Excelsior-HENDERSON 1999 HCX, Super X HCX 1999 Riders Handbook

RIDER'S HANDBOOK

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: 612.656.4204

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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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, clea ning, 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 ExcelsiorHenderson 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.

orward

“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

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 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.

iii

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Dan Hanlon

ennie Hanlon Dave Hanlon

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Contents

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

vi Contents

Product Description ...................................................... 27

Instruments and Controls ..............................................35

Reporting Safety Defects.................................................25

Vehicle Components.......................................................28

Vehicle Identification Number (VIN)..................................30

Engine Identification Number...........................................31

Key Identification Number ...............................................32

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

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

viiContents

Foot Controls..................................................................49

viii Contents

Pre-Operation Check.....................................................63

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

Fuel...............................................................................64

Fuel Level .................................................................64

Fuel Hose, Rail, and Connections................................64

Evaporative Emission Control System

(California model only)................................................64

Engine Oil Level .............................................................65

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

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Brake Light................................................................73

x Contents

Operation and Riding....................................................77

Maintenance .................................................................95

Running Lights.......................................................... 73

Turn Signals..............................................................73

Sidestand.......................................................................74

Fasteners .......................................................................74

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

New Motorcycle Break-In Maintenance.............................96

Periodic Maintenance Intervals.........................................96

Engine Oil......................................................................99

Change Oil and Oil Filter............................................99

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

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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

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

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Install Rear Wheel ....................................................138

xiv Contents

Cleaning and Storage..................................................145

Align Rear Wheel.....................................................139

Sidestand.....................................................................141

Fasteners .....................................................................141

Road Test ....................................................................142

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

Our Tradition of State of the Art.................................. 157

Traditions Alive Today ..................................................160

The 1999 Super X ..................................................160

The Company.........................................................166

The Road from 1993 through 1998...............................172

The Trail from 1876 through 1931................................185

1876-1910: The Beginnings of Excelsior...................186

1911-1917: The Joining of Forces ...........................190

1918-1925: Excelsior-Henderson and The Super X....210

1926-1931: The Birth of the “Cruiser” .....................224

Specifications............................................................. 235

Fuel Specifications........................................................238

Engine Oil Specifications...............................................239

Torque Specifications....................................................240

Identification Numbers for Your Super X.........................242

Index ......................................................................... 245

xvContents

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Introduction

Read the Rider’s Handbook

The Rider’s Handbook contains information that is essential to safe riding and proper maintenance of your Super X motorcycle. Read it thoroughly before you ride. Understand and follow the procedures in the Rider’s Handbook to keep your Super X in top condition on the road or in storage. Failure to follow operation and maintenance procedures may result in injury to you, your passenger, or damage to your Super X. We want you to enjoy motorcycling. Following the safety and maintenance procedures will add to your enjoyment, and keep you riding.

2 Introduction

Hazard Symbol and Terms in the Rider’s Handbook

The hazard symbol indicates a potential hazard to you, others, or your motorcycle. Pay special attention to information in the

Rider’s Handbook that begins with this symbol.

The following terms have special meaning in the Rider’s Handbook. Be certain you understand the meaning of each term, as the terms communicate important information about the Super X 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.

Notes:

3Introduction

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Safety Information

This section contains information to help you operate your Super X motorcycle safely and enjoyably while minimizing risk to you, your passenger, and others. Your ability to safely operate the Super X depends on your judgment and use of safe riding techniques. Motorcycling has inherent risks. You can minimize those risks, but you can’t eliminate them completely.

We want to keep you riding. Take the time to read and understand the following information to help minimize risk and maximize pleasure when operating the Super X. Even if you are an experienced rider , read this section and the rest of the Rider’s Handbook before riding the Super X.

• Read, understand, and use the information contained in this section. This section contains safety information specific to the Super X, as well as information about general motorcycle safety.

• Read and understand the entire Rider’s Handbook before operating the Super X; the Handbook contains safety information throughout. Also pay attention to the maintenance requirements in this Handbook. For professional technical service specified in the Rider’s Handbook or required by mechanical circumstances, see the Super X Service Handbook or your authorized Excelsior-Henderson Dealer.

• Read, understand, and use the information in the booklet you received with your Super X, You and Your Motorcycle — Riding Tips (Excelsior-Henderson

6 Safety Information

document part no. 6999-0008). The booklet contains general information about safe motorcycle operation and tips for developing safe riding habits.

• Take a rider education course from the Motorcycle Safety Foundation (MSF) or another qualified instructor. The course will help you develop or refresh your expertise in safe riding habits through instruction and riding. For information on MSF rider education courses, see the pamphlet you received with your Super X, Rider Course (Excelsior-Henderson document part no. 6999-0066).

• Until you are thoroughly familiar with the Super X and all of its controls, practice riding where there is little or no traffic. Practice riding at moderate speed on varying road surfaces and under varying weather conditions.

Safe Riding

Super X Design Characteristics

The following Super X design characteristics affect how you should ride the motorcycle:

• The Super X is designed for on-road use with one rider and one passenger. Do not exceed the gross vehicle weight rating (see Specifications or the certification label on the steering head). Riding off-road, riding with more than one passenger, or carrying weight exceeding the maximum weight rating can make handling difficult, which could cause you to lose control of the motorcycle.

• In the first 500 miles, operate the Super X according to the break-in procedures described in “Operating During Break-In Period (First 500 Miles)‚” page 78. Operating the Super X without following break-in procedures can result in serious engine damage.

• The Super X is designed not to “dive” when the front brake is applied. “Diving” is the tendency for the front suspension to compress rapidly when the front brake is applied. The anti-dive design of the Super X makes braking more positive and stable than on motorcycles without an anti-dive design. If you have ridden motorcycles without an anti-dive design, the Super X may initially feel different when you apply the front brake.

Safe Riding Practices

Follow these general safe riding practices:

• Before you ride, make sure you can operate the Super X safely and properly by following the recommendations given at the beginning of the Safety Information section.

7Safety Information

• Before you ride each time, make the checks described in the Pre-Operation Check section. Operating the Super X without making the pre-operation checks can cause damage to the motorcycle or result in an accident.

• Know your skills and limits, and ride within them.

• Allow only licensed, experienced operators to ride your Super X, and then only after they have become familiar with its controls and operation.

8 Safety Information

• Do not ride when you are fatigued or under the influence of alcohol, prescription drugs, over-the-c ounter drugs, or any other drugs. Fatigue, alcohol, and drugs can cause drowsiness, loss of coordination, loss of balance, and can affect your awareness and judgment.

• If your Super X operates abnormally, correct the problem immediately (see the Super X Service Handbook or contact your authorized Excelsior-Henderson Dealer). If you continue to operate the Super X in this condition, you are likely to aggravate the initial problem, increase the cost of repairs, and threaten your safety.

• The most common cause of accidents involving a motorcycle and an automobile is the automobile driver’s failure to see the motorcycle. Ride defensively, as if you are invisible to other motorists, even in broad daylight. Ride where you are visible to other motorists and observe their behavior carefully, as they may not see or be aware of you.

• Be especially cautious at an intersection, as this is the most likely place for an accident. Remember that you are more vulnerable to injury on a motorcycle than in an enclosed vehicle.

• To prevent loss of control while operating the motorcycle, keep your hands on the handlebars and your feet on the footrests.

• Obey the speed limit and adjust your speed and riding technique based on road, weather, and traffic conditions. As you travel faster, the influence of all other

conditions increases, which can lessen the motorcycle’s stability and increase the possibility of your losing control of the motorcycle.

• Do not move or operate the motorcycle with the forks locked, as steering is severely restricted and you could drop or lose control of the motorcycle.

• If in doubt, reduce your speed when:

- The road has potholes or is otherwise rough or uneven.

- The road has sand, dirt, gravel or other loose substances on it.

- The road is wet, icy, or oily.

- The road contains painted surfaces, manhole covers, metal grating, railway

crossings, or other slippery surfaces.

- The weather is windy, raining, or otherwise causing slippery or rapidly

changing conditions.

- The traffic is heavy, congested, not allowing sufficient space between

vehicles, or otherwise not flowing smoothly.

9Safety Information

- You are being passed in either direction by a large vehicle that produces a

wind blast in its wake.

• To maximize braking effectiveness, use the front a nd rear brakes together. Be aware of the following braking facts and practices:

- The rear brake provides 40% of the motorcycle’s stopping power, at most.

10 Safety Information

- Consider road conditions before applying the brakes; when the road is wet, rough, or contains loose or other slippery substances, apply the brakes gradually.

- Bring the motorcycle to upright position before applying the brakes, and avoid applying the brakes in a corner if at all possible. When the motorcycle is leaned, the amount of tire surface contacting the road is reduced, decreasing tire traction and increasing the possibility of the tires skidding when you apply the brakes.

- Improper braking may cause you to lose control of the motorcycle or may not slow you in time to avoid a collision.

• As you approach a curve, choose a speed and a lean angle that allow you to pass through the curve in your own lane without applying the brakes. Excessive speed, improper lean angle, or braking in a curve can cause you to lose control of the motorcycle.

• Ground clearance is reduced when you lean the motorcycle. Do not allow components to contact the road surface when leaning the motorcycle in a curve, as this could cause you to lose control of the motorcycle.

• Retract the sidestand fully before riding. If the stand is not fully retracted while you are riding, it could contact the road surface and cause you to lose control of the motorcycle.

• Do not tow a trailer. Towing a trailer can make the motorcycle hard to handle and cause you to lose control of the motorcycle.

Carrying a Passenger

To carry a passenger safely, do the following:

• Direct the passenger to hold onto you, or the saddle strap, with both hands and to keep both feet on the passenger footrests. Do not carry a passenger who cannot place both feet firmly on the passenge r footrests. A passenger who is not holding on properly or who cannot reach the passenger footrests can shift erratically, which can make the motorcycle hard to handle and cause you to lose control of the motorcycle.

• If necessary, adjust the rear shock absorber preload and damping rate according to the instructions in “Changing Preload Adjustment‚” page 54, and “Changing Damping Rate Adjustment‚” page 57. Improper preload or damping rate adjustment can make your motorcycle hard to handle and cause you to lose control of the motorcycle.

• Before you ride, be sure your passenger knows safe riding procedures. Discuss any safety information unfamiliar to your passenger. A passenger who is unaware of safe riding procedures may distract you or make movements that make the motorcycle hard to handle and cause you to lose control of the motorcycle.

11Safety Information

• Adjust your riding style to compensate for the differences in handling, acceleration, and braking caused by the additional weight of the passenger. Failure to do so can cause you to lose control of the motorcycle.

12 Safety Information

Transporting the Super X

If you must transport the Super X, do the following:

• Use a truck or trailer. Do not tow the Super X with another vehicle, as the motorcycle’s steering and handling will be impaired by towing, which can cause you to lose control of the motorcycle.

• Position and restrain the Super X so it is kept upright on the truck or trailer, as gasoline may leak out of the fuel tank if the motorcycle leans over. Leaked gasoline is a fire hazard and can also damage the finish and components of the Super X.

Protective Apparel

We respect your right to make your own choices. However, we recommend that you wear an approved helmet and eye protection. Some state laws require that you wear an approved helmet, eye protection, or both. In accidents involving motorcycles, head injuries are the leading cause of motorcyclist fatalities, and statistics prove that an approved helmet is the most effective protection in preventing or reducing head injuries. Eye protection reduces the chance that your vision could be impaired by wind or by airborne particles and objects.

You and your passenger should wear bright or light colored and/or reflective clothing to improve your visibility to other motorists. A motorist’s failure to see or recognize a motorcycle is the leading cause of automobile/motorcycle accidents.

Wear gloves, heavy boots and pants, and a jacket to prevent or reduce abrasions, lacerations, or burns that you can suffer if you fall. Wear boots with low heels because boots with high heels can catch on pedals or footrests. The combination of your boots and pants should completely cover your legs, ankles, and feet, protecting you from engine and exhaust system heat. The engine and exhaust system get hot soon after the engine is started, and stay hot for about half an hour after the engine is turned off.

Do not wear loose, flowing clothing or long boot laces, as they can catch on components like handlebars, levers, or footrests, or get caught in the wheels, causing you to lose control of the motorcycle.

Product Modifications

Modifying the Super X by removing any equipment or adding equipment not approved by Excelsior-Henderson may void your warranty. Such modifications may also make the motorcycle unsafe to ride and could severely injure you or others or damage the motorcycle. Some modifications may be illegal in some states. If in doubt, contact your authorized Excelsior-Henderson Dealer.

13Safety Information

14 Safety Information

Gross Vehicle Weight Rating

Gross vehicle weight is the total weight of the motorcycle, the rider, and the passenger.

• The weight of the motorcycle includes: the motorcycle and all its fluids; any accessories and their contents; and any additional cargo on the motorcycle.

• The weight of the rider or passenger includes: body weight, all apparel, and objects in or on apparel.

WARNING

Do not exceed the motorcycle’s gross vehicle weight rating. Exceeding the weight rating can lessen stability and handling and could cause you to lose control of the motorcycle.

The gross vehicle weight rating of the Super X is 1140 lb. The total weight of the Super X is approximately 700 lb with a full capacity of all fluids, and without any accessories or cargo. The combined weight of the rider, passenger, accessories, and cargo cannot exceed 440 lb. The following two examples show how to stay within the gross vehicle weight rating.

Example 1: Super X with no accessories or cargo

Item Weight

Super X with full capacity of all fluids 700 lb Rider - dressed and ready to ride 260 lb Passenger - dressed and ready to ride 180 lb

Total gross vehicle weight 1140 lb

Example 2: Super X with all accessories and cargo

Item Weight

Super X with full capacity of all fluids 700 lb Excelsior-Henderson accessories 80 lb Attached cargo 35 lb Rider - dressed and ready to ride 205 lb Passenger - dressed and ready to ride 120 lb

Total gross vehicle weight 1140 lb

15Safety Information

WARNING

Adding additional weight to the Super X can affect its stability, handling characteristics, and safe operating speed.

16 Safety Information

Use the following guidelines when attaching cargo or accessories to the Super X. Where applicable, these guidelines refer to accessories and their contents.

• Keep cargo and accessory weight to a minimum, and keep it as close to the motorcycle as possible, to minimize a change in the motorcycle’s center of gravity. Changing the center of gravity can lessen stability and handling and could cause you to lose control of the motorcycle.

• Distribute weight evenly on both sides of the motorcycle. Maintain even weight distribution by checking accessories and cargo to make sure they are securely attached to the Super X before riding and whenever you take a break while riding. Uneven weight distribution, or accessories or cargo that shift suddenly while you are riding, can make the motorcycle hard to handle and cause you to lose control of the motorcycle.

• Do not attach large or heavy cargo such as sleeping bags, duffle bags, or tents to the handlebars, front fork area, or front fender. If you add accessories to the handlebars or the front fork area, they must be as small and as lightweight as possible. Cargo or accessories placed in any of these areas can cause instability due to improper weight distribution or aerodynamic changes, and can cause you to lose control of the motorcycle. Such items can also block air flow to the engine and could cause overheating that can damage the engine.

• Do not exceed the maximum cargo weight limit of any accessory (see accessory instructions and labels), and do not attach cargo to an accessory not designed

for that purpose, as either of these could result in an accessory failure that could cause you to lose control of the motorcycle.

Selecting and Installing Accessories

WARNING

Adding accessories to the Super X can affect its stability, handling characteristics, and safe operating speed.

Because Excelsior-Henderson cannot test and make specific recommendations concerning every accessory or combination of a ccessories sold, you are responsible for determining that your Super X can be safely operated with accessories you install or additional weight you carry. Use the following guidelines when choosing and mounting accessories:

• Do not install accessories that impair the stability, handling, or operability of the Super X. Before installing an accessory, be sure that it does not:

17Safety Information

- Reduce ground clearance when the motorcycle is either leaned or in a vertical

position.

- Limit suspension or steering travel or your ability to operate controls.

- Displace you from your normal riding position.

- Obscure lights or reflectors.

18 Safety Information

Bulky or large accessories can make the Super X unstable due to the lifting or buffeting effects of wind and can cause you to lose control of the motorcycle.

• Do not install electrical accessories that exceed the capacity of the Super X’s electrical system. An electrical failure could result and cause hazardous loss of engine power or lights, or damage to the electrical system.

• If you want to add a windshield, backrest, or luggage rack, choose one designed and approved by Excelsior-Henderson specifically for the Super X, and follow the instructions for proper installation and use. An improperly designed or installed windshield, backrest, or luggage rack can reduce stability, causing you to lose control of the motorcycle.

Gasoline and Exhaust Gases

For fueling procedures, see “Fueling and Fuel Fill Height‚” page 79. Gasoline is highly flammable and can be explosive in certain conditions. Observe

the following precautions when you refuel or service the fuel system:

• Turn off the engine.

• Use a well-ventilated area.

• Remove the fuel cap slowly.

• Do not spill gasoline on the engine or the exhaust system. Immediately wipe, or rinse with water, gasoline spilled on any part of the Super X or the surrounding area.

• Do not smoke while fueling.

• Do not fuel in an area where there are sparks or open flame.

Gasoline and gasoline vapors are poisonous and can cause severe injury. Do not swallow gasoline, inhale gasoline vapors, or spill gasoline on yourself or your clothes. If you swallow gasoline, inhale more than a few breaths of gasoline vapor, or get gasoline in your eyes, see a physician immediately. If you spill gasoline on your skin, wash it off immediately with soap and water. If you spill gasoline on your clothes, change your clothes immediately.

Exhaust gases contain carbon monoxide, a colorless, odorless gas that can cause unconsciousness or severe injury. Observe the following precautions to avoid the effects of exhaust gases:

• Do not breathe exhaust gases.

19Safety Information

• Do not start or run the engine in a closed area.

Parking

For complete parking procedures, see “Parking‚” page 91.

20 Safety Information

When leaving the Super X unattended, turn the engine off, lock the main switch and the fork lock, and take the main switch key with you.

The engine and exhaust system are very hot after the engine has been running. Therefore, park the Super X where people are not likely to touch the engine or exhaust system or place combustible materials in close proximity to these hot areas.

Do not park near a flammable source such as a kerosene heater or an open flame, as the Super X could catch fire.

Park on a level, firm surface if possible. Sloped or soft surfaces may not support the Super X adequately when it is parked, and it may fall over . If you must park on a sloped or soft surface, reduce the likelihood of the Super X falling over by following the procedures described in “Parking‚” page 91.

Maintenance

Maintain the Super X according to the following requirements:

• Perform periodic maintenance according to the intervals specified in “Periodic Maintenance Intervals‚” beginning on page 96. Operating the Super X without performing periodic maintenance can damage the motorcycle or injure you.

• Maintain proper tire inflation pressure and tread condition, and proper wheel and tire balance. Inspect tires regularly and replace them if they are worn or damaged. Use only an approved replacement tire and see the Super X Service Handbook or your authorized Excelsior-Henderson Dealer for tire replacement. Operating the Super X with improper tire pressure or tread condition, or improper wheel or tire balance, can make the motorcycle hard to handle and cause you to lose control of the motorcycle.

• Check proper steering head bearing adjustment. Regularly inspect the rear shock absorber and the front forks. Check for leaks. Operating the Super X with a loose, worn, or damaged steering system or front or rear suspension system can make the motorcycle hard to handle and cause you to lose control of the motorcycle. T o repair steering or suspension system wear or damage, see the Super X Service Handbook or contact your authorized Excelsior-Henderson Dealer.

• Keep equipment required by federal, state, and local laws in place and in good working condition. Your license plate must be clean, clearly visible in all conditions, and installed in a position specified by law.

21Safety Information

• Each fastener used in the Super X meets our quality specifications for strength, finish, and type. If you need a replacement fastener, use only a genuine Excelsior-Henderson fastener, tightened to the proper torque. A fastener that does not meet original specifications could fail and damage the motorcycle or injure you.

22 Safety Information

Safety and Vehicle Information Labels

10378

Super X — left side view (all models)

VEHICLE EMISSION CONTROL INFORMA TION

Engine Displacement: 1386CC Engine Family: XEMCC01.4001 Engine Exhaust Emission Control: SMFI Engine Tune Up Specifications Idle Speed: 900 - 950 RPM Ignition Timing: Fixed Fuel: Unleaded Gasoline only, 92 pump octane or higher. Oil: See Rider’s Handbook

This vehicle conforms to USEPA Regulations applicable to 1999 Model Year new motorcycles.

EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY

WARNING: The rear shock absorber contains nitrogen gas under high pressure. To prevent injury, do not disassemble, rebuild, puncture, or apply heat to the shock absorber. See Rider’s Handbook.

(Under seat)

WARNING

USE ONLY DOT5 BRAKE FLUID FROM A SEALED CONTAINER. CLEAN FILLER CAP BEFORE REMOVING.

Also on rear brake and clutch reservoirs. (Not shown.)

Super X—right side view (all models)

23Safety Information

10377

MOTORCYCLE NOISE EMISSION CONTROL INFORMATION

This 1999 Excelsior-Henderson EMC42X1386 motorcycle, 4599-0029, meets USEPA noise emission requirements of 80 dBA at 2750 RPM by the Federal test procedure. Modifications which cause this motorcycle to exceed Federal noise standards are prohibited by Federal law . See Rider’s Handbook.

EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY

MOTORCYCLE EXHAUST

SYSTEM NOISE CONTROL INFORMATION

THIS EXCELSIOR HENDERSON EXHAUST SYSTEM 4599-0029 MEETS EPA NOISE EMISSION REQUIREMENTS OF 80 dB(A) FOR THE FOLLOWING MOTORCYCLES SUPER X INSTALLATION OF THIS EXHAUST SYSTEM ON MOTORCYCLE MODELS NOT SPECIFIED MAY VIOLATE FEDERAL LAW

24 Safety Information

10498

Super X—left side view (California model only)

(Under seat)

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying the Excelsior-Henderson Motorcycle Manufacturing Company.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or the Excelsior-Henderson Motorcycle Manufacturing Company.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, DC area) or write to: NHTSA, US Department of Transportation, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.

25Safety Information

10380

Product Description

This section identifies the main Super X motorcycle components and shows their locations. It gives the locations of the V ehicle Identification Number (VIN), explains the VIN code, and tells you where to find the engine identification number and the key identification number.

The Super X meets or exceeds applicable US Federal Motor Vehicle Safety Standards and US Environmental Protection Agency regulations.

28 Product Description

Vehicle Components

1. Ho rn

2. Headlamp

3. Front left turn signal/running light

4. Clutch Lever

5. Clutch fluid reservoir

6. Left mirror

7. Left handlebar controls

8. Instrument pod

Super X—left side view

9. Air filter

10. Fuses (under saddle)

11. Rider’s saddle

12. Tandem saddle

13. Left rear turn signal

14. Tail light

15. Rear axle adjuster (one each side)

16. Rear brake caliper

10381

17. Passenger footrest

18. Battery

19. Sidestand

20. Rider footrest

21. Gear shift pedal

22. Evaporative canister (California model only)

23. Front brake caliper

1. Right rear turn signal

2. Drive belt (under guard)

3. Tandem saddle

4. Rider’s saddle

5. Rear shock absorber (under saddle)

6. Main switch

7. Instrument pod

8. Throttle control grip

Super X—right side view

9. Right handlebar controls

10. Right mirror

11. Front brake fluid reservoir

12. Front brake lever

13. Throttle cables

14. Front right turn signal/running light

15. Fuel cap

16. Fork lock

17. Rear brake fluid reservoir

29Product Description

10386

18. Rear brake pedal

19. Rider footrest

20. Engine oil filter cover

21. Engine oil drain plugs (under engine)

22. Engine oil fill cap and dipstick

23. Passenger footrest

24. Exhaust mufflers

30 Product Description

Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) is a unique 17-character identifier for your Super X. The VIN is stamped on the right side of the steering head and also appears on the certification label on the front of the steering head.

You may need the VIN to title, register, or license the Super X, or to order parts. Record the VIN in the space provided in the Specifications section on page 242.

The VIN is decoded as follows:

10382

VIN stamped on steering head

Motorcycle type: HC = heavyweight cruiser

SAE-assigned World Manufacturing Identifier

5EH1HCX00XB000001

Engine type: X = X-Twin

0 = inaugural Check digit

Model year: X = 1999

Plant location: B = Belle Plaine

Serial number

Engine Identification Number

The engine identification number is a unique six-character identifier for your Super X engine, stamped on the left side of the engine.

You may need the engine identification number to title, register, or license the Super X, or to order parts. Record the engine identification number in the space provided in the Specifications section on page 242.

The engine identification number is composed of an asterisk (*), followed by the serial number portion of the Super X VIN, followed by another asterisk. For instance, the engine number is *000326* for the Super X with VIN 5EH1HCX06XB000326.

31Product Description

10383

Engine identification number stamped on

right side of engine

32 Product Description

Key Identification Number

The key identification number is a seven-character identifier for your Super X main switch and fork lock key. The key identification number is located on a key tag supplied with your Super X.

If you need a replacement key, contact your dealer, and have proof of ownership, your VIN, and your key identification number. Record the key identification number in the space provided in the Specifications section on page 242.

EH00001

Sample key identification number

Notes:

33Product Description

10 38 4

Instruments and Controls

This section shows you where to find the instruments and controls on the Super X motorcycle and explains their function and use.

Location

1. Clutch lever

2. Left handlebar switches

3. Mirrors

4. Right handlebar switches

5. Front brake lever

6. Throttle control grip

10385

7. Fuel cap

8. Odometer/trip meter

9. Odometer/trip meter function button

10. Fuel gauge

11. Tachometer

12. Speedometer

36 Instruments and Controls

19. Rear suspension adjusters (preload and damping rate adjusters) (under saddles)

20. Main switch

21. Fork Lock

22. Rear brake pedal

23. Rider footrest

24. Passenger footrest

13. Rider’s saddle

14. Tandem saddle

15. Passenger footrest

16. Sidestand

17. Gear shift pedal

18. Rider footrest

10387

10388

Key

A single key operates the Super X main switch and fork lock. For your convenience, the Super X comes with a spare key.

Fork Lock

The Super X is equipped with a fork lock to deter others from moving or using the motorcycle without your permission while it is parked. The fork lock is on the right side of the steering head.

To lock the fork lock, turn the handlebars fully to the left, insert the key and turn it clockwise. To unlock the fork lock, turn the key counterclockwise. Remove the key after locking or unlocking the forks.

WARNING

Moving or operating the motorcycle with the forks locked severely restricts steering and can cause you to drop or lose control of the motorcycle.

1. Fork lock

37Instruments and Controls

10497

38 Instruments and Controls

Main Switch

The main switch energizes the ignition, the lighting systems, and all electrical switches and buttons.

The main switch has a key-operated lock and an indicator you use to select a switch setting: On, Acc, or Off.

To lock or unlock the main switch:

1. Move the indicator to the Off position and insert the key into the lock.

2. To lock the switch, turn the key to the vertical

1. Lock

2. Indicator

10389

position. To unlock the switch, turn the key to the

horizontal position.

3. After you lock or unlock the main switch, remove the key.

Locked

Unlocked

10499

Notice

T o energize electrical systems, you must remove the key from the lock after you unlock the switch. When the main switch is locked, you can move the indicator, but the switch does not energize any electrical systems.

When the main switch is unlocked and in the On position, all electrical circuits are energized. The headlamp, running lights, tail light, and instrument lights illuminate. With the engine stop/run switch set to the run position (see “Engine Stop/Run Switch‚” page 48), you can start the engine. You can also activate the emergency flashers, turn signals, and all other switch- and button-operated controls.

10390

Caution

Before starting the engine, read the instructions for starting the motorcycle.

1. On position

2. Accessories position

3. Off position

Acc (Accessories)

When the main switch is unlocked and in the Acc position, all lighting systems come on. You can activate all switch- and button-operated controls except the electric starter button (see “Electric Starter Button‚” page 49). You cannot start the engine with the switch in the Acc position.

39Instruments and Controls

Off

When the main switch is in the Off position, all electrical circuits are inactive.

40 Instruments and Controls

Instrument Pod

The instrument pod includes the indicator lights, instrument gauges, digital odometer/trip odometer, and the odometer/trip meter function button.

Indicator Lights

There are seven indicator lights — six on the speedometer face and one on the fuel gauge face.

1. Headlamp high beam indicator

2. Check engine indicator

3. Turn signal indicator

4. Neutral indicator

10391

5. Low oil pressure indicator

6. Low battery voltage indicator

7. Low fuel indicator

Notice

Instructions for replacing all light bulbs are in the Maintenance section, beginning on page 95.

Caution

If an indicator reports a problem, refer to the Super X Service Manual or contact your Excelsior-Henderson Dealer as soon as possible.

Headlamp High Beam Indicator

The headlamp high beam indicator illuminates when the headlamp dimmer switch (see “Headlamp Dimmer Switch‚” page 46) is set to high beam.

Check Engine Indicator

If the check engine indicator illuminates while the engine is running, the Engine Control Module sensors are reporting abnormal sensor or engine

operation and a serious engine problem may exist. The check engine indicator also illuminates when the main switch is in the On

position, the engine stop/run switch is set to run (see “Engine Stop/Run Switch‚” page 48), and the engine is not running. This demonstrates that the indicator bulb is functioning properly.

41Instruments and Controls

Turn Signal Indicator

The turn signal indicator flashes when either the left or right turn signals are active, or when the emergency flashers are active.

If none of the turn signal bulbs is working, or if there is a short circuit in the turn signal system, the turn signal indicator flashes at twice the normal rate.

42 Instruments and Controls

Neutral Indicator

The neutral indicator illuminates when the transmission is in neutral. If the

indicator does not illuminate and you are able to roll the motorcycle freely forward and backward with the clutch lever released, the neutral indicator may not be functioning.

Low Oil Pressure Indicator

If the low oil pressure indicator illuminates while the engine is running, the oil

pressure has dropped below the minimum pressure, which indicates either a low oil level or an oil system malfunction. If this indicator illuminates while the engine is running, turn the engine off immediately and check the oil level. Add oil if necessary. If the oil level is correct and the light remains illuminated when the engine is running, turn the engine off immediately.

The low oil indicator also illuminates when the ignition is on and the engine is not running. This demonstrates that the indicator bulb is functioning properly.

Low Battery Voltage Indicator

The low battery voltage indicator illuminates when the battery voltage drops

below the minimum level. See “Battery‚” page 119.

Low Fuel Indicator

The low fuel indicator illuminates when approximately 1 gallon of fuel remains.

Speedometer

The speedometer indicates riding speed in miles per hour (mph).

Odometer/Trip Meter

A single, digital display on the speedometer face indicates either the odometer or the trip meter mileage.

The digital odometer indicates total miles traveled. When the odometer reading is displayed, “ODO” appears as part of the display.

The digital trip meter indicates total miles traveled since the trip meter was reset. When the trip meter reading is displayed, “TRIP” appears as part of the display. You can use the trip meter to estimate your miles per gallon and calculate the approximate number of miles you can travel on a tank of fuel.

1. Speedometer

2. Odometer/trip meter

3. Odometer /trip meter function button

43Instruments and Controls

10392

44 Instruments and Controls

Odometer/Trip Meter Function Button

The odometer/trip meter function toggles the digital display between the odometer and trip meter. It also resets the trip meter.

To toggle the digital display between the odometer and the trip meter, press and release the odometer/trip meter function button.

To reset the trip meter, display the trip meter reading. Then press and hold the odometer/trip meter function button for two seconds.

Tachometer

The tachometer indicates the engine speed in revolutions per minute (rpm). A red line on the gauge indicates the rpm in excess of the safe operating range.

WARNING

Do not operate the engine at or over 5500 rpm. Excessive rpm could cause engine damage or failure which could result in you losing control of the motorcycle.

Fuel Gauge

10392

1. Tachometer

2. Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank.

Handlebar Controls

Left Side Handlebar Controls

The left side handlebar controls include the clutch lever, the left mirror, the headlamp dimmer switch, the turn signal switch, and the horn button.

Clutch Lever

To disengage the clutch, pull the clutch lever toward the handlebar. To engage the clutch, gradually release the clutch lever. For smooth clutch operation, pull the lever quickly and release it gradually.

Left Mirror

The mirror is convex and therefore objects you see in it are actually closer to you than they appear to be in the mirror.

45Instruments and Controls

10394

1. Clu tch lev er

2. Mirror

46 Instruments and Controls

Headlamp Dimmer Switch

The headlamp dimmer switch toggles the headlamp between the low beam and the high beam. To activate the low

beam, press the lower portion of the switch; to activate the high beam, press the upper portion of the switch.

Turn Signal Switch

The turn signal switch activates and

cancels the turn signals. To activate the left turn signals, push the switch to the left; to activate the right turn signals, push the switch to the right. To cancel the turn signals, push the switch in, toward the handlebar.

The turn signals cancel automatically after you have travelled approximately 1/5 mile.

Horn Button

To sound the horn, press the horn button.

10395

1. Headlamp dimmer switch

2. Turn signal switch

3. Horn button

Right Side Handlebar Controls

The right side handlebar controls include the front brake lever , the throttle control grip, the right mirror, the engine stop/run switch, the emergency flasher switch, and the electric starter button.

Front Brake Lever

T o apply the front brake, pull the front brake lever toward the handlebar.

For braking procedures in various riding conditions, see “Braking‚” page 89.

Throttle Control Grip

The throttle control grip controls the engine speed. To increase engine speed, twist the throttle control grip toward you; to decrease engine speed, twist the grip away from you. When you release the grip, it returns to the idle speed position.

1. Front brake lever

2. Throttle control grip

3. Mirror

10396

47Instruments and Controls

Right Mirror

The mirror is convex and therefore objects you see in it are actually closer to you than they appear to be in the mirror.

48 Instruments and Controls

Engine Stop/Run Switch

The engine stop/run switch

completes or interrupts the

ignition and starter circuits. To

complete the ignition and starter circuits, allowing the engine to start or run, press the lower portion of the engine stop/run switch. To interrupt the ignition and starter circuits, press the upper portion of the switch; the engine cannot start or run when the switch is in this position.

Use the engine stop/run switch to turn the engine off under normal or emergency conditions.

Emergency Flasher Switch

10397

1. Engine stop/run switch

2. Emergency flasher switch

3. Electric starter button

The emergency flasher switch activates and cancels the emergency flashers.

When the emergency flashers are active, the turn signals flash. To activate

the emergency flashers, slide the switch to the left; to cancel the flashers,

slide the switch to the right.

Electric Starter Button

To start the engine, with the main switch in the On position and the engine stop/run switch in the run position, press the right side of the electric starter button.

Foot Controls

Gear Shift Pedal

The gear shift pedal is located on the left side of the motorcycle. To shift to a lower gear, press down on the front of the gear shift pedal. To shift to a higher gear, press down on the rear , or lift up on the front, of the gear shift pedal.

For proper gear shifting procedure, see “Shifting Gears‚” page 84.

49Instruments and Controls

10398

1. Gear shift pedal

50 Instruments and Controls

Rear Brake Pedal

The rear brake pedal is on the right side of the motorcycle. To engage the rear brake, press down on the rear brake pedal.

For braking procedures in various riding conditions, see “Braking‚” page 89.

10399

Fuel Cap

The Super X fuel cap is vacuum vented. The fuel cap is right-hand threaded (turn clockwise to tighten). When tightening the fuel cap, continue turning the cap until a clicking sound is heard, indicating proper tightness.

For fueling procedure, see “Fueling and Fuel Fill Height‚” page 79.

1. Rear brake pedal

10400

1. Fuel cap

Rear Suspension Adjustment

Proper rear suspension adjustment is essential for a safe and comfortable ride. The Super X rear suspension can be adjusted by changing the setting of either the preload adjuster or the damping rate adjuster, both located on the rear shock absorber. This section identifies the location of the rear shock absorber and the two adjusters. It provides the value set at the factory, the range of settings, and instructions for changing each setting. It also explains how the preload and damping rate adjusters affect shock absorber and rear suspension behavior.

WARNING

Insufficient preload or damping rate adjustment can reduce ground clearance, which could allow components to come into contact with the ground, causing you to lose control of the motorcycle.

To remove or replace the rear shock absorber, see the Super X Service Handbook or contact your authorized Excelsior-Henderson Dealer.

51Instruments and Controls

WARNING

The rear shock absorber contains nitrogen gas under high pressure. To prevent injury, do not disassemble, rebuild, puncture, or apply heat to the shock absorber.

52 Instruments and Controls

Location of Adjusters

The rear shock absorber is located under the rider’s saddle. The damping rate adjuster is at the top of the shock absorber, and the preload adjuster is at the bottom.

Factory Adjustment Settings

Preload and damping rate are set at the factory to provide a rider of average weight a comfortable ride under normal conditions, without passenger, cargo, or accessories on the motorcycle.

• The preload is set to setting 2 at the factory.

• The damping rate is set to detent 6 at the factory.

Adjusters and Their Setting Ranges

10401

1. Damping rate adjuster

2. Rear shock absorber

3. Preload adjuster

The preload adjuster is a cam with seven notches, labeled 1–7. Setting 1 provides the minimum preload; setting 7, the maximum preload.

The damping rate adjuster is a screw head with 14 detents. Each detent is a point of slight resistance that you feel as you turn the damping rate adjusting screw with a screwdriver.

To find detent 1, the minimum damping setting, turn the screw counterclockwise until it stops. Then turn the screw slowly clockwise until you feel it stop at the first detent. Turn the screw approximately 180° to locate the next detent.

Changing Adjustment Settings

Change the preload adjustment setting whenever the current setting is not correct for load you intend to carry (see “Changing Preload Adjustment‚” page 54). Adjust the preload before you adjust the damping rate. When you are satisfied that the preload is properly adjusted, change the damping rate setting if necessary (see “Changing Damping Rate Adjustment‚” page 57). Changing the damping rate setting is necessary if the rear suspension continues to move up and down after the rear shock absorber has absorbed a shock, or if you are not satisfied with the feel of the rear suspension.

For weight limitations, see “Gross Vehicle Weight Rating‚” page 14. For loading considerations, see “Loading‚” page 15.

For additional information, see “Effects of Rear Suspension Adjustments‚” page 58.

53Instruments and Controls

54 Instruments and Controls

Changing Preload Adjustment

This procedure involves using the Excelsior-Henderson rear shock adjusting wrench (part no. EH-6999-0029), which is designed specifically for changing the preload adjuster setting.

1. In the following table, find the weight closest to your own, including your riding apparel and all its contents, and identify the rider payload. If your weight is between two of the weights in the table, choose the higher rider payload.

You r w ei g h t

(in pounds)

10 0 110 12 0 13 0 14 0 15 0 16 0 17 0

Rider payload

(in pounds)

70 180 12 6 2 6 0 18 2 77 190 13 3 2 7 0 18 9 84 200 14 0 2 8 0 19 6 91 210 14 7 2 90 203

98 220 15 4 3 0 0 210 10 5 2 3 0 161 310 217 112 2 40 16 8 3 20 224 119 2 50 17 5 3 30 231

You r w ei g h t (in pounds)

Rider payload

(in pounds)

You r w ei g h t (in pounds)

Rider payload

(in pounds)

2. Determine the weight of your passenger, and cargo and accessories located rear of the rider’s saddle, if any. Accessories located forward of the rider’s saddle do not affect preload.

3. Calculate the total rear wheel payload: total rear wheel payload =rider payload + (weight of passenger + cargo

+ accessories located rear of the rider’s saddle)

For example, if you weigh 200 lb, the rider payload is 140 lb. If you carry 30 lb of cargo and have 35 lb of accessories located to the rear of the rider’s saddle, you would make the following total rear wheel payload calculation:

140 lb + 30 lb + 35 lb = 205 lb rear wheel payload

4. In the following table, find the total rear wheel payload closest to the one you calculated and identify the preload setting. If your total rear wheel payload is exactly halfway between two of the payloads in the table, choose the higher preload setting.

55Instruments and Controls

Total rear wheel payload

(in pounds)

12 5 15 5 175 205

Preload setting

12305 22606 32857 4

Total rear wheel payload

(in pounds)

Preload setting

If your total rear wheel payload is over 285 lb, choose preload setting 7 and be aware that your load will reduce ground clearance, which could cause you to lose control of the motorcycle.

56 Instruments and Controls

5. If you have not already done so, remove the tandem and rider’s saddles (see “Saddles‚” page 117).

6. Each notch in the preload adjuster is la belled with a number 1–7, indicating the preload adjustment setting. Using the rear shock adjusting wrench, turn the preload adjuster until the notch you need rests on the adjuster setting tab.

7. Test ride the Super X on a road that is in the poorest condition you expect to encounter, carrying your intended load. After the test ride,

1. Preload adjuster

2. Rear shock adjusting wrench

10403

make additional preload adjustments if necessary.

8. When you are satisfied that the preload is properly adjusted, if you are going to change the damping rate adjustment, see “Changing Damping Rate Adjustment‚” page 57. Otherwise, reinstall the rider’s and tandem saddles (see “Saddles‚” page 117).

Changing Damping Rate Adjustment

Adjust the preload setting before you make any adjustment to the damping rate.

1. If you have not already do ne so, remove the tandem and rider’s saddles (see “Saddles‚” page 117).

2. Using a flat blade screwdriver with the appropriate size blade, turn the damping rate adjustment screw counterclockwise to reduce the damping rate for a softer ride, or clockwise to increase the damping rate for a firmer ride. Each detent is a point of slight resistance that you feel as you turn the damping rate adjusting screw.

3. Reinstall the rider’s and tandem saddles (see “Saddles‚” page 117) and test ride the motorcycle with the load you intend to carry on a road that is in the poorest condition you expect to encounter. During the test ride, if the rear suspension continues to move up and down after the rear shock absorber has absorbed a shock, or if you are not satisfied with feel of the rear suspension, repeat the damping rate adjustment and test riding procedure until you eliminate this condition.

57Instruments and Controls

58 Instruments and Controls

Effects of Rear Suspension Adjustments

WARNING

Insufficient preload or damping rate adjustment can reduce ground clearance, which could allow components to come into contact with the ground, causing you to lose control of the motorcycle.

A properly adjusted rear suspension travels up and down smoothly because the shock absorber compresses and decompresses at a rate and force that does not jar the rear suspension. Taking road conditions into account, when the rear suspension is properly adjusted, the ride is smooth, the motorcycle’s ground clearance is adequate, and steering characteristics are normal. Based on your total rear wheel payload (see calculation, page 55), you can adjust the shock absorber preload and damping rate settings to produce a solid-handling ride that suits your comfort preference.

Preload is a measure of how much the shock absorber spring is compressed when the shock absorber itself is uncompressed. The degree of preload affects the amount of rear suspension travel. It affects how much force is necessary to compress the shock absorber, allowing the rear suspension to move up. The degree of preload also affects how much force is applied to decompress the shock absorber, moving the rear suspension down. The smaller the preload, the lower the motorcycle is to the ground. Smaller preload settings decrease the saddle

height, but also bring the exhaust pipes and other components at or near the bottom of the motorcycle closer to the ground.

The proper preload setting ensures that the rear suspension moves up and down under the total rear wheel payload without causing the motorcycle to “bottom out” or “top out,” either of which produces a jarring sensation. The motorcycle bottoms out when the suspension has completely compressed before it has fully absorbed a shock, causing the upward motion of the rear wheel (downward motion of the motorcycle) to stop abruptly. Similarly, the motorcycle tops out when the suspension has completely extended to its full length, causing the downward motion of the rear wheel (upward motion of the motorcycle) to stop abruptly.

The damping rate affects the smoothness of the ride by determining how quickly and to what degree the shock absorber resists compression and rebound. When the rear wheel moves up, the shock absorber compresses; when the wheel moves down, the shock absorber rebounds. The higher the damping rate, the more quickly and strongly the shock absorber resists compression and rebound, resulting in a “firmer” feel to the ride. Too much damping causes a jarring ride. The lower the damping rate, the less the shock absorber resists compression and rebound, producing a “softer” ride. Too little damping allows the rear suspension to continue moving up and down after the rear shock absorber has absorbed a shock, which can cause instability and, in corners, reduce ground clearance. Damping rate also helps prevent bottoming out and topping out.

59Instruments and Controls

60 Instruments and Controls

When the damping rate is properly adjusted:

• The rear suspension does not continue moving up and down after the rear shock absorber has absorbed a shock.

• The motorcycle has a solid feel going through turns, and during and after bumpy stretches.

• When traveling over a series of bumps, handlebar vibration is minimal and the ride is relatively smooth.

The proper damping rate is also somewhat subjective, depending on your preference for the feel of the ride.

Sidestand

The sidestand is located on the left side of the motorcycle. When the sidestand is extended, it locks into position as long as the motorcycle’s weight is on it, preventing it from retracting if the motorcycle moves forward.

WARNING

Do not operate the motorcycle without the sidestand completely retracted. It could come into contact with the ground and cause you to lose control of the motorcycle.

To extend the sidestand, swing it out from the end until it is fully extended. Lean the motorcycle toward the sidestand until the sidestand supports the motorcycle. The sidestand is now locked in position.

To retract the sidestand, lean the motorcycle away from the sidestand until the motorcycle is fully upright. The sidestand is released from its locked position. Swing the sidestand back into its retracted position.

61Instruments and Controls

Saddles

The Super X has a rider’s saddle and a tandem saddle. The tandem saddle has a saddle strap for the passenger to hold on to while riding.

10405

Pre-Operation Check

To keep your Super X motorcycle in good working order, make the checks described in this section before each ride. This is especially important before you make a longer trip or when you remove the Super X from storage. You must be familiar with the Super X instruments and controls to make these checks. You can find additional service information in the Maintenance section of the Rider’s Handbook, in the Super X Service Handbook, or from your local authorized Excelsior-Henderson Dealer.

During the pre-operation check you might use products that are potentially hazardous, such as oil. When using any of these products, follow the instructions and warnings on the product packaging.

WARNING

Failure to perfor m these checks before you ride may result in injury or damage. Adjust components designed for normal wear adjustment, and repair or replace worn or damaged components, as ne cessary.

64 Pre-Operation Check

Fuel

Fuel Level

1. Mount the Super X on level ground and bring it to a vertical position.

2. Turn the main switch to the On position and note the fuel level once the fuel gauge needle stops moving.

3. Estimate your next fuel stop and plan acco rdingly.

Fuel Hose, Rail, and Connections

Inspect the fuel hose, and its connection to the fuel pump and to the fuel rail, for dampness or stains from leaking or dried fuel.

10406

Evaporative Emission

1. Fuel hose

Control System

(California model only)

Visually inspect all evaporative emission control system hoses and connections. Make sure all connections are tight. Also, inspect the evaporative canister to make sure it has not been damaged.

Engine Oil Level

A dipstick attached to the oil fill cap registers the engine oil level.

1. With the engine at normal operating temperature, mount the motorcycle and bring it to an upright position on level ground.

2. With the transmission in neutral, start and run the engine at 2500 - 3000 rpm for 30 seconds. Shut the engine while the motorcycle is still in the upright position.

3. Rest the motorcycle on the sidestand and on level ground. Remove the oil fill cap and wipe the dipstick clean. Reinstall the dipstick and turn the cap clockwise until it seats.

4. Remove the dipstick again and note the oil level.

1. fill cap and dipstick

1. ADD m ark

2. MAX. COLD mark

3. MAX. HOT mark

65Pre-Operation Check

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66 Pre-Operation Check

5. If necessary, add or remove oil to bring the level into the area on the dipstick above the ADD mark and below the appropriate MAX. mark (see “Engine Oil Specifications‚” page 239). Repeat steps 3–4 each time you adjust the oil level.

WARNING

Do not operate the motorcycle with the oil level above the appropriate MAX. mark or below the ADD mark. Operating the engine with too much or too little oil can cause serious engine damage or engine seizure, resulting in you losing control of the motorcycle.

Tires

Tire Pressure

Normal riding warms the tires and increases the tire air pressure. For an accurate reading, check the tire pressure before you ride. Adjust tire pressure as required for the total weight of your intended load.

Up to 200 lb load 200 lb-440 lb load

Front: Dunlop tires 491 Elite II MT90HB16 36 psi (cold) 36 psi (cold) Rear: Dunlop tires 491 Elite II MU90HB16 36 psi (cold) 40 psi (cold)

Tire Condition

Inspect the tire sidewalls, road contact surface, and tread base for cuts, punctures, and cracking. Replace damaged tires immediately (see your Super X Service Handbook or an authorized Excelsior-Henderson Dealer).

Tread Depth

Raised areas at the base of the tread, known as wear bars, act as easily-visible tread depth indicators. When the road contact surface has worn to the top of the wear bars, replace the tire.

If you have installed tires that do not have wear bars, use an accurate ruler or depth gauge to measure the shallowest tire tread you can find (usually near the center of the tire surface). Replace a tire with a tread depth less than 1/16” (see your Super X Service Handbook or an authorized ExcelsiorHenderson Dealer).

1. We ar b ar

10060

67Pre-Operation Check

68 Pre-Operation Check

Drive Belt

Replace the drive belt if it is cracked or has broken teeth or frayed edges (consult your Super X Service Handbook or an authorized Excelsior-Henderson Dealer).

Steering

Mount the motorcycle and bring it to a vertical position. Turn the handlebars from stop to stop. The action should be smooth but not loose or interfered with by wires or control cables.

Hydraulic Controls — Clutch and Brakes

Check Hoses and Connections

Inspect all brake and clutch hoses and connections for dampness or stains from leaking or dried brake fluid.

Check Front Brake & Clutch Fluid Level

1. To check the front brake or clutch fluid level, mount the motorcycle and bring it to a vertical position. Turn the handlebars until the reservoir is horizontal.

2. View the hydraulic fluid through the sight glass. The fluid should be clear and at a

Fluid reservoir with sight glass

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level above the “Lower” marking on the reservoir. Add hydraulic fluid if necessary.

Check Rear Brake Fluid Level

1. To check the rear brake fluid level, bring the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame.

69Pre-Operation Check

2. View the hydraulic fluid through the sight glass. The fluid should be clear and at a level at or near the top of the sight glass. Add hydraulic fluid if necessary.

Check Clutch Lever Movement

Squeeze the clutch lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released.

70 Pre-Operation Check

Check Front Brake Lever Movement

Squeeze the front brake lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released. You should feel a firm resistance in the lever within the first 3/4” of lever travel.

Check Rear Brake Pedal Movement

Press and release the rear brake pedal. It should move freely and smoothly and should return to its rest position quickly when you release it. You should feel a firm resistance in the pedal within the first 3/4” of pedal travel.

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10411

Check Brake Pads

Looking in through the back of the front brake caliper, and down through the top of the rear caliper, you should see at least 1/16” of friction material on the pads. If in doubt, measure remaining friction material. Replace brake pads having less than 1/16” of friction material at their thinnest point. Replace brake pads in pairs.

Throttle Control Grip and Cables

Rotate the throttle control grip. It should rotate smoothly from its rest position to its completely open position and back again. It should return to its rest position quickly when released.

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10412

Throttle freeplay — the amount of throttle control grip movement from the rest position to the point of cable resistance — should be between 1/16” and 3/16”.

10413

72 Pre-Operation Check

Electrical Equipment

Engine Stop/Run Switch

Be sure the engine stop/run switch stops the engine. If you regularly use this switch to shut off the engine, you are checking its operation each time you use the motorcycle.

Instrument Pod

The odometer/trip meter display should show the mileage reading, and “ODO” or “TRIP” should be part of the display. The low oil pressure indicator should illuminate. If the transmission is in neutral, the neutral indicator should illuminate. The gauge lights under the speedometer, tachometer, and fuel gauge should also illuminate.

To inspect the remaining electrical items in this section, set the main switch to the On position. When you have completed these checks, set the main switch to the Off position.

Set the engine stop/run switch to the run position. The check engine indicator should illuminate. Return the engine stop/run switch to the stop position.

Press the horn button. The horn should sound.

Press the odometer/trip meter function button. The odometer/trip meter display should change to show the current trip meter reading.

Headlamp

Check the headlamp to see that it is on. Set the headlamp dimmer switch to the high beam position. The headlamp brightness should increase and the high beam indicator in the instrument pod should illuminate.

Brake Light

Apply slight pressure to the front brake lever; tail light brightness should increase. Apply slight pressure to the rear brake pedal; tail light brightness should increase.

Running Lights

The two amber front running lights and the tail light should illuminate. The license plate light should also illuminate.

73Pre-Operation Check

Tu r n S i g n a l s

Move the turn signal switch to the left. The front and rear left turn signal lights, and the turn signal indicator, should flash. Push the switch in toward the housing. The turn signals and turn signal indicator should stop flashing. Repeat the operation for the right turn signals.

74 Pre-Operation Check

Sidestand

Move the sidestand to its stored (up) position, then to its fully extended (down) position, and back again. It should move smoothly. When the sidestand is in its stored position, the sidestand return spring should hold the sidestand tightly against the motorcycle.

Fasteners

Visually inspect the entire motorcycle chassis and engine for loose, damaged, or missing fasteners. Each fastener has an important purpose or it wouldn’t be there. Tighten loose fasteners to the proper torque (see “Torque Specifications‚” page

240). Replace stripped, damaged, or broken fasteners immediately. Some genuine Excelsior-Henderson threaded fasteners are coated with a

thread-locking patch. After removing and reinstalling the fastener 2 or 3 times, the thread-locking patch wears away and the fastener should be replaced with the same genuine Excelsior-Henderson fastener.

10404

1. Sidestand

2. Return spring

Notes:

75Pre-Operation Check

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Operation and Riding

This section describes how to operate the Super X motorcycle for best performance and longevity, including:

• motorcycle break-in period

• starting the engine

• shifting gears

• accelerating

• braking

• stopping the engine

• parking For safe operation and riding, see Safety Information‚ beginning on page 5.

78 Operation and Riding

Operating During Break-In Period (First 500 Miles)

Your new Super X is designed and built with premium-quality materials and expert craftsmanship, providing optimum performance from the first mile. During the first 500 miles, critical parts require special wear-in procedures so they seat and mate properly. Use the following rules for operation during the first 500 miles to ensure your engine’s long-term performance and durability.

During the first 500 miles:

• Vary the engine speed. Do not keep a steady engine speed for an extended time.

• Do not exceed 70 mph. Within this limitation, you can run the engine at speeds up to 3000 rpm. Select gears that prevent lugging the engine.

At 500 miles:

Perform the break-in maintenance after you’ve ridden your new Super X 500 miles. This maintenance is one of the most important services your motorcycle requires and should be performed by an authorized Excelsior-Henderson Dealer. Break-in maintenance includes servicing all adjustments, tightening all fasteners, and changing engine oil. Performing this maintenance at the required mileage point helps the engine maintain top performance for its entire service life.

Excelsior-HENDERSON 1999 HCX, Super X HCX 1999 Riders Handbook

Specifications and Main Features

Frequently Asked Questions

User Manual