• Psc-5 Operations Manual

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. 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. 12 months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired by Ultima if the parts are returned to Midwest Motorcycle Supply by the purchaser within the specified warranty period or within 10 days thereafter. Cost associated with removing or installation of complete engines are not covered under this warranty. You must also include a copy of the original invoice and detailed letter outlining the nature of the problem.

You must also outline how the part was used and the circumstances at the time of failure. If, after an evaluation has been made by Ultima and the part was found to be defective, repair to the existing part or replacement will be granted at Ultima’s discretion. Forged Dome Cylinder Length 5.550 5.565 4.995 4.995 4.995 NOTE (1) Case Deck Height 5.375 5.375 5.875 5.875 5.875 Ultima ® engines are Rod Length 7.44 7.44 7.44 7.44 7.44 supplied with 93/L breathers operating Flywheel Forged 5 Pc Forged 5Pc.

92/L (NOTE 1) 92/L (NOTE 1) modification or replaced by a larger ® ® ® ® Cam Cover Type 84/89 Ultima 84/89 Ultima 84/89 Ultima 84/89 Ultima bore Carburetor. Horsepower ratings Rocker Box Type 93/L 93/L 93/L Billet Reed Valve 93/L Billet Reed Valve on all Engines will also be greatly affected by Exhaust systems selected.

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 Lobe Center 103 Ex 69/23 272 Dur Lift.520 TDC.194 Lobe Center 113 Lobe Sep 108 Overlap 51 100 and 107 CI engines: MW 248 Cam (1.69 rocker arm ratio) Timing information is Open/Close @.053. Fitment Issues: All 130 & 140 Ci 1. The Ultima ® 130 Ci and 140 Ci engines are over 5/8” taller than a stock engine. These engines will fit in most Ultima ® frames but other aftermarket manufactured frames must be checked for fitment. All fitment issues for 113Ci thru 127 Ci engines apply to the 130 Ci and 140 Ci. Ultima ® brand FXST ® type oil tanks.

Figure 4 Tank cutaway shows the oil line identification for Ultima ® brand round oil tanks. Mercedes sprinter repair service manual. OPTIONAL FEED LOCATION (NEXT As you can see, both tanks have an internal return line that goes to the far side of the TO RETURN) tank to improve oil circulation. 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. 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. ® belt drives. Primary Belt Drive Considerations: When installing belt drives on Ultima engines it is recommended that RTV silicone be applied behind the stator where the casting meets the steel liner & between the crankshaft splines & the rotor spacer. 37t clutch basket divided by 24t engine sprocket = 1.54 1.54 x 2.19 = 3.37 overall 70t rear pulley divided by 32t transmission pulley = 2.19 3000 rpm @ 69mph Ultima ® belt drives 71t clutch basket divided by 45t engine pulley = 1.6 1.6 x 2 = 3.20 overall. 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”. ® 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. 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 ®. Some of these are listed at www.ultimaproducts.com. ® On ignitions such as Ultima, Crane, Dyna 2000 and Compu-Fire that have adjustable advance curves, do not select the most aggressive curves for break in. The instructions show 4 different advance curves for this scenario.

Select the curve with the proper total timing shown in this book for your engine size. Ultima Ignitions have preset curves for each engine size and will get you close by static timing the engine at TDC.

Dyna 2000 Ignitions will require you to modify the base timing on most engines so the total advance is not too excessive. Set the ignition to the OEM with VOES mode but do not install the VOES switch. Instead tape up the wire — Do NOT Ground this wire on the HI4 System or Ultima ignition system. Put the ignition in Kick Start Mode as they will fire on the first revolution and typically start much easier this way. 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. Prior to starting your engine you should check your carburetor’s initial ® idle mixture setting and fuel pump setting recommended by the manufacturer.

Ultima provides the proper base line jetting for each engines size but idle mixture and fuel pump setting must be done on an individual basis. 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. High quality fuel will have a direct effect on your engine’s performance. ® Ultima engines are designed to run on a Minimum of 92 octane fuel.

Higher octane fuels will be beneficial to your engine only up to a point and above about 100-105 octane you can lose performance as the engine’s fuel requirements and ignition timing requirements with these. INSTALLATION INSTRUCTIONS - ULTIMA PERFORMANCE AIR CLEANER Step 1: Install the head Step 4: Install coupling onto the air breather/spacer into the head filter backing plate after installing using a quality pipe thread sealant both 3” hose clamps onto the Step 3: Install carb into the on the 1/2-13 threads. NOTE: Due to the cylinder height & spread of the 130 & 140 El Bruto motors, an adapter is required & provided to properly mount the Ultima air cleaner assembly. Step 8: At this time tighten both hose clamps on coupler &. 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!!!!!! Remove the Air Filter Cover.

Twist the throttle wide open and make sure that the fuel pump is working. 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. “Wear-In” period, engines produce very small metallic pieces that need a good filter to remove them. We do not recommend extremely fine 10-micron filters during this time as they can clog quickly and begin to by-pass oil instead of filtering it.

Use the 40 Micron Filters during break-in and for the life of the engine. 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. Extend the adjuster another 3 full turns beyond zero lash and lock the jam nut tight.

(This applies to pushrods with 18 threads per inch. If the ® pushrods are not the stock Ultima pushrods use the manufacturer’s recommended setting.) 5. Also be careful of oil filter housings. If you have over filled your oil tank and have this problem you must drain the engine’s crankcase before ® refilling. Ultima Cases have a drain plug located at the bottom of the engine and you can drain the case if needed. When refilling the oil tank only put in about 2.5-3 quarts before starting the engine and add additional oil cautiously.

(3) 20 Ft Lb (4) 28-30 Ft Lb (5) 40-42 Ft Lb Pushrod Adjustment 3 full turns extended beyond zero lash using Crane or Ultima® Speedrods® pushrods. Cam Cover/Lifter Block 1/4-20 bolts 120-150 In Lb Oil Pump Bolts 120-140 In Lb. Technician Signature Date first initial 3000 miles.

In an event warranty is needed, Ultima reserves the right to request copies of the signed scheduled maintenance lists. These guidelines are provided to give you maximum engine life, enjoyment & service life of your Ultima engine. Ultima requires following the scheduled maint. Guidelines every 3000 miles after the first initial 3000 miles. In an event warranty is needed, Ultima reserves the right to request copies of the signed scheduled maintenance lists. These guidelines are provided to give. 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.

Psc-5 Operations Manual

ENGINE SERIAL #: DISPLACEMENT: DATE OF PURCHASE: END USER: PHONE NUMBER: ADDRESS: COMPETITION SERIES I, the undersigned, agree and understand that this Ultima ®. AFFIX STAMP HERE ULTIMA COMPANY., LLC WARRANTY DEPARTMENT 2100 HIGHWAY Z PEVELY, MO 63070.