Excelsior-HENDERSON 1999 HCX User manual

RIDER'S HANDBOOK

A
ll text, photographs, and illustrations in this handbook are based on the most
current product information available at the time of publication. Product
improvements or other changes may result in differences between this handbook
and the motorcycle. Excelsior-Henderson reserves the right to make production
changes at any time, without notice and without incurring any obligation to make
the same or similar changes to motorcycles previously built.
EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY
805 HANLON DRIVE • BELLE PLAINE, MINNESOTA 56011 • TELE: 952.873.7000/FAX: [phone]
Copyright©2009 Excelsior-Henderson Motorcycle Manufacturing Company. All rights reserved. Excelsior-Henderson,
the X & Bar logo, Super X, the Super X Logo, Rider’s Handbook, X-Twin and Road Crew are trademarks of
Excelsior-Henderson Motorcycle Manufacturing Company. Dunlop is a registered trademark of Dunlop Tire Corporation.
Features of the Super X motorcycle are covered by U.S. Patent No. D.406,088 with additional patents pending.
Document part no. 6999
-
0001 Rev. D Printed in the United States of America

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1999 Super X

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1931 Super X

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i
Forward
Thank You!
The people of Excelsior-Henderson thank you for purchasing your new Super X
motorcycle. We appreciate your enthusiasm and faith in our products and in us.
Your new Super X is an American-made, premium-quality, heavyweight cruiser. It
combines advanced technologies with a style reminiscent of its ancestors. We have
designed, built, and will support your Super X in the tradition of The
Excelsior-Henderson Motorcycle Manufacturing Company.

ii Forward
There’s More to The Rider’s Handbook
The Super X Rider’s Handbookcontains information you need to operate
your Excelsior-Henderson Super X safely, responsibly, and with maximum
enjoyment. It also explains the routine maintenance, cleaning, and storage that
will help keep your Super X running and looking great for years to come.
To make the most of your Super X EXperience, this Handbook also includes
stories, photographs, and illustrations from throughout Excelsior-Henderson’s
history. In the section “The Tradition of the State of the Art” the Rider’s
Handbook introduces you to the heritage that is an essential part of the Excelsior-
Henderson EXperience and reestablishes our place in the history of American
motorcycling.
You, the Super X, and the Excelsior-Henderson Motorcycle Manufacturing
Company each have a place in the continuing history of American motorcycling.
• As a Super X owner, you make your own contribution to the
Excelsior-Henderson heritage that began over a century ago and continues with
today’s Excelsior-Henderson Motorcycle Manufacturing Company.
• The 1999 Super X bears the rich heritage of the original Super X and its
manufacturer’s history and tradition.
• The Excelsior-Henderson Motorcycle Manufacturing Company is the first
American manufacturer to successfully revive an original American motorcycle
brand.

F
orward iii
“It’s not so much the destination that matters, but the journey”
—
motorcyclists
may understand this better than anyone. When you twist the throttle of your
Super X along an open stretch of highway or through a deep curve, you will
discover the roar of the X-twin™ engine as the road disappears behind you. With
the images and stories of Excelsior-Henderson’s present and past in mind, you will
EXperience the spectacular vision of the journey before you. Enjoy the ride!
From the Hanlon Famil
y
On behalf of the entire Excelsior-Henderson Road CrewTM, we welcome you to
our family. When you own an Excelsior-Henderson Super X, you own much more 10372
than just a motorcycle, you own an enduring legacy of quality and
performance. You are part of the American dream…and you are part of
our dream. Together we will make motorcycling history as we bring back
the most legendary brand of the past
—
Excelsior-Henderson.
The Excelsior-Henderson team members are proud you selected the Super
X, as we have designed and manufactured the Super X to the highest
standards. This Rider’s Handbook has been specially prepared and
detailed to show you our commitment to ensure motorcycling fun.
We wish you a safe and pleasurable ride as together we carry forward a
proud tradition that dates back to 1876. So, get ready to throw a leg over
your Super X and join us on the highways of this great country, the United
States of America.
Dan Hanlon
J
ennie Hanlon Dave Hanlon

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v
Introduction....................................................................1
Read the Rider’s Handbook................................................1
Hazard Symbol and Terms in the Rider’s Handbook.............2
Safety Information ..........................................................5
Safe Riding.......................................................................6
Super X Design Characteristics......................................6
Safe Riding Practices....................................................7
Carrying a Passenger..................................................11
Transporting the Super X ...........................................12
Protective Apparel...........................................................12
Product Modifications ......................................................13
Gross Vehicle Weight Rating............................................14
Loading..........................................................................15
Selecting and Installing Accessories...................................17
Gasoline and Exhaust Gases.............................................18
Parking ..........................................................................19
Maintenance...................................................................20
Safety and Vehicle Information Labels...............................22
Contents

vi Contents
Reporting Safety Defects.................................................25
Product Description ......................................................27
Vehicle Components.......................................................28
Vehicle Identification Number (VIN)..................................30
Engine Identification Number...........................................31
Key Identification Number ...............................................32
Instruments and Controls ..............................................35
Location ........................................................................35
Key ...............................................................................37
Fork Lock ......................................................................37
Main Switch...................................................................38
Instrument Pod...............................................................40
Indicator Lights..........................................................40
Headlamp High Beam Indicator.............................41
Check Engine Indicator .........................................41
Turn Signal Indicator.............................................41
Neutral Indicator...................................................42
Low Oil Pressure Indicator.....................................42
Low Battery Voltage Indicator................................42
Low Fuel Indicator................................................43

viiContents
Speedometer .............................................................43
Odometer/Trip Meter............................................43
Odometer/Trip Meter Function Button ...................44
Tachometer...............................................................44
Fuel Gauge................................................................44
Handlebar Controls .........................................................45
Left Side Handlebar Controls ......................................45
Clutch Lever.........................................................45
Left Mirror............................................................45
Headlamp Dimmer Switch .....................................46
Turn Signal Switch................................................46
Horn Button.........................................................46
Right Side Handlebar Controls ....................................47
Front Brake Lever.................................................47
Throttle Control Grip.............................................47
Right Mirror..........................................................47
Engine Stop/Run Switch........................................48
Emergency Flasher Switch .....................................48
Electric Starter Button............................................49
Foot Controls..................................................................49

viii Contents
Gear Shift Pedal ........................................................49
Rear Brake Pedal.......................................................50
Fuel Cap........................................................................50
Rear Suspension Adjustment............................................51
Location of Adjusters .................................................52
Factory Adjustment Settings........................................52
Adjusters and Their Setting Ranges .............................52
Changing Adjustment Settings ....................................53
Changing Preload Adjustment................................54
Changing Damping Rate Adjustment......................57
Effects of Rear Suspension Adjustments.......................58
Sidestand.......................................................................61
Saddles..........................................................................61
Pre-Operation Check.....................................................63
Fuel...............................................................................64
Fuel Level .................................................................64
Fuel Hose, Rail, and Connections................................64
Evaporative Emission Control System
(California model only)................................................64
Engine Oil Level .............................................................65

ixContents
Tires ..............................................................................66
Tire Pressure .............................................................66
Tire Condition ...........................................................67
Tread Depth..............................................................67
Drive Belt.......................................................................68
Steering..........................................................................68
Hydraulic Controls — Clutch and Brakes...........................68
Check Hoses and Connections....................................68
Check Front Brake & Clutch Fluid Level.......................69
Check Rear Brake Fluid Level......................................69
Check Clutch Lever Movement....................................69
Check Front Brake Lever Movement............................70
Check Rear Brake Pedal Movement.............................70
Check Brake Pads...........................................................71
Throttle Control Grip and Cables......................................71
Electrical Equipment........................................................72
Engine Stop/Run Switch.............................................72
Instrument Pod ..........................................................72
Headlamp..................................................................73
Brake Light................................................................73

xContents
Running Lights..........................................................73
Turn Signals..............................................................73
Sidestand.......................................................................74
Fasteners .......................................................................74
Operation and Riding ....................................................77
Operating During Break-In Period (First 500 Miles)............78
Fueling and Fuel Fill Height .............................................79
Starting the Engine .........................................................80
Jump-Starting............................................................82
Shifting Gears.................................................................84
Recommended Shift Points..............................................87
Accelerating...................................................................88
Braking..........................................................................89
Stopping the Engine .......................................................90
Parking..........................................................................91
Maintenance .................................................................95
New Motorcycle Break-In Maintenance.............................96
Periodic Maintenance Intervals.........................................96
Engine Oil......................................................................99
Change Oil and Oil Filter............................................99

xiContents
Check Oil Level........................................................101
Air Filter Element..........................................................103
Drive Belt.....................................................................104
Check Drive Belt Tension .........................................104
Adjust Drive Belt Tension..........................................105
Check Drive Belt Condition.......................................106
Throttle........................................................................107
Check Throttle Control Grip and Cables.....................107
Adjust Throttle Freeplay............................................107
Fuel Hose, Rail, and Connections...................................108
Evaporative Emission Control System
(California model only)..............................................108
Oxygen Sensor .............................................................109
Hydraulic Controls — Clutch and Brakes.........................110
Check Hoses and Connections..................................110
Check Front Brake & Clutch Fluid Level.....................110
Check Rear Brake Fluid Level....................................111
Add Hydraulic Fluid..................................................111
Check Clutch Lever Movement..................................112
Check Front Brake Lever Movement..........................113

xii Contents
Check Rear Brake Pedal Movement ..........................113
Check Brake Pads.........................................................114
Spark Plugs..................................................................114
Inspect Spark Plugs..................................................114
Remove Spark Plugs................................................115
Replace Spark Plugs ................................................116
Saddles........................................................................117
Tandem Saddle........................................................117
Rider’s Saddle..........................................................118
Battery.........................................................................119
Remove Battery.......................................................120
Charge Battery........................................................121
Install Battery ..........................................................122
Electrical Equipment......................................................123
Replace Fuse...........................................................123
Check Engine Stop/Run Switch................................124
Check Instrument Pod Lights....................................124
Replace Instrument Pod Light Bulb............................125
Check Headlamp.....................................................125
Replace Headlamp Sealed Beam Lamp .....................126

xiiiContents
Check Brake Light ...................................................126
Replace Brake/Tail or License Plate Light Bulb...........127
Check Running Lights ..............................................127
Check Turn Signals ..................................................128
Replace Turn Signal/Running Light Bulb....................128
Steering........................................................................129
Inspect Steering Movement.......................................129
Inspect Steering Head Bearings.................................129
Tires ............................................................................130
Check Tire Pressure .................................................130
Check Tire Surface Condition....................................130
Check Tread Depth..................................................130
Wheels.........................................................................131
Check Spokes..........................................................131
Remove Front Wheel................................................132
Inspect Front Wheel Bearings....................................133
Install Front Wheel ...................................................134
Remove Rear Wheel.................................................135
Inspect Rear Wheel Bearings.....................................137
Install Rear Wheel ....................................................138

xiv Contents
Align Rear Wheel.....................................................139
Sidestand.....................................................................141
Fasteners .....................................................................141
Road Test ....................................................................142
Cleaning and Storage..................................................145
Cleaning ......................................................................145
Washing and Drying.................................................146
Waxing, Polishing, and Applying Protectants..............148
Repairing Painted Surface Damage ...........................149
Storage........................................................................149
Preparing for Storage...............................................150
Choose an Adequate Storage Location.................150
Clean and Protect the Motorcycle.........................150
Stabilize Fuel......................................................151
Protect Engine Components................................151
Inflate Tires........................................................152
Remove, Clean, and Store Battery .......................152
Park and Cover the Motorcycle............................153
Maintaining During Storage......................................153
Removing from Storage ...........................................153