I finished installing a new 120R motor in my CVO Ultra a few weeks ago and thought I would post some details here in case it can help anyone. Overall it's pretty easy and took me about two days of work since I had to paint the Transmission and Inner Primary as well as replace the swing arm bearings, pulleys and engine/trans mounts.

Engine Swap Details:

1. Bike has 109K miles on it
2. Original engine main bearings went out at 38K miles (HD replaced original engine under warranty)
2. Pulled old motor, painted the transmission and inner primary to match the engine.
3. Replaced pulleys, belt, swing arm bearings, trans and engine mounts.
3. Installed 58 mm HPI Throttle Body with 5.3 injectors.
4. Tuned bike using Power Commander V and Autotune, bike runs great, no decel popping and smooth idle. Took a few rides for AT to adjust the map.

I've got just over 1000 miles on it now and it runs great. Here are a few notes and impressions:

1. Since I already had a PC V with Autotune I just left the 110 map I created in it and let Autotune adjust
2. Initially the bike idled a bit rough, would "hunt" a bit and when I would start it up after being shut down for 10 minutes or so would idle high and not come back down for a couple minutes.
3. After accepting some Autotune trims and making a couple manual adjustments the bike fires right up, doesn't idle high, doesn't hunt anymore and runs hard and as I expected fuel mileage took a hit.
4. Oil pressure is higher than stock, runs about 50 lbs at speed. and about 20 or so at idle.
4. Bike runs quieter that the 110 and also seems to run cooler although I haven't ridden it in 90+ temps yet.
5. Man it pulls hard! Took a few rides to get used to the new power curve.
6. Still using stock CVO clutch spring, I wanted to run this to see if I need a stiffer spring but so far it hasn't slipped. The CVO spring is stiffer than stock.
7. Three of my friends want me to put one in their bikes now....

Bike:
2010 CVO Ultra
SE 120R
HPI 58 mm Throttle Body
SE 5.3 injectors
Rinehart True Duals
SE Agitator Extreme Air Cleaner
Ultra Cool Reefer Oil Cooler
Progressive Mono Tubes
Progressive Remote Reservoir adjustable shocks
Corbin Seat, backrest and passenger rest
Klock Werks windshield
Jensen HD Stereo
Hawg Tunes amp and Lower fairing speakers
Boom Audio fairing and rear speakers
Various doo dads and custom pieces

 

Congratulation's on your purchase...Be smart and get it tuned properly. You should be getting 38-42 mpg when its tuned properly. I put 30000 trouble free miles on my stock 120r. Get ready for all the 120 envy people to chime in.

 

Congrats! I'm jealous of your ability to do all that work yourself.

Nice job.

 

Thanks man, when I was younger I worked in shops for 5 years then ran my own shop for 10 years. Now I just work on my own stuff and help friends out. It's actually pretty easy to do as long as you have a few special tools. I have a lift as well so that makes it a lot easier. I wouldn't have done this with the bike on the ground, I'm too old to crawl around on the floor!

 

Nice job. I and two other of my best friends used to do all of our own work. We built bikes from the frame up and also pulled stock 88" inch motors and modified them with an S&S 116 kit or a basic 95" engine upgrade. Sadly both of my friends have passed away but seeing your pictures reminds me of some great memories. Thanks for sharing and enjoy your build.

 

Glad to hear my post brought back some good memories of building bikes with your friends. Sorry to hear of their passing, I know they're in the wind with you!

 

any idea of what kind of HP's and tourque you're pulling with that engine???

 

Not sure about the HP/Torque numbers, haven't had it on a dyno yet. I'm definitely curious, I'll post numbers when I do that.

 

from what I have heard they push out 130 hp with the standard motor and you can get upgraded 12:1 pistons that produce even more..... can anyone confirm this??

 

Awesome! Enjoy!!!