AMERICAN IRONHORSE Classic SX User manual

CONGRATULATIONS!
1
The AMERICAN IRONHORSE® Motorcycle you have just purchased utilizes the latest technology and
the highest quality components to produce a motorcycle that strains at the chains of the past and dares
to race into the future. Our motorcycles are not for everyone, only the select, free-spirited souls like you.
Your AMERICAN IRONHORSE was built with great care for your enjoyment. To ensure that your AMERICAN
IRONHORSE performs to its capabilities and to advise you of safety issues, please read this manual in its
entirety before riding your AMERICAN IRONHORSE Motorcycle.
This manual provides operating, safety, and maintenance information on the AMERICAN IRONHORSE
Classic SX, Outlaw SY, Slammer SZ, Texas Choppers TX, Tejas SJ, Ranger SG, Legend SC, and Thunder SW.
Following the recommended inspection and maintenance procedures will ensure that your AMERICAN
IRONHORSE is in optimum condition for your comfort, pleasure, and safety. The inspections and maintenance
should be performed by an experienced, professional mechanic to ensure this high quality. Enjoy the AMERICAN
IRONHORSE Motorcycle that will make your dreams reality.

AMERICAN IRONHORSE VEHICLE INFORMATION
2
Model__________________________________________
V.I.N. __________________________________________
Motor Serial No._________________________________
Trans. Serial No. ________________________________
Ignition Key No. _________________________________
Dealer Name____________________________________
Number ________________________________________
Address ________________________________________
_______________________________________________
Phone Number __________________________________
FAX Number ____________________________________

IMPORTANT NOTICE
3
Printed type face in this manual is designed to highlight certain sections, paragraphs, sentences or
phrases. Please take special note of the following key:
DANGER: BOLD CAPITALS CONTAINED IN A BOX INDICATE THAT THE SUBJECT IS ONE THAT COULD
POSSIBLY LEAD TO PERSONAL BODILY INJURY TO THE RIDER, PASSENGERS, OR OTHERS.
WARNING: BOLD PRINT IN CAPITAL LETTERS INDICATES THAT THE SUBJECT IS ONE THAT COULD
POSSIBLY LEAD TO DAMAGE TO THE MOTORCYCLE.
CAUTION: Italic print indicates other important matters.
This manual covers all models of AMERICAN IRONHORSE motorcycles with standard and optional equipment.
Consult your local AMERICAN IRONHORSE dealer for any questions you may have.

TABLE OF CONTENTS
4
Section No. Page No.
AMERICAN IRONHORSE Vehicle Information...........2
1-1 Safety ...........................................................6
1-2 Vehicle Specifications ....................................9
a) Mechanical..............................................9
b) Weight ........………………………………….9
c) Fluid Capacities .....................................10
d) Engine Specifications .............................10
e) Transmission Specifications ...................10
f) Drive Train Specifications .......................11
g) Electrical Specifications .........................11
h) Tire Specification ...................................12
i) Brake Specifications ..............................13
j) Fueling and Fuel Specifications...............14
1-3 Engine Break In Period .................................15
Operation: Features, Controls, and Indicators
2-1 Ignition Switch .............................................16
2-2 Engine Throttle/Speed Controls....................17
2-3 Fuel/Air Mixture Controls..............................18
2-4 Starting and Stopping Engine .......................19
2-5 Clutch and Gear Shifting ..............................22
2-6 Braking Systems..........................................28
2-7 Turn Signal Indicators ..................................29
2-8 Control Panel Indicator Lights .......................30
2-9 Control Panel Speedometer, Odometer..........31
2-10 Headlight Switch & High Beam Activation .........32
2-11 Horn Switch.................................................32
2-12 Kick Stand ..................................................33
2-13 Rear/Side View Mirrors ................................34
2-14 Securing Your Motorcycle .............................35
2-15 Vehicle Gas Caps.........................................36
2-16 Shock Absorbers .........................................37
2-17 Vehicle Loading & Accessories .....................37
Recommended Inspection and Maintenance Procedures
3-1 Introduction .................................................38
3-2 Theory of Maintenance.................................38
3-3 Rider Checks and Procedures.......................39
3-4 Professional Mechanical Checks and
Maintenance Procedures..............................40
a) Engine Systems.....................................41
b) Electrical Systems .................................41
c) Drive Train.............................................41
d) Fuel, Ignition, Throttle ............................42
e) Braking .................................................42
f) Wheels and Tires ...................................43
g) Suspension ...........................................43
h) Other Checks.........................................43
3-5 Road Testing ...............................................44
3-6 Washing Motorcycle .....................................44

TABLE OF CONTENTS (CONTINUED)
5
Detailed Maintenance Procedures
4-1 Engine Lubrication .......................................45
4-2 Checking and Adding Engine Oil....................46
4-3 Changing Engine Oil and Oil Filter .................47
4-4 Transmission Lubrication..............................48
4-5 Primary and Rear Drive Belt..........................50
4-6 Clutch System .............................................51
4-7 Brake System..............................................52
4-8 Tires ...........................................................53
4-9 Bearing Maintenance ...................................55
4-10 Shock Absorbers .........................................55
4-11 Spark Plugs.................................................56
4-12 Ignition System............................................56
4-13 Vehicle Alignment ........................................57
4-14 Battery........................................................58
4-15 Voltage Regulator and Alternator...................62
4-16 Circuit Breakers...........................................62
4-17 Vehicle Lights ..............................................63
4-18 Hydraulic Tappets ........................................64
4-19 Motorcycle Lubrication .................................65
Mechanical Specifications
5-1 AMERICAN IRONHORSE Consumable Table ....66
5-2 Torque Specifications ...................................68
Important Notices
6-1 Reporting of Safety Defects..........................70
6-2 Noise Emission Warranty..............................70
6-3 Tampering ...................................................71
6-4 Limited Warranty on Emission Control System .......73
I. Coverage
II. Limitations
III. Limited Liability
6-5 Limited Warranty..........................................78
Figures
Figure 1 ......................................................82
Figure 2 ......................................................83
Figure 3 ......................................................84
Figure 4 ......................................................85
Figure 5 ......................................................86
Figure 6 ......................................................87
Figure 7 ......................................................88
Figure 8 ......................................................89
Figure 9 ......................................................90
Figure 10 ....................................................91
Figure 11 ....................................................92
Figure 12 ....................................................93
Figure 13 ....................................................94
Figure 14 ....................................................95
Figure 15 ....................................................96
Figure 16 ....................................................97
Figure 17 ....................................................98
Figure 18 ....................................................99
Maintenance Records ..................................99

SAFETY
6
1-1
Literally millions of people world-wide ride motorcycles daily for transportation, work and pleasure. At the
same time, tens of thousands of accidents occur, many avoidable.
As a motorcyclist, you have taken on additional responsibilities to yourself, passengers and others to
ride safely. Here is a safety checklist to review as you enjoy your AMERICAN IRONHORSE motorcycle:
• If you are an inexperienced operator, take a formal motorcycle safety riding course. If you are an experienced
rider and have not done so in a long time, consider a refresher course.
• Be aware of the fact that as a responsible rider, you must always know the condition of your vehicle,
especially the condition of those systems that directly correlate to bike safety.
• Read this manual in its entirety before riding your AMERICAN IRONHORSE. Follow all of the recommendations,
danger, warnings and caution information.
• Find a professionally trained, experienced mechanic with whom you can develop confidence and who can
come to know your vehicle’s operation over time.
• Ensure that all the recommended inspection and maintenance procedures in this manual are strictly followed
within the prescribed time intervals.
• Stay acutely aware of road and ambient conditions. Motorcycles (with only two wheels) are not as stable as
four wheeled vehicles. Consequently, wet or slippery road sur faces, wind, rough pavement, high speeds,
oncoming traffic, foreign material on pavement and similar conditions increase the risk to a rider’s control of
the vehicle and possible result in personal injury.
• Always wear an approved helmet when riding. Avoid the wearing of loose fitting or flowing garments that can
interfere with safe operation of your vehicle. Always wear appropriate eyewear and footwear.
• Always follow the posted speed limits and make appropriate reductions in speed consistent with deteriorating
road conditions, traffic, ambient conditions and similar safety factors.

SAFETY
7
1-1
• REMEMBER THAT THE INCIDENCE OF HAVING A MOTORCYCLE MISHAP GENERALLY INCREASES WITH
VEHICLE SPEED.
•Before starting your engine and setting off on a ride, always visually and manually check the condition of
your vehicle to ensure proper operation, especially the condition of tires, brakes, throttle, clutch, vehicle
indicator lights, headlamp, signal and brake lamps and turning radius freedom.
• Gasoline and battery gases are extremely volatile. Pay special attention to the sections of this manual
dealing with those two important subjects.
• NEVER OPERATE YOUR ENGINE IN AN ENCLOSED SPACE AS CARBON MONOXIDE GAS FOUND IN YOUR
VEHICLE’S EXHAUST FUMES IS EXTREMELY DANGEROUS, EVEN DEADLY, IF INHALED.
• Always ride your motorcycle defensively. Remember, as a rider, you are the most vulnerable vehicle operator on
the road with little or no bodily protection in the event of an accident. Always operate under the premise that
the “other guy” will act in a way that will increase the risk of you becoming involved in an accident.
Remember, as a motorcyclist, you are often not seen by other vehicle operators. Take particular care of
motorists making turns into your oncoming traffic lanes. Always operate with your headlight on, day or night,
to help increase your visibility to other vehicle operators.
• NEVER OPERATE YOUR VEHICLE IN LESS THAN 100% CONTROL OF ALL OF YOUR FACULTIES. OPERATING
UNDER THE INFLUENCE OF ALCOHOL, DRUGS, FATIGUE OR OTHER SUCH CONDITIONS GREATLY
INCREASES THE CHANCE OF BECOMING INVOLVED IN AN ACCIDENT.
• DO NOT OVERLOAD YOUR VEHICLE WITH WEIGHT. SEE THE MAXIMUM ALLOWABLE GROSS VEHICLE WEIGHT
RATING IN THIS MANUAL AND DO NOT EXCEED IT. OVERLOADING OR UNBALANCED LOADING CAN LEAD TO
VEHICLE INSTABILITY AND MAY RESULT IN PERSONAL INJURY. NEVER TOW A TRAILER OR OTHER VEHICLE.

SAFETY
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1-1
SIMILARLY, A DISABLED MOTORCYCLE SHOULD NEVER BE TOWED BY ANOTHER VEHICLE. TOWING FORCES
CREATE AN UNSTABLE CONDITION THAT COULD LEAD TO PERSONAL INJURY. NEVER ADD A SIDECAR TO
YOUR AMERICAN IRONHORSE VEHICLE. IT IS NOT DESIGNED OR CONSTRUCTED FOR SUCH USE.
• The vehicle’s exhaust system becomes very hot from normal operation. Always wear appropriate clothing to
prevent direct skin contact with exhaust pipes and mufflers. Never touch exhaust system components until
they have had about 25 minutes or more to cool down after shutting down your engine.
• NEVER LET OTHER INDIVIDUALS OPERATE YOUR VEHICLE UNLESS YOU ARE CERTAIN OF THEIR RIDING
SKILLS AND THEIR FAMILIARITY WITH YOUR AMERICAN IRONHORSE VEHICLE, WHICH MAY OPERATE
DIFFERENTLY FROM THOSE VEHICLES WITH WHICH THEY MAY BE FAMILIAR.
• Always secure your vehicle when left unattended by locking at the rotor with a rotor lock and locking and
removing the ignition key. This will help prevent unauthorized use or theft.
• When your vehicle will not be in use, close the fuel supply valve to prevent accidental gasoline spillage. For
California vehicles with Evaporative Emission Systems, failure to do so could cause serious damage to your
engine when gasoline leaks into crankcase oil.
• Pay particular attention to the traction, steering components, and systems of your vehicle. Tires should be
continuously monitored for correct inflation pressure, tread wear condition, cuts and abrasions. Steering and
vehicle suspension systems should not exhibit excessive “play” under operation. Such conditions can lead to
vehicle instability and result in possible personal injury. The condition of shock absorbing components such as
front forks and shock absorbers should be monitored for function and possible leaks. The presence or
suspicion of the presence of any of these conditions should lead to immediate consultation with a
professionally trained mechanic.

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
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1-2
A. Dimensions: (inches) Texas
Slammer Thunder Outlaw Legend Classic Tejas Ranger Choppers
Wheel Base 68 67 66.5 71 66.5 71.5 65.5 80
Overall Length 94 98 98 98 94 97 96 108
Overall Width 31.5 42 35 31.5 31.5 37 36 35
Overall Height 47.5 45.5 49 51.5 46.5 48 48 51
Ground Clearance 4.75 4.75 4.75 5.25 4.75 4.75 5.25 5.5
Seat Height 25.5 25.5 25.5 25.5 24.75 25.25 26.5 25.5
B. Weight: (pounds) Texas
Slammer Thunder Outlaw Legend Classic Tejas Ranger Choppers
Weight 610 610 610 610 610 580 590 610
GVWR 1200 1100 1200 1200 1100 1200 1100 1200
GAWR – Front 490 450 490 490 450 490 450 490
GAWR – Rear 710 650 710 710 650 710 710 710

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
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1-2
C. Fluid Capacities:
Fuel Tank Capacity 5 gallons (Texas Choppers 3.8 gallons)
Transmission 24 ounces
Primary Fill to bottom of clutch diaphragm spring
Oil Reservoir w/Filter 98 ounces
Front Forks (each)
All Models 12 ounces
D. Engine Specifications:
107 cubic inch 113 cubic inch
Number of Cylinders 2 2
Design 4 cycle, V-twin 4 cycle, V-twin
Compression Ratio 9.6 : 1 10.1 : 1
Bore 4.0" 4.0"
Stroke 4 1/4" 4 1/2"
Volume Displacement:
Cubic Inches 107 113
Cubic Centimeters 1753 1852
E. Transmission Specifications:
Number of Forward Speeds 5 speed / 6 speed optional
Type Constant Mesh