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
8
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
9
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
10
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

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
11
1-2
F. Drive Train Specifications:
Number of Teeth
Engine 24
Clutch 37
Transmission 34
Rear Wheel 70 tooth standard
Driving Gear Ratios (standard):
1st Gear 2.94 : 1.00
2nd Gear 2.21 : 1.00
3rd Gear 1.60 : 1.00
4th Gear 1.23 : 1.00
5th Gear 1.00 : 1.00
6th Gear (optional) 1.00 : 0.86
G. Electrical Specifications:
Battery 12 volt negative ground
Spark Plug Champion
Type RN12YC
Gap 0.040 inches
Size Thread 14 mm

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
12
1-2
H. Tire Specifications:
• FOLLOWING PROPER PROCEDURES FOR YOUR MOTORCYCLE TIRES AND RIMS IS CRITICAL
TO YOUR SAFETY.
• USE ONLY TIRES MEETING AMERICAN IRONHORSE SPECIFICATIONS AS OUTLINED IN “AMERICAN
IRONHORSE CONSUMABLE TABLE.” NEVER MISMATCH TIRES, TUBES, RIMS OR AIR VALVES – THIS
COULD RESULT IN TIRE FAILURE.
• ALWAYS USE TUBED TYPE TIRES WITH WIRE SPOKE WHEELS AND TUBELESS TYPE TIRES WITH CAST,
DISC OR BILLET WHEELS. IN ADDITION, PROTECTIVE RUBBER RIM LINERS MUST ALWAYS BE
EMPLOYED WITH WIRE SPOKE WHEELS.
• NEVER SWAP FRONT AND REAR TIRES. THEY ARE NOT INTERCHANGEABLE AND CAN LEAD TO VEHICLE
INSTABILITY IN USE.
• NEVER EXCEED MAXIMUM INFLATION PRESSURE AS INDICATED ON TIRE SIDEWALL.
• NEVER INSTALL A NEW WHEEL/TIRE ASSEMBLY WITHOUT PROPER BALANCING.
Front Tire Size 130/70 VB 18 tire
Front Wheel Size 18" x 3.00" D. rim
Front Tire Size 90/90 H 21 tire
Front Wheel Size 21" x 2.15" D. rim
Rear Tire Size 180/55 VB 18 tire
Rear Wheel 18" x 5.50" D. rim
Rear Tire Size 240/40 H 18 tire
Rear Wheel 18" x 8.50" D. rim

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
13
1-2
I. Brake Specifications:
Rotor Diameter Calipers # Pistons
Front – All Models 11.5” 1 4
or AIH equivalent
Rear – All Models 11.5” 1 4
or AIH equivalent

AMERICAN IRONHORSE VEHICLE SPECIFICATIONS
14
1-2
J. Fueling & Fuel Specifications:
Always use a high quality, high octane unleaded fuel. Minimum octane should be 91 to ensure maximum
engine performance.
•ALWAYS REMOVE GAS TANK CAP SLOWLY. PRESSURE BUILD UP IN FUEL TANKS CAN CAUSE GASOLINE
FLUID AND MIST TO CONTACT PERSON REFUELING.
• ALWAYS FILL TANK SLOWLY AND LEAVE THE TANK NECK SPOUT VOID AS FUEL EXPANDS WITH AMBIENT,
AND OPERATING, TEMPERATURE INCREASES.
• ALWAYS ENSURE THAT GAS TANK CAP IS SECURELY TIGHTENED AFTER REFUELING, TAKING SPECIAL CARE
NOT TO CROSS THREAD.
Note that the gas caps are a left and right thread and cannot be interchanged. Only the right cap is vented.
WARNING:
• GASOLINE WITH FUEL ADDITIVES MAY CAUSE DAMAGE TO VEHICLE PARTS.
• GASOLINE SPILLS CAN DISCOLOR VEHICLE PAINT AND FINISHES.
• GASOLINE WITH METHANOL ADDITIVES SHOULD NOT BE USED.

ENGINE BREAK-IN PERIOD
15
1-3
The Critical First 500 Miles
Your AMERICAN IRONHORSE motorcycle has been operated on a ride-out dyno by a trained AMERICAN
IRONHORSE mechanic prior to shipment. Besides initiating the critical engine “break-in” period, a check of
proper in-use systems operations has been conducted and any noted deficiencies corrected.
Now it is your turn to complete the critical engine “break-in” period. (Improper engine break-in may void
your AMERICAN IRONHORSE limited warranty.)
First 500 Miles:
• Do not overrev the engine during break-in period.
• Never rev the engine in neutral gear.
• Avoid running engine in 4th or 5th gear at very low rpm.
• Never hold engine speed constant for long periods of time; vary the speed frequently.
• Avoid “jackrabbit” starts or racing from a standstill with engine throttle wide open.
• Change oil and filter.
1000 Miles:
• Avoid engine overheating.
• Keep speed at or below 65 mph maximum.
• Vary engine speed.
• Change oil and filter.
Over 2000 Miles – HAVE FUN AND RIDE SAFELY!

IGNITION SWITCH
16
2-1
OPERATION: FEATURES, CONTROLS & INDICATORS
A key to prevent unauthorized use controls access to the ignition switch. Always lock the ignition switch
and remove the ignition switch key when vehicle is not in use. The ignition switch is wired to activate the
headlight.
DO NOT MODIFY IGNITION SWITCH TO BYPASS THIS FEATURE. ALWAYS OPERATE YOUR AMERICAN
IRONHORSE WITH THE HEADLIGHT ON TO IMPROVE YOUR VISIBILITY TO OTHERS FOR IMPROVED SAFETY.
The ignition switch (Fig. 1 Letter B ) has two operative positions as wired from the factory. The
“off/lock” mode is located approximately at the 12 o’clock position. The switch mechanism is activated
by inserting the key into the ignition key slot and turning the switch mechanism straight up and down and
parallel with the bike frame.
To reach the “ON” position, rotate the ignition switch to approximately the 2 o’clock position. The
headlight will come on when the switch has been positioned in the “ON” position.

ENGINE THROTTLE SPEED CONTROLS
17
2-2
OPERATION: FEATURES, CONTROLS & INDICATORS
Engine speed is controlled by the Engine Throttle Control Grip (Fig. 2 Letter A )
• Turn the Engine Throttle Control Grip counterclockwise (towards the operator) to increase engine speed.
• Turn the Engine Throttle Control Grip clockwise (away from operator) to reduce engine speed.
An Engine Throttle Tension Adjustment Screw (Fig. 2 Letter B ) is provided to increase or decrease
gripping pressure required to activate throttle control.
Unscrew the Engine Throttle Tension Adjustment Screw such that the throttle control returns to the idle
position when operator’s hand is removed. This is the normal operating tension for the throttle control grip.
The Engine Throttle Tension Adjustment Screw may be screwed in from the normal operating tension to
reduce the continuous grip pressure that the operator must apply to keep the Engine Throttle Control Grip
activated. This will reduce operator fatigue on long highway trips.

FUEL/AIR MIXTURE LEVER (CHOKE)
18
2-3
OPERATION: FEATURES, CONTROLS & INDICATORS
Your AMERICAN IRONHORSE has been tuned at the factory for optimum fuel-to-air mixture ratio. However, to
facilitate initial starting of the engine, it is sometimes necessary that the fuel-to-air mixture ratio be increased
with a higher concentration of fuel than what is required for normal, warm engine operation.
This temporary adjustment to fuel-to-air mixture ratio is accomplished by adjusting the fuel/air mixture
lever (CHOKE or enrichener). See Section 2-4 Starting Procedures.
As the CHOKE or enrichener is engaged, engine speed will increase as a richer fuel mixture is delivered to
the engine. During normal operation, the CHOKE should always be in the “OFF” (fully depressed) position.
WARNING:
OPERATING ENGINE FOR EXTENDED PERIODS WITH THE FUEL/AIR MIXTURE LEVER (CHOKE) IN THE “ON”,
ENGAGED POSITION MAY CAUSE IMPROPER ENGINE PERFORMANCE AND FOULING OF SPARK PLUGS.

STARTING AND STOPPING ENGINE
19
2-4
OPERATION: FEATURES, CONTROLS & INDICATORS
To facilitate an easy start of the vehicle’s engine, the following choking, throttle speed control sequence is
recommended. Always ensure transmission is in the “NEUTRAL” position. Determine if your American
IronHorse motorcycle came equipped with an S&S carburetor or a Mikuni carburetor (ask your dealer), and
follow appropriate starting instructions.
A. FOR COOL WEATHER (lower than 45˚F) AND COOL ENGINE with S&S carburetor (Fig. 5 ):
• Turn fuel petcock (located on bottom of left tank to “ON” position.)
• Twist throttle control grip counterclockwise (toward operator) two times and return grip to engine
idle position.
• Pull up enrichener lever (Letter C ) to its maximum extended position. Lever is located just above and
to the rear of the S&S air cleaner cover.
• Start engine.
• Twist throttle speed control grip as required to keep engine running.
• After engine has run for a period long enough to warm-up (usually no longer than 1 minute) depress the
enrichener to the “OFF” position.
NOTE: If enrichener is left on while throttle is actuated, the spark plugs will foul and cause motor to
perform poorly. To fix fouled plugs, remove and replace.

STARTING AND STOPPING ENGINE
20
2-4
OPERATION: FEATURES, CONTROLS & INDICATORS
B. FOR COOL WEATHER (lower than 45˚F) AND COOL ENGINE with Mikuni carburetor (Fig. 3 ):
• Turn fuel petcock (locate on bottom of left tank) to “ON” position.
• Twist throttle control grip counterclockwise (toward operator) two times and turn grip to engine
idle position.
• Pull out choke knob (Letter A ). Knob is located above horn bracket on all softstyle models, and to the
rear of the coil on a rubber mounted models.
• Start engine.
• Twist throttle speed control grip as required to keep engine running.
• After engine has run for a period long enough to warm-up (usually no longer than 3 minutes) depress
the choke knob inward to the “OFF” position.
NOTE: If choke is left on while throttle is actuated, the spark plugs will foul and cause motor to perform
poorly. To fix fouled plugs, remove and replace.
C. FOR WARMER WEATHER (above 45˚F) AND COOL ENGINE for both carburetor types:
Use similar procedures as indicated in the preceding paragraph (A) but reduce the warm-up time and
choke by approximately one half.
D. FOR ENGINE ALREADY WARM OR HOT FROM RECENT PRIOR USE:
• Turn fuel petcock to “ON” position.
• Ensure choke is in the “OFF,” fully pushed-in position.
• Twist throttle counterclockwise approximately one quarter turn.
• Start engine.