Excelsior-HENDERSON HCX 1999 How to use

6999-0003 7/15/99
FOREWORD
6999-0003 7/15/99
All 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: 612.873.7000/FAX: [phone]
Copyright© 1999 Excelsior-Henderson Motorcycle Manufacturing Company. All rights reserved. Excelsior-Henderson, the X & Bar logo,
Super X, Rider’s Handbook, and Examinator are trademarks of the Excelsior-Henderson Motorcycle Manufacturing Company. Dunlop is
a registered trademark of the Dunlop Tire Corporation. Loctite is a registered trademark of the Loctite Corporation.

FOREWORD
6999-0003 7/15/99 i
INTRODUCTION
Notice
This is a preliminary draft of the Service
Handbook. It is a subset of the information and
procedures that will appear in the final version. A
limited number of photographs and illustrations
appear in this draft; space is reserved for those
that are missing. The revision date is noted at the
bottom of each page next to the document part
number.
This preliminary Service Handbook has been prepared
exclusively for Excelsior-Henderson Service
Technicians.
We have arranged the procedures in the Service
Handbook to be simple and complete, reducing the
need to search for additional information.
To ensure competent and durable repair or replacement,
follow instructions carefully. Thoroughly read the
procedure for the component you’re servicing, before
you begin the procedure. It can save you time and
unnecessary disassembly.
SPECIAL SYMBOLS AND TERMS IN THE
HANDBOOK
The hazard symbol indicates a potential
hazard to yourself, others, or the motorcycle.
Pay special attention to information in the
Handbook that begins with this symbol.
The following terms have special meaning in the
Handbook. Be certain you understand the meaning of
each term, as the terms communicate important
information about the motorcycle and its operation and
maintenance.
WARNING
!
Indicates a potential hazard that could injure you
or others.
Caution
!
Indicates a potential hazard that could damage
the motorcycle.
Notice
Emphasizes important information that might
otherwise be overlooked.
DEALER SUPPORT
NORTH/NORTHEAST REGIONAL SALES
PH 1-612-873-7032
FAX [phone]
WEST/NORTHWEST REGIONAL SALES
Phone: [phone]
Fax: [phone]
SOUTH/SOUTHWEST REGIONAL SALES
Phone: [phone]
Fax: [phone]
ORDERING
Fax: [phone]
TECHNICAL
Phone: [phone]
Fax: [phone]
WARRANTY
Phone: [phone]
Fax: [phone]
CONSUMER SUPPORT
Phone: [phone]
SPECIAL TOOLS
Ordering special tools is easy and convenient.
Simply contact:
Mail: Kent-Moore*
SPX Corporation
OE Tool and Equipment Group
28635 Mound
Warren, MI 48092-3499
Phone: [phone]
Fax: [phone]
*Also use this address for order follow-up, unlisted tool
information, claims, repairs and pricing conformation.
!

ii 6999-0003 7/15/99
FOREWORD
REPLACEMENT PARTS
Use only genuine Excelsior-Henderson replacement
parts. This is your insurance the parts you are using
are specifically designed, engineered and
manufactured for an Excelsior-Henderson motorcycle.
SERVICE BULLETINS
Additional information, in the form of Service Bulletins
are issued to Excelsior-Henderson Dealers on a
periodic basis. Service Bulletins inform Dealers of
product changes, interim engineering changes and
improvements, in addition to supplementary dealer
information.
WARRANTY BULLETINS
Warranty Bulletins contain information on warranty
amendments or warranty campaigns. They are issued to
Excelsior-Henderson Dealers as necessary.
SERVICE PREPARATION
Preparation is an important part of maintenance or
service. Taking the time to prepare your tools, work
area, the motorcycle and supplies permits you to
perform procedures as quickly and easily as possible.
If the motorcycle is dirty it should be cleaned before
starting maintenance or service. Cleaning the
motorcycle can uncover the source of problems, saving
you time troubleshooting.
SERVICE INFORMATION
Notice
• Use genuine Excelsior-Hendersonreplace-
ment parts and lubricants, or substitute parts
and/or lubricants recommended by Excelsior-
Henderson.
• Special tools should be used as service
procedures recommend to avoid damaging
parts, incorrect assembly and/or installation.
• Wear safety glasses and proper safety
equipment when performing service,
maintenance, or shop procedures. Always use
safe shop practices.
• Clean parts upon dissembly. Inspect parts and
equipment for abnormal wear or damage.
• When replacing or servicing engine
components, or performing multiple
disassembly tasks simultaneously, mark the
disassembled parts to ensure they are installed
in their original location.
• When replacing parts, or preforming
maintenance, install new gaskets, O-rings,
cotter pins, snap rings, and seals.
• Lubricate all moving parts with an assembly
lubricant or a specified lubricant during
assembly.
• Apply the recommended thread locker,
adhesives, or sealing compounds as stated in
the procedures. Always follow the
manufacturer’s instructions when using these
items.
• When tightening nuts or bolts, use the
recommended torque pattern. If a procedure
does not have a specified torque pattern,
tighten diagonally (star pattern), using
incremental steps until the proper torque is
reached.
• When tightening nuts or bolts, use the specified
torque.

FOREWORD
6999-0003 7/15/99 iii

CONTENTS
6999-0003 7/15/99 iv
ROUTINE MAINTENANCE . . . . . . . . . . . . . 1
BODY/EXHAUST . . . . . . . . . . . . . . . . . . . . . 2
LUBRICATION SYSTEM . . . . . . . . . . . . . . . 3
ENGINE CONTROL SYSTEM . . . . . . . . . . . 4
ENGINE REMOVAL/INSTALLATION . . . . . 5
CYLINDER HEAD/CAM DRIVE. . . . . . . . . . 6
CYLINDER/PISTON. . . . . . . . . . . . . . . . . . . 7
CRANKCASE/CRANKSHAFT. . . . . . . . . . . 8
PRIMARY DRIVE. . . . . . . . . . . . . . . . . . . . . 9
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . 11
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT SUSPENSION/STEERING . . . . . . 13
REAR SUSPENSION. . . . . . . . . . . . . . . . . 14
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY/CHARGING SYSTEM . . . . . . . 16
STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIGHTS/GAUGES/SWITCHES . . . . . . . . . 18
WIRING SCHEMATIC . . . . . . . . . . . . . . . . 19

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ROUTINE MAINTENANCE 1

1. ROUTINE MAINTENANCE
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SERVICE INFORMATION
GENERAL
TORQUE VALUES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INFORMATION . . . . . . . . . . 1-1
TROUBLESHOOTING . . . . . . . . . . . . . 1-2
MAINTENANCE INTERVALS. . . . . . . . 1-2
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . 1-3
AIR FILTER ELEMENT . . . . . . . . . . . . 1-3
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . 1-3
CHECK TENSION . . . . . . . . . . . . . . . . . . 1-4
ADJUST TENSION . . . . . . . . . . . . . . . . . 1-4
THROTTLE CABLES . . . . . . . . . . . . . . 1-5
FUEL HOSE/RAIL . . . . . . . . . . . . . . . . 1-5
EMISSION CONTROL SYSTEM . . . . . 1-5
OXYGEN SENSOR. . . . . . . . . . . . . . . . 1-6
HYDRAULIC CONTROLS. . . . . . . . . . .1-6
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 1-6
LEVERS AND PEDAL. . . . . . . . . . . . . . . 1-6
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . 1-7
SPARK PLUGS . . . . . . . . . . . . . . . . . . .1-7
STEERING HEAD BEARINGS . . . . . . .1-7
BATTERY. . . . . . . . . . . . . . . . . . . . . . . .1-7
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
WHEELS AND SPOKES. . . . . . . . . . . .1-8
SIDESTAND. . . . . . . . . . . . . . . . . . . . . .1-8
NUTS/BOLTS/FASTENERS . . . . . . . . .1-8
ROAD TEST. . . . . . . . . . . . . . . . . . . . . .1-9
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT

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ROUTINE MAINTENANCE
TROUBLESHOOTING
MAINTENANCE INTERVALS

ROUTINE MAINTENANCE
6999-0003 7/15/99 1-3
(StepNumber)
(StepNumber)
(StepNumber)
ENGINE OIL
1. 2.
AIR FILTER ELEMENT
1. 2.
DRIVE BELT
Check the drive belt condition . . .
1. 2.

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ROUTINE MAINTENANCE
(StepNumber)
(StepNumber)
(StepNumber)
CHECK TENSION
1. Mount the motorcycle and bring it to a vertical position.
Notice
• The motorcycle should be dry and at room
temperature.
• The rear suspension should be properly adjusted (see
SHOCK ABSORBER ADJUSTMENT page 14-2).
2. Position the small O-ring on the belt tension gauge
directly over the 10 lb mark on the plunger.
Tool: Belt tension gauge EH-6999-0038
3. Place the base of the tension gauge bracket squarely
against the lower strand of the drive belt at the front of the
lower belt guard. On the lower belt guard, mark the position of
the base of the tension gauge bracket. This mark represents
zero force.
4. Push the plunger upward until the small O-ring touches
the tension gauge body. Make sure the tension gauge is
seated squarely against the drive belt, and move the large
O-ring until it aligns with the zero force mark you made on the
lower belt guard.
1. TENSION GAUGE
2. SMALL O-RING
3. PLUNGER
4. BASE OF BRACKET
5. BODY
6. LARGE O-RING
7. LOWER BELT GUARD
5. Remove the belt tension gauge and measure the
distance between the base of the tension gauge bracket and
the large O-ring.
Standard: 1/4 - 3/8" deflection
6. Adjust belt tension if necessary.
1. DRIVE BELT
ADJUST TENSION
1. Loosen the axle adjuster jam nuts and turn both
adjusters an equal amount.
Notice
• The axle nut must be loose before adjusting drive belt
tension.
• Make sure the axle adjusters are firmly seated against
the adjuster collars.
2. Check the drive belt tension and readjust if necessary.
1. ADJUSTER 2. ADJUSTER COLLAR
10035

ROUTINE MAINTENANCE
6999-0003 7/15/99 1-5
(StepNumber)
(StepNumber)
(StepNumber)
(StepNumber)
3. Tighten the adjuster jam nuts.
4. Tighten the rear axle castle nut.
Torque: 111 ft-lbs
5. Install a new rear axle cotter pin.
Caution
Always use a new cotter pin when installing the rear axle
nut.
1. COTTER PIN
2. CASTLE NUT
3. ADJUSTER JAM NUT
4. ADJUSTER
THROTTLE CABLES
1. 2.
FUEL HOSE/RAIL
1. 2.
EMISSION CONTROL SYSTEM
(CALIFORNIA MODELS ONLY)
1. 2.

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ROUTINE MAINTENANCE
(StepNumber)
(StepNumber)
(StepNumber)
(StepNumber)
OXYGEN SENSOR
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.
HYDRAULIC CONTROLS
inspect all hoses and connections . . .
Make sure the front and rear brake light switches . . .
1. 2.
FLUID LEVEL
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.
LEVERS AND PEDAL
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.

ROUTINE MAINTENANCE
6999-0003 7/15/99 1-7
(StepNumber)
(StepNumber)
(StepNumber)
(StepNumber)
BRAKE PADS
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.
SPARK PLUGS
1. 2.
STEERING HEAD BEARINGS
Turn bars side to side . . .
Lift and . . . front to back
To adjust, refer to Front Suspension Chapter.
1. 2.
BATTERY
1. 2.

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ROUTINE MAINTENANCE
(StepNumber)
(StepNumber)
(StepNumber)
(StepNumber)
TIRES
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.
WHEELS AND SPOKES
1. 2.
SIDESTAND
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.
NUTS/BOLTS/FASTENERS
1. 2.

ROUTINE MAINTENANCE
6999-0003 7/15/99 1-9
(StepNumber)
(StepNumber)
ROAD TEST
1. 2.
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
(StepCaptionHold) “Used to hold table height consistency”
1. 2.

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ROUTINE MAINTENANCE

ROUTINE MAINTENANCE
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ROUTINE MAINTENANCE
NOTES
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