 1976/120.6 127 Ci 2092/127.7 130Ci 2118/129.3 140 Ci 2305/140.6 Bore Stroke Compression Valve : Int Valve: Ex Cam Lift: Int Cam Lift: Ex Cam Duration Pushrod Length Piston Cylinder Length Case Deck Height Rod Length Flywheel Case Spigot bore Pump Type Breather Type Cam Cover Type Rocker Box Type Rocker Arm/ Ratio Engine Height Rated power RW Engine Weight 4.250” 4.250” 9.8:1 2.100” 1.700” .640” .600” 264/268 +.250 Longer Forged Flat 5.
Cam Information All Models 96 CI engines: MW 520 Cam Timing information is Open/Close @ .053 Int 28/54 262 Dur Lift .520 TDC .209 Ex 69/23 272 Dur Lift .520 TDC .194 Lobe Sep 108 Overlap 51 100 and 107 CI engines: MW 248 Cam (1.69 rocker arm ratio) Timing information is Open/Close @ .053 Int 18/50 248 Dur Lift .625 TDC .181 Ex 54/18 252 Dur Lift .600 TDC .171 Lobe Sep 107 Overlap 36 113-120-127 CI engines: MW 264 Cam (1.69 rocker arm ratio) Timing information is Open/Close @ .053 Int 24/60 264 Dur Lift .
Installation Notes: Ultima® Engines should be installed by a trained professional mechanic into a motorcycle for which its use was intended. Failure to do so may result in injury and even death. It is the customer’s responsibility to insure their mechanic has proper training. Fitment and Clearance Issues: Every effort has been made to insure these engines will install into most available frame models without modifications. Some of the known fitment issues we have encountered are listed below.
CRANKCASE VENT Oil Pump Fittings Identification: ® Ultima engines use a 1992 & later style oil pump as shown in Figure 2. 1. The feed line is mounted in the center of the outer cover of the pump and is pointing up. 2. The return line is mounted to the very bottom of the outer cover and is pointed forward. This line goes to the Filter Input. See Figure 5. 3. The Crank case vent is mounted to the engine case just above the oil pump. 4.
Oil Recommendations For the first 500 miles of operation we recommend using high quality petroleum based API service SJ rated motor oils, such as Ultima 20W50, MW# 103-114. The oil’s viscosity should be matched with the climate conditions but in most cases Ultima 20w50 motor oil will work fine. After initial break-in (over 500 miles) we recommend using Ultima full synthetic motor oil, MW#103-115. Oil Filters All Ultima® engines require oil filters.
General Information Compression Release Valves 100-107-113-120-127-130-140 CI All Ultima® 100 CI and larger engines are supplied with manually operated push button compression release valves. These valves aid in starting your engine and can greatly increase your starter and battery life. To operate these simply depress the Top Cap as shown in Figure 1 and they will pop back up automatically once the engine is cranking.
Clutch and Driveline Considerations: When installing any performance engine you should consider upgrading your clutch and inspecting or replacing your Primary Chain and adjuster. Increased power levels and aggressive riding styles can cause stock or worn components to fail or work poorly and they may need to be upgraded. Ultima® recommends Midwest part#96-730 high performance clutch for use on 98’-06’ HD® chassis & Midwest part#96-731 for use on 90’-97’ HD® chassis.
Gearing Considerations: When installing a performance engine selecting the proper gearing is very important in achieving the performance levels you desire. In many cases engines with less power that are geared properly can outperform more powerful engines that are geared poorly for particular applications. Another important factor is gross vehicle weight. Motorcycles that are heavy should not be geared with highway gears and a Six Speed unless the engine used is very, very powerful.
Exhaust System Selection Ultima® engines can be very exhaust-system sensitive and proper selection of exhaust system will yield the highest power levels. Ultima® horsepower and torque tests were done with Hooker Step Tuned drag pipes and Hooker 2 into 1 systems. When selecting exhaust systems avoid large diameter pipes that do not have a smaller primary pipe that exits the head for at least 4-8” and avoid installing torque cones as these were made for small cubic inch engines (80ci-96ci).
Ignition Systems All complete assembled Ultima® engines come with an Ultima Fixed Curve Single Fire Ignition System (by Dynatek) with advance Curves and the Rev Limiter preset from the factory and do not require further adjustment. Rev limiter is set at 6,000 RPM. Modifying or tampering with the ignition settings during the engines warranty period will result in your warranty being void. COILS: 2.5 - 3.
Setting Aftermarket Ignition Systems These instructions are provided for professional mechanics when replacing the OEM Ultima® fixed curved ignitions after warranty, or for proper settings when assembling long blocks only. Installing aftermarket ignitions during the warranty period on any Ultima® competition series engines will void your warranty. (For Total TIMING use the information supplied in this book and not from any ignition manufacturer other than Ultima®.
Mark 4. = ( ) TDC on the rear cylinder. This mark is rarely used for ignition timing and is only listed as a reference for professional engine builders or when checking timing on the rear cylinder with a dial back type timing light. NOTE 1: All 80-113 Ci engines have 30˚ reference marks and 120-140Ci configurations use 25˚ reference marks. Range of timing hole: Shown with Mark (2).
Example for settings on Ultima & Dyna 2000i Programmable Ignitions 1. Follow the Manufacturers instruction to set the Static timing and understand the instructions. Make sure you have the engine on TDC (TF on the Flywheel) on the Front Cylinder on the compression stroke before you begin. 2. Set the ignition to the Normal VOES mode but do not install the VOES switch. Instead tape up the wire (violet) — Do NOT Ground this wire. 3. Set the Rev Limit to Minimum for Break-in. (Switch 4 & 5 off) 4.
Example for settings on Ultima SF Hi-Perf. & Crane HI4 Ignitions 1. Follow the Manufacturers instruction to set the Static timing and understand the instructions. Make sure you have the engine on TDC (TF on the Flywheel) on the Front Cylinder on the compression stroke before you begin. The ignition will be nearly vertical — slightly to the 1 o’clock position if you got it right. 2. Set the ignition to the OEM with VOES mode but do not install the VOES switch.
Rev Limiters During break-in we suggest setting Rev Limiters to the lowest setting (5,500 or less) to insure over revving will not occur. Most Ultima® engines will not produce power beyond 6,000 rpm and little if anything is gained by revving these engines past this rpm when in the stock configuration. A major contributor to a shortened engine life is high RPM. Spark plugs Recommendations: There are a variety of spark plug manufacturers who make the proper style and heat range plugs for these engines.
Carburetors and Initial Tuning Your Ultima® engine has been supplied with a Mikuni Carburetor that will require initial setting to be made prior to Initial start-up. Typically higher elevations or hotter climates will require different jetting and ignition timing than those shown in this guideline.
START UP AND BREAK IN RECOMMENDATIONS To give your engine maximum life and performance please read these recommendations thoroughly. These recommendations are assuming that your engine has been installed by a professional mechanic and all aspects of proper engine installation have been addressed. Pre-Start Checks Oil System: Some things that you should not do prior to starting your engine are: 1.
Priming the oil system prior to Start-up All engines should be checked for oil pressure prior to start up. Oil pressure should be visible at the top end feed screen plug, which is located to the rear of the rear lifter block on the cam cover side. See Figure 6. To verify that you have pressure before running your engine follow these steps: Make sure you have filled your oil tank with clean engine oil and no oil lines are crimped. 1. Remove the top end feed screen plug. 2. Disconnect all wires from the coil.
INSTALLATION INSTRUCTIONS - ULTIMA PERFORMANCE AIR CLEANER Step 1: Install the head breather/spacer into the head using a quality pipe thread sealant on the 1/2-13 threads. Do not overtighten. Step 2: Install carb to manifold seal onto the manifold. Step 3: Install carb into the manifold. Lightly lubing the seal beforehand will aid in seating the carb fully into the manifold. Leave enrichener facing forward.
Step 7: Insert & thread the 5/16-18 bolts with their washers through the top holes of the backing plate & tighten. Do not over torque. Use blue threadlocker (med strength). Always check that the 5/16-18 bolts have a hole drilled through them. This allows the motor to breathe. Step 8: At this time tighten both hose clamps on coupler & tighten enrichener knob nut to the backing plate. Make sure carb & coupler are correctly & fully seated. 24 Step 9: Install the air filter onto the backing plate.
Initial Start Up One of the most important parts of the break-in procedure is the initial starting of your engine!!!! Read this completely before starting the engine!!!!!! 1. Remove the Air Filter Cover. 2. Twist the throttle wide open and make sure that the fuel pump is working. 3. Give the engine 2 full fuel squirts and full enrichment or choke. 4. Leave the throttle shut and start the engine. Upon start of the engine, immediately set the idle at approx.
Break-in procedures for Ultima® Engines Follow these guidelines closely or you may void your warranty. Avoid over heating your engine!!!!!!!!!!! The heat of a new engine can be directly related to engine rpm, load and friction. Do not lug the engine. If you have a 6-speed transmission do not run your bike in 6th gear during break-in. We strongly recommend you keep the engine rpm above 2400 and below 3500 rpm for the first 500 miles and run the engine at varying speeds.
Break-In Service and Hardware Re-torquing With a new engine we feel the first oil/filter change should occur after the first 50-100 miles and all cover bolts and engine-mounting bolts should be checked for proper torque. Keeping your engine oil clean is very important to the overall life of the engine. During the Break-In, or look at it as the “Wear-In” period, engines produce very small metallic pieces that need a good filter to remove them.
Troubleshooting Below you will find a list of common issues we have encountered with new engine installations. If you do not see your problem or cannot resolve one of these problems please contact your dealer for more information. Engine Won’t Start Common causes: 1. No fuel supply. 2. No spark. 3. Engine has been flooded. When trying to start the engine for the first time, and it is difficult, you need to verify that you have compression, fuel and spark.
Lifter Adjustment procedure for Ultima® Engines When performing any service work always disconnect the battery!!! Remove the spark plugs and pushrod tube clips to access the pushrods. With a stable lift get the rear wheel of the bike off of the ground and put the bike in 5th gear. Use the rear wheel to rotate the engine slowly. Never rotate the engine with the Starter motor while adjusting pushrods. 1. Rotate the engine until you are on the compression stroke for the cylinder you are adjusting.
Oil blowing out of Cylinder Head Breather Vents: Common causes: 1. Oil tank is over filled. 2. Oil Tank vent lines and return lines are crossed. 3. Oil filter lines are crossed or plugged. 4. Filter has a check valve and lines are crossed (this will sometimes cause the filter to burst). Typically this problem occurs when either the engine is not returning oil or the crankcase vent is not open to the oil tank. The most common cause is when Softail® style tanks are used and get over filled.
General Torque Specs and Adjustments Rocker Box Bolts Head Bolts Pushrod Adjustment Cam Cover/Lifter Block Oil Pump Bolts Case Bolts Inner Primary to Engine Alternator Plug Retainer Engine Sprocket Bolt Motor Mount bolts Spark Plugs Compression Releases Lower (1/4-20 120-140 In Lb) (5/16-18 15-22 Ft Lb) Upper 80-120 In lb Antiseize or Lubricated Thread and bolt washer — Torque in 5 steps — twice per sequence. Torque in X Pattern.
MAINTENANCE SCHEDULE First 100-150 MILE SCHEDULED MAINTENANCE First 500 MILE SCHEDULED MAINTENANCE Change oil Change oil filter Check fuel valve, lines & fittings for leaks Check oil lines & fittings for leaks Check torque of all fasteners except head bolts Change oil Change oil filter Check fuel valve, lines & fittings for leaks Check oil lines & fittings for leaks Check engine mounting bolts ❑ ❑ ❑ ❑ ❑ Technician Signature ❑ ❑ ❑ ❑ ❑ Date ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change oil Change oil filter Check fuel valve,
MAINTENANCE SCHEDULE 9000 MILE SCHEDULED MAINTENANCE 6000 MILE SCHEDULED MAINTENANCE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change oil Change oil filter Inspect & clean air filter as necessary Check fuel valve, lines & fittings for leaks Check oil lines & fittings for leaks Check engine mounting bolts Technician Signature Date Change oil Change oil filter Inspect & clean tappet screen Inspect & clean air filter as necessary Check fuel valve, lines & fittings for leaks Check oil lines & fittings for leaks Check tor
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WARRANTY REGISTRATION CARD THIS CARD MUST BE FILLED OUT AND MAILED TO THE ULTIMA WARRANTY DEPARTMENT WITHIN 30 DAYS OF ORIGINAL PURCHASE BY THE END USER. ENGINE SERIAL #: DISPLACEMENT: CUT & DETACH HERE DATE OF PURCHASE: END USER: PHONE NUMBER: ADDRESS: COMPETITION SERIES I, the undersigned, agree and understand that this Ultima® engine is not EPA compliant and is meant for competition and/or off-road use only. I also agree to & understand the warranty terms outlined in this Ultima® Owners Manual.
AFFIX STAMP HERE ULTIMA COMPANY.
