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  #1 (permalink)  
Old 06-11-2012, 03:01 PM
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Question Ultima Ignition Install 02 XL1200-Need guidance

I've decided to make my ignition install tonight's project but the installation instructions included only cover jumper settings and wire color codes.

I've never changed out an ignition myself, although it looks straight forward.

1. The current condition is: factory ignition...never been screwed with. Was running great the last time the motor fired in 2007 when I tore everything down.

2. My concerns are:

A. Before I remove the stock ignition do I need to take not of the position or is it irrelevant?

B. Do I need to remove the factory timing cup and install the ultima timing cup?

C. If I need to install the Ultima timing cup is it pretty straight forward?

D. Does the motor need to be TDC before I start all of this?

E. Anything else I should be aware of before I take this on?

Note: The bike isnt wired yet so I can't set static timing at this time.

Also I looked all over the www for a how to video but if one exists I can't find it. Any input, guidance, photos, advice, etc is greatly appreciated.

Thanks guys
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  #2 (permalink)  
Old 06-11-2012, 03:18 PM
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Old 06-11-2012, 03:24 PM
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A)...it doesnt matter at this point

B)...yes, you must use the ultima timing cup

C)...real easy...just unscrew the bolt in the middle,new one will go on and locate with a dimple into the cut in the end of the cam....factory cup has the same dimple in it

D)...when you come to time it up you need to set the motor at TDC on the front cylinder compression stroke

E)...thats about it for now...come back when ya gonna fire her up and I can go into detail with ya.....it is the same as with the Buell but with any luck you won't need to re-index the timing cup as I had to...(BUELL nose cone slightly differant to sportster made it harder)
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Old 06-11-2012, 04:30 PM
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sounds great, going to tackle this tonight. Should be simple since I'm not ready to do wiring yet. Just a straight install to get it in place!

Appreciate the help. I'll be back for more. Please subscribe this thread if you havent already and I owe you one.
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  #5 (permalink)  
Old 06-12-2012, 11:16 AM
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For those interested....so far so good.

1. Removed the two allen heads holding the ignition cover in place, then removed two bolts holding the stock ignition in place with a flat head screw driver.



2. Cut the factory connector off so I could pull the wires through the cover and remove



3. Used a socket to remove the stock cup. Behind the cup is an indexing groove.



4. Aligned new timing cup from kit with indexing groove. Installed with original bolt. Pulled wires from Ultima ignition through the hole in the cam cover.



5. Installed new ignition module in same position as old unit. There is a notched arrow on the factory unit and the ultima unit. I just put the new unit in the same orientation as the factory unit.



6. Buttoned her up...see you again when I wire the bike soon.

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Old 06-12-2012, 11:30 AM
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looking good....ya shouldn't have any problems with that...........
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Old 06-17-2012, 11:32 AM
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So I got the bike started for the first time yesterday. I tried static timing the bike in the TDC position (vertical line indicator in the timing window) and I am not able to get the red light to come on at all by rotating the ignition. I next forwarded the bike until I got the 20 degree advance mark in the window.

When I had the 20 degree advance mark (the two dots side by side) I'm able to get the light to come on, and it shut off just at the maximum counter clockwise adjustment. This is how I have the bike static timed now and it has some backfiring and clinking noises. (obviously it's not supposed to be timed to the 20 degree advance mark) however it starts right up.

Will I need to re-notch the cup in order to get it timed at TDC position?
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Old 06-17-2012, 12:28 PM
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go back to the TDC mark ,front cylinder compression stroke.
score or mark a line from the locating dimple in the end of the cam to the outer inside edge of the nosecone
then ,using a brass drift,,,flatten and remove the indexing dimple in the cup.
re-fit the cup,,,without the dimple,do the bolt up tight enough to basicly hold the cup but so you can still turn it clockwise,
then re-instal the pick up modual into a middle position where the mount bolts are concerned.
again do not fully tighten the bolts...leave it snug but moveable.
at this point,you should be able to see how far out the cup is in relation to the modual.
using a small screwdriver,rotate the cup to the point were the light comes on.
then turn the pickup modual clockwise till the light goes out.....
at this point ,your timing is set...OTHER THAN the fact that you have no indexing dimple in the cup and nothing is tight....
using the marked line in the nose cone as a guide...mark the cup with the position that the new dimple needs to be....remove the cup retaining bolt but leave the cup in place...using a punch,re- indent the cup with a couple of sharp blows into the slot of the cam cutout.
then re-assemble with everything tight,re-set the timing to the point the light goes out.... and then ride it like ya stole it!!!...it should then be set at the correct position......

....hope this makes sense....
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  #9 (permalink)  
Old 06-17-2012, 12:42 PM
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yup, makes perfect sense. I'm not sure why the cup isn't set up properly in the first place but hey, what can you do?

I'll work on this today and report back.

Once it's static timed, how critical will dynamic timing be?
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Old 06-17-2012, 12:47 PM
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I just thought of something. Should the engine have been TDC on front cylinder when I initially lined up the cup with the cam mark and installed?

Could this be why I'm not able to get it static timed properly?
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Old 06-17-2012, 01:29 PM
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it should have been ,but the cup being indexed to the cam, it wouldn't make too much of a differance,but always best to start as ya mean to go on....
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Old 06-17-2012, 01:31 PM
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I just went out and repeated the process. I thought about my question as I pulled the cup and realized the cup spins with the cam, so the position shouldn't have mattered...but you're right...start as you mean to go.

So I got TDC and repeated the process, worked like a charm. No problems, got it static timed without making any changes to the cup, fired her up and she ran like a top! Sounds mean too...
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Old 06-17-2012, 01:57 PM
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good to here.... how big was your grin.....
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Old 06-17-2012, 03:11 PM
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Ear to ear brother, ear to ear. In the end, it was a simple task. Hopefully someone down the line will find themselves in the same position and find this thread to guide them through.
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