SHOVELHEAD 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® SHOVELHEAD ENGINES DISTRIBUTED EXCLUSIVELY BY MIDWEST MOTORCYCLE SUPPLY Failure to read and comply with this document completely may Void Warranty. SHOVELHEAD ENGINE WARRANTY: Ultima’s Complete Assembled Shovelhead engines are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 6 months/6,000 miles from the original date of purchase.
General Specifications 96” Cam Information Displacement CI Displacement CC 96Ci 1564 96 CI engine: Timing information is Open/Close @ .053 Bore Stroke Compression Valve : Int Valve: Ex Cam Duration Pushrod Length Piston Cylinder Length Case Deck Height Engine Weight 3.625” 4.625” 9.5:1 1.940” 1.750” 256/256 Adjustable 2618 Forged 5.530” 5.375” 170 Lb Rod Length Flywheel Case Spigot bore Pump Type Breather Type Cam Cover Type Rocker Box Type Rocker Arm/ Ratio Engine Height Est. Rated power RW 7.
CRANKCASE VENT Oil Pump Fittings Identification: ® Ultima Shovelhead 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 break-in and standard operation of the Ultima Shovelhead engine we recommend using high quality petroleum based API service SJ rated motor oils, such as Ultima’s 60 weight oil, MW# 103-111. The oil’s viscosity should be matched with the climate conditions but in most cases Ultima 60 weight motor oil will work fine. Oil Filters All Ultima® engines require oil filters.
General Information Compression Release Valves All Ultima® Shovelhead 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. For custom applications, Ultima® recommends using industry proven Ultima® belt drives.
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 Shovelhead motors utilize a 3-bolt exhaust mount for added durability, but stock single-bolt exhaust can be used. 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”. Overall the owner’s satisfaction of the selected pipe is most important but it can also have a negative effect on rated power levels.
Ignition Systems Ultima® Shovelhead 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. Ultima® Shovelheads utilize a dual plug design to prevent detonation, overheating, spark plug fouling and hard starting.
SINGLE PLUG WIRING DUAL PLUG WIRING REAR CYL FRONT CYL REAR CYL FRONT CYL GREEN WHITE GREEN NOTE: OUTPUTS CAN BE REVERSED FOR BEST SPARK PLUG WIRE ROUTING BY SWAPPING PINK AND BLUE PRIMARY CONNECTIONS. VIOLET COILS: 2.5 - 3.5 OHM VIOLET NOTE: OUTPUTS CAN BE REVERSED FOR BEST SPARK PLUG WIRE ROUTING BY SWAPPING PINK AND BLUE PRIMARY CONNECTIONS. PINK (TACH) SINGLE-FIRE/ DUAL COIL/DUAL PLUG WIRING DIAGRAM COILS: 2.5 - 3.
Setting Aftermarket Ignition Systems These instructions are provided for professional mechanics when replacing the OEM Ultima® fixed curved ignitions after the warranty period expires. Installing aftermarket ignitions during the warranty period on any Ultima® Shovelhead engine 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. Range of timing hole: Shown with Mark (2). When timing an engine with a 30˚ mark on the flywheel, if the mark is to the front of the hole the total timing is Retarded to 26 degrees. If the mark is to the rear of the hole the total timing is advanced to 34 degrees.
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.
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.
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 accelerator 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.
Oil blowing out of Lower End/Case Breather Vent: 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.
Excessive lifter noise Common causes: 1. Engine was not properly primed prior to start-up. 2. No oil feed to lifters. 3. Improper pushrod adjustment. 4. Oil lines are not connected properly. If you have excessive lifter noise at start-up shut the engine off immediately and go through the priming process described earlier in this document. Ultima® engines are primed from the factory but if no oil is being fed from the oil pump the lifters will lose their prime quickly.
General Torque Specs and Adjustments Rocker Cover Nuts Rocker Arm Shaft Locknut Cylinder-Head Bolts Cylinder-Base Nuts Cam Cover/Lifter Block Oil Pump Bolts Pinion Gear Nut Case Bolts Inner Primary to Engine Alternator Plug Retainer Engine Sprocket Bolt Motor Mount bolts Spark Plugs Compression Releases 24 12-15 ft lbs 12-18 ft lbs 55-75 ft lbs 32-40 ft lbs 1/4-20 bolts 120-150 In Lb 120-140 In Lb 42 ft lbs Left hand (reverse) thread All 5/16-18 bolts 14-18 Ft Lb — Torque 1/4-20 bolt last 90-110 In Lb 22-
MAINTENANCE SCHEDULE First 500 MILE SCHEDULED MAINTENANCE First 100-150 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 Technician Signature Date ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change oil Change oil filter Check fuel valve, lines & fittings for leaks Check oil lines & fittings for leaks Check engine mounting bolts Technician Signature Technician Signature Date First 3000 MILE
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
SHOVELHEAD 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: 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.
