Forward
6999-0006 Rev. A
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: 612.873.7030
Copyright© 1999 Excelsior-Henderson Motorcycle Manuf acturing Company. All rights reserved.
Super X,
trademark of the Dunlop Tire Corporation.
and
Rider’sHandbook
are trademarks of the Excelsior-Henderson Motorcycle Manufacturing Company.
RiderCourse
is a registered trademark of the Motorcycle Safety Foundation.
6999-0006 Rev. A
Excelsior-Henderson
Dunlop
, the X& Bar logo,
is a registered
Forward
Introduction
This
Handbook
Excelsior-HendersonDealerNetwork,andis
designedtobeusedwiththeExcelsior-Henderson
Certificate of Vehicle Setup & Predelivery
partno.6999-0067).
1. Vehicle Setup
ServiceTechnician,andincludesdetailedinstructions
essentialtoproperSetupofExcelsior-Henderson
motorcycles.
2. Owner Predelivery
SalesStaffinsafelyorientingthenewOwnerwith
theirExcelsior-Hendersonmotorcycle.
Werecommendthatyourefertothefollowing
informationoften,asitwillassistyouinmakingsure
thatspecificproceduresarenotoverlooked.
Timeismoney,andwerespectyourtime.Wehave
madeeachofthestepsinthis
completetoreducetheneedtosearchforadditional
informationelsewhere.
Toensurecustomersafetyandsatisfaction,please
readthis
PredeliveranExcelsior-Hendersonmotorcycle.
has been prepared exclusively for the
is written specifically for the Dealer
is designed to assist the Dealer
Handbook
Handbook
thoroughly before you Setup and
(document
simple and
DealerSupport
North/NortheastRegionalSales
PH1-612-873-7032
FAX1-612-873-7030
West/NorthwestRegionalSales
Phone:1-612-873-7031
Fax:1-612-873-7030
South/SouthwestRegionalSales
Phone:1-612-873-7033
Fax:1-612-873-7030
Ordering
Fax:1-800-873-8121
Technical
Phone:1-800-873-4957
Fax:1-612-873-5951
Warranty
SpecialSymbolsAndTerms
Thehazardsymbolindicatesapotential
hazardtoyourself,others,orthemotorcycle.
!
Payspecialattentiontoinformationinthe
Handbook
Thefollowingtermshavespecialmeaninginthe
Handbook.
eachterm,asthetermscommunicateimportant
informationaboutthemotorcycleanditsoperationand
maintenance.
Be certain you understand the meaning of
WARNING
•Indicatesapotentialhazardthatcouldinjureyou
orothers.
Caution
•Indicatesapotentialhazardthatcoulddamage
themotorcycle.
Notice
•Emphasizesimportantinformationthatmight
otherwisebeoverlooked.
that begins with this symbol.
Phone:1-612-873-7034
Fax:1-612-873-5951
ConsumerSupport
Phone:1-612-873-5800
Thecheckedboxsymbolisusedthroughoutthis
Handbooktoindicatethecompletionofaspecific
procedure,andtoremindyoutomarktheappropriate
boxonthe
Certificate Of Vehicle Setup & Predelivery.
6999-0006Rev.A i
Vehicle Setup 1
10539
Super X -leftsideview
1. HORN
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
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
17. PASSENGER FOOTREST
18. BATTERY
19. SIDESTAND
20. RIDER FOOTREST
21.GEAR SHIFT PEDAL
22. EVAPORATIVECANISTER
(CALIFORNIA MODEL ONLY)
23. FRONT BRAKE CALIPER
Super X - right side view
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
9. RIGHT HA NDLEB AR
CONTROLS
10. RIGHT MIRROR
11. FRONT BRAKE FLUID
RESERVOIR
12. FRONT BRAKE LEVER
13. THROTTLE CABLES
14. FRONT RIGHT TUR N SIGNAL/
RUNNING LIGHT
15. FUEL CAP
16. FORK LOCK
17. REAR BRAKE FLUID
RESERVOIR
18. REAR BRAKE PEDAL
1-0 6999-0006 Rev. A
10540
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
1. Vehicle Setup
GeneralInformation..............1-2
MovingtheCrate..................1-2
Signing the Bill Of Lading...........1-2
Replacement Parts.................1-2
Modifications.....................1-2
Fastener Information . . . ............1-2
Dealer Installed Accessories ........1-2
Special Tools .....................1-2
OpeningtheCrate................1-3
RemoveMotorcycle ..............1-3
Initial Motorcycle Inspection.........1-4
RemoveSeparateComponents.....1-4
Sidestand.......................1-5
Battery.........................1-5
FillBattery .......................1-5
ChargeBattery....................1-7
RemoveSaddles ..................1-7
DriveBeltTension...............1-15
Check Drive Belt Tension ..........1-15
Adjust Drive Belt Tension ..........1-15
EngineOil......................1-16
LowFuelIndicator...............1-16
FuelTank.......................1-17
Evaporative Control System. . . . . . .1-17
Electrical Components . . . . . . . . . . .1-18
MainSwitch .....................1-18
IndicatorLights..................1-18
InstrumentPodLights.............1-20
Odometer/TripMeter..............1-20
Fuel Gauge . .....................1-21
Headlamp . . .....................1-21
TurnSignals.....................1-21
Horn............................1-21
Emergency Flashers . . . ...........1-22
InstallBattery.....................1-8
InstallSaddles....................1-8
Tires...........................1-9
Spokes.........................1-9
SteeringHead...................1-9
ForkLock......................1-10
InstallMirrors ..................1-10
Throttle........................1-10
Throttle Control Grip and Cables . . . . 1-10
Adjust Throttle Freeplay ...........1-11
FrontBrake....................1-11
Clutch.........................1-12
RearBrake.....................1-12
Adding Hydraulic Fluid. . . . . . . . . . . 1-13
RearWheelAlignment...........1-13
CheckRearWheelAlignment.......1-13
Running Lights...................1-22
BrakeLight......................1-22
StartingtheEngine..............1-22
ElectricStarter...................1-23
IndicatorLights-OFF.............1-23
EngineIdle-Tachometer...........1-23
EngineStop/RunSwitch...........1-24
RoadTest......................1-24
Protective Apparel ................1-24
EngineOperation.................1-24
ClutchOperation.................1-25
TransmissionOperation...........1-25
BrakeOperation..................1-27
MotorcycleHandling..............1-27
Speedometer/Odometer Function . . . 1-28
EngineOilLevel.................1-28
Adjust Rear Wheel Alignment.......1-14
6999-0006 Rev. A 1-1
CleaningtheMotorcycle..........1-29
SuperXSpecifications...........1-30
Super X Torque Specifications . . . . .1-32
Vehicle Setup
General Information
Damage to the motorcycle can occur from the time the motorcycle leaves the factory until it is delivered. ExcelsiorHenderson wants to help you protect your investment and smooth out any bumps in the road. Please pay special
attention to the following general information.
Moving the Crate
The Excelsior-Henderson motorcycle shipping crate is designed to be lifted from a truck or trailer by fork lift from the
end marked “Fork This End” only. Once removedfrom the truck or trailer, the crate may be lifted by fork lift from either
side or the end marked “Fork This End”.
Signing the Bill Of Lading
Open each packing crate and inspect the motorcycle(s) in the presence of the delivery driver before the delivery
vehicle leaves your Dealership.
Notice
• The Carrier’s responsibility ends when the Bill of Lading is signed.
• Claims against the carrier must be filed at the time of delivery.
Replacement Parts
Replace any items that may have been damaged during shipment or setup with Genuine Excelsior-Henderson
replacement parts only.
Modifications
WARNING
• Do not disable or alter the exhaust, evaporative, or fuel systems on the motorcycle to circumvent federal, state
or local regulations. Environmental and safety systems or devices must be left intact as designed and
manufactured. Changes to the exhaust, evaporative, or fuel systems may void the motorcycles warranty.
• Do not modify the automatic headlight “ON” feature of the motorcycle. Any deliberate action to disable or alter
this system may contribute to an accident and result in personal injury.
Fastener Information
When performing the different setup procedures, keep an eye out for loose or missing fasteners.
If it becomes necessary to retighten a fastener (see Torque Specifications page 1-32).
Notice
• All fasteners come tightened to the correct torque from the factory.If you do not see a problem with a
fastener, it should not be disturbed.
• 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 awayand the fastener should be
replaced with the same genuine Excelsior-Henderson fastener.
Dealer Installed Accessories
For model year 1999, all Excelsior-Henderson accessories installed by the Dealer at the time of vehicle delivery are
warranted for 12 months. Excelsior-Henderson accessories installed by the Owner at any time, or those installed by
the Dealer after vehicle delivery are warranted for 90 days.
Special Tools
Rear wheel alignment gauge ---- PartNo.EH-6999-0037
Belttensiongauge--------- PartNo.EH-6999-0038
Rearshockadjustingwrench---- PartNo.EH-6999-0029
1-2 6999-0006 Rev. A
Opening the Crate
Use a flat pry bar to remove the packing crate top.
1. Start the pry bar under any corner of the crate top. Work
all around the crate top until all the fasteners and the top are
completely loose.
2. Remove the packing crate top.
Caution
Make sure the top of the crate does not drop into the
crate, damaging the motorcycle.
3. Using the pry bar, start at the top corner of either side of
the packing crate back (rear of motorcycle). Work your way
down to the bottom of the crate until all the fasteners and side
are completely loose. Repeat this procedure for the opposite
side.
4. Complete the removal of the crate back by loosening the
fasteners and bottom edge of the crate back.
5. Remove the protective dust cover. The dust cover should
be given to the Owner when the bike is delivered.
Vehicle Setup
10510
1. FLAT PRY BAR 2. CRATE TOP
Remove Motorcycle
1. Remove the mounting screws from the board behind the
rear wheel of the motorcycle. This board is installed to hold
the motorcycle in place during shipping.
2. Remove the board from the packing crate. Use this board
as a ramp when removing the motorcycle from the crate.
3. Line up the board with the rear wheel behind the crate.
4. Check the pallet to make sure there are no nails, staples
or screws protruding from the pallet bottom that could
puncture the tires.
5. Mount the motorcycle.
6. Release or cut the front tie-down straps.
7. Release or cut the rear tie-down straps.
Caution
Use care when releasing tie-down straps. The
motorcycle’s front and rear suspension are secured in
a compressed state for shipment. When the straps are
released or cut they will unwind or release rapidly. This
will cause the motorcycle to rise and pitch to the
opposite side.
1. FLAT PRY BAR
2. CRATE BACK
1. BOARD
(BEFORE REMOVAL)
2. BOARD
(ALIGNED WITH WHEEL)
10511
3. PROTECTIVE COVER
10512
3. FRONT TIE-DOWN STRAP
4. REAR TIE-DOWN STRAP
6999-0006 Rev. A 1-3
Vehicle Setup
8. Pump the front and rear brakes 3 to 4 times to make sure
they have hydraulic pressure.
9. Pull in the clutch lever.
10. Carefully roll the bike backwards, out of the crate.
11. Park the motorcycle on a flat, firm surface.
Initial Motorcycle Inspection
1. Verify that the Packing List matches the information on
the U.P.C. label attached to the packing crate. Make sure both
documents match the VehicleIdentification Number (V.I.N.) of
the motorcycle.
2. Visually inspect the motorcycle to make sure that no
damage occurred during packing for shipment or during
unpacking from shipment.
10513
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
If any damage to the motorcycle is discovered, you must
submit a warranty claim request form to receive a credit from
the factory. Be sure to include an accurate description of the
damage, and its effect on the motorcycle. (i.e. damage to
front brake line - front brake system leaks).
Remove Separate Components
The motorcycle is shippedwith the following separately
packaged components:
• Literature Kit
• Battery
• Mirrors
Release the tie-down strap and move all the items into your
work area.
1. PACKING LIST
2. U.P.C. CODE
1. WARRANTY CLA IM REQUEST FORM
3. V.I.N. NU MBER
10514
10515
1-4 6999-0006 Rev. A
1. TIE-DOWN STRAP
2. LITERATURE KIT
10516
3. BATTERY
4. MIRRORS
Sidestand
1. Make sure the sidestand locks in the extended (down)
position, holds firmly in the stored (up) position and moves
freely between both positions.
2. Set the sidestand in the extended position. Turn the
handle bars fully to the left. Lean the motorcycle to the left
until the sidestand is in the locked and parked position.
(StepCaptionHold) “For demonstration only”
(StepCaptionHold) “These are BLIND (white text)
Battery
The battery is supplied dry. It must be filled and properly
charged before it is put into service. Do not fill the battery with
electrolyte until it is to be placed into service.
We recommended you have fully charged batteries on hand
since it requires approximately 16 hours to fully charge a
battery. If you do not have charged batteries on hand, start
charging the battery as soon as possible.
Vehicle Setup
10517
1. STORED (UP) POSITION 2. EXTENDED (DOWN)
POSITION
WARNING
• ACID IS POISONOUS
– Contains sulfuric acid. Ventilate the area when filling
or charging batteries.
• ACID CAN CAUSE SEVERE BURNS
– Shield eyes, protect skin and clothing when handling
acid or working near any batteries.
• Keep sparks and open flames awa yfrom batteries during
filling or charging.
Antidote:
• EXTERNAL-Flushwithwater.
• INTERNAL - Drink large quantities of water or milk.
Follow with milk of magnesia, beaten eggs, or vegetable
oil and get prompt medical attention.
• EYES - Flush with water for 15 minutes and get prompt
medical attention.
Fill Battery
1. Place the battery on a level surface.
2. Remove the sealing strip from the battery filler ports.
3. Removethe electrolyte container from the protective vinyl
bag.
4. Detach the cap strip from the container and save it. The
cap strip will be used to plug the battery filler ports after the
battery is filled.
10518
10519
1. SEALING STRIP
2. ELECTROLYTE
CONTAINER
6999-0006 Rev. A 1-5
3. CAP STRIP
Vehicle Setup
5. Align the sealed openings of the electrolyte container
with the battery filler ports.
6. Push the container down firmly to break the seals of the
electrolyte container. The electrolyte should start to flow from
the container.
Caution
Do not peel or pierce the six sealed openings of the
electrolyte container by hand.The battery filler ports are
designed to pierce the seals when the container is
pushed into the filler ports.
7. Make sure air bubbles are coming up from all of the filler
ports on the battery. If no air bubbles are coming up from a
filler port, tap the bottom of the container two or three times.
Notice
Tipping or tilting the electrolyte container during filling
may stop the flow of electrolyte.
10520
1. FILLER PORTS
Caution
Removing the container from the battery during filling
may cause the electrolyte to spill.
8. Make sure all of the electrolyte in each bottle section has
emptied into the cells of the battery.
9. Tap each bottle section to remove any remaining
electrolyte. Make sure each bottle section is completely
empty and the corresponding cells of the battery are filled
before removing the container from the battery.
10. Remove the electrolyte container from the battery. Rinse
empty container sections with water before disposing of the
container.
11. Install the cap strip into the filler ports of the battery.
When correctly installed, the cap strip should fit tightly and be
level with the top of the battery.
1. AIR BUBBLES 2. FILLER PORT
1. ELECTROLYTE
CONTAINER
2. EMPTY CELLS
10521
10522
Caution
Once the battery is filled and sealed, never remove any
caps, the cap strip, or try to add water to the battery.
12. Let the battery sit for at least 30 minutes before charging
to allow the plates and separators to absorb all of the acid.
There is should be no flowing acid in the battery.
(StepCaptionHold) “For demonstration only” 1. CAP STRIP 2. TOP OF BA TTERY
1-6 6999-0006 Rev. A
10523
Charge Battery
Use a 12 volt 1 amp charger and charge the battery at the
rate shown. If a taper or trickle charger is used, charging
times will be longer.
Vehicle Setup
Notice
You can quick charge the battery with a constant
current charger. Charge at a rate of 9.0 amps for
1 hour.
If the battery gets hot to the touch, stop charging immediately.
Allow the battery to cool down before resuming charging.
Allow the battery to sit 1-2 hours before measuring the
voltage. Battery voltage must be checked before putting the
battery into service.
The battery should produce a minimum of 12.8 volts after
charging. If voltage is not 12.8 volts or more, repeat the
charging cycle.
Remove Saddles
To gain better access to the battery wires and terminals, we
recommend removing the motorcycle saddles before
installing the battery.
1. Remove the tandem saddle screw.
2. Lift the back of the tandem saddle slightly and pull it to
the rear, out from the tandem saddle posts.
Battery
Type Rate
YTX20L-BS
*Charging rate will vary depending on type of charger used
1. VOLTMETER
Charging
*Time of Charge
Using 1 Amp Charger
1.8 AMPS 16 HOURS
10524
3. Remove the rider’s saddle screws and tandem saddle
posts.
4. Lift the back of the rider’s saddle slightly and pull it to the
rear, out from the rider’s saddle post.
6999-0006 Rev. A 1-7
1. TANDEM SADDLE
2. TANDEM SADDLE SCREW
1. RIDER’S SADDLE
2. RIDER’S SADDLE SCREW
10187
3. TANDEM SADDLE POSTS
4. RIDER’S SADDLE
10188
3. TANDEM SADDLE POST
4. RIDER’S SADDLE POST
Vehicle Setup
Install Battery
Before installing the battery, make sure it is fully charged,
clean and dry. If necessary, clean any oxidation from the
cable connectors or battery terminals with a wire brush.
1. Remove the battery box cover strap and the battery box
cover from the motorcycle.
2. Remove the terminal protection label and place the
battery in the battery box with the terminals facing outward.
3. Connect the positive (+) battery cable (black with a
plastic boot covering a red sleeve and the connector).
4. Connect the negative (–) cable (black with an exposed
connector).
WARNING
• Connecting the negative cable first can produce spark
or electric shock that could result in damage or injury.
• Connecting the battery cables to the wrong terminals can
damage the electrical system.
5. Apply a thin coat of grease to the cable connectors.
6. Install the battery box cover and the battery box cover
strap.
Install Saddles
1. Slide the front of the rider’s saddle into the rider’s saddle
post at the rear of the fuel tank.
2. Install the tandem saddle posts and the rider’s saddle
screws.
3. Slide the front of the tandem saddle into the tandem
saddle posts at the rear of the rider’s saddle.
4. Install the tandem saddle screw.
5. Check the tandem saddle strap to make sure it is secure.
1. BATTERY BOX COVER
STRAP
1. RIDER’S SADDLE
2. RIDER’S SADDLE SCREW
10525
2. BATTERY BOX COVER
3. BATTERY
10188
3. TANDEM SADDLE POSTS
4. RIDER’S SADDLE POST
1-8 6999-0006 Rev. A
1. TANDEM SADDLE
2. TANDEM SADDLE SCREW
10187
3. TANDEM SADDLE POSTS
4. RIDES SADDLE
Tires
Check and adjust the front and rear tire pressure. Normal air
pressure for front and rear tires is 36 psi (cold) for loads up to
200 lbs. and 40 psi (cold) on the rear tire only for loads from
200 lbs. up to 440 lbs.
Spokes
Inspect both wheels for loose, bent, broken, or missing
spokes. To identify loose spokes, grasp each spoke and try to
move it side to side or up and down. All spokes should be
equally tight and have the same amount of flex.Tighten loose
spokes or replace bent, broken, or missing spokes.
motorcycle’s Service Handbook.
See the
Vehicle Setup
10543
WARNING
Spokes adjusted or replaced improperly could distort
the wheel, making the motorcycle difficult to handle
causing the rider to lose control of the motorcycle.
Steering Head
1. Mount the motorcycle and bring it to an upright position.
Turn the handlebars from side to side (stop to stop). The
action should be smooth but not loose. There should be no
interference from the wires, control cables, or turn signals.
10541
10538
6999-0006 Rev. A 1-9
Vehicle Setup
2. Position the motorcycle on level ground in an upright
position. Raise the front wheel off the ground with an
appropriate motorcycle lift or by placing a block of wood or
steel securely under the frame.
3. With the front wheel straight, hold the lower end of the
front forks near the axle and try to move the forks forward and
backward. The forks should have no freeplay (forward and
backward movement).
4. If any freeplay is present, the steering head bearings
should be adjusted.
See the motorcycle’s Service Handbook.
Fork Lock
1. Turn the handlebars fully to the left. Insert the key into the
fork lock and turn it clockwise. Remove the key and make
sure the handlebars are locked.
2. Reinsert the key and turn it counterclockwise. Remove
the key and make sure the handlebars turn freely from side to
side.
10479
Install Mirrors
1. To install both right and left mirrors, insert the threaded
end of the mirror into the threaded receiver on either right or
left hydraulic fluid reservoirs.
2. Thread each mirror all the way into the receiver, then
back each mirror out until it faces the rear of the motorcycle.
3. Tighten the locking nut on the mirror shaft to lock the
mirror in place.
4. Adjust the mirrors as necessary.
Throttle
Throttle Control Grip and Cables
1. 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.
2. 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”.
3. Adjust throttle freeplay as necessary.
10497
1. FORK LOCK
10545
1. LOCKING NUT
10544
1-10 6999-0006 Rev. A
Adjust Throttle Freeplay
1. Slide the rubber covers off both cable adjusters, and
loosen both adjuster jam nuts.
2. Turn both cable adjusters into the cable as far as
possible.
3. Turn the cable adjuster on the throttle opening cable out
until the throttle freeplay is between 1/16” and 3/16”.
4. Hold the throttle control grip at the fully closed position
and turn the cable adjuster on the throttle closing cable out
until resistance is felt.
5. Tighten the adjuster jam nuts on both cables, and
reinstall both rubber covers.
1. RUBBER COVER
2. ADJUSTERJAM NUT
Vehicle Setup
10546
3. CABLE ADJUSTER
Front Brake
1. Inspect all hoses and hose connections for dampness or
stains from leaking or dried hydraulic fluid.
2. Bring the motorcycle to an upright position. Turn the
handlebars until the reservoir is horizontal.
3. The fluid should be clear and at a level above the “Lower”
marking on the reservoir. Add hydraulic fluid if necessary,
(see Adding Hydraulic Fluid page 1-13)
4. 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 3/4” of lever travel. If
the brake lever does not function as described,
motorcycle’s Service Handbook.
.
see the
1. RUBBER COVER
2. ADJUSTERJAM NUT
3. CABLE ADJUSTER
1. LOWER MARK
10547
4. OPENING CABLE
5. CLOSING CABLE
10548
10549
6999-0006 Rev. A 1-11
Vehicle Setup
Clutch
1. Inspect all hoses and hose connections for dampness or
stains from leaking or dried hydraulic fluid.
2. Bring the motorcycle to an upright position. Turn the
handlebars until the reservoir is horizontal.
3. View the hydraulic fluid through the sight glass. The fluid
should be clear and at a level above the “Lower” marking on
the reservoir. Add hydraulic fluid if necessary, (see Adding
Hydraulic Fluid page 1-13).
4. 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. If the clutch
lever does not travel all the way to the handlebar,
motorcycle’s Service Handbook.
see the
10550
1. LOWER MARK
Rear Brake
1. Inspect all hoses and hose connections for dampness or
stains from leaking or dried hydraulic fluid.
2. Bring the motorcycle to an upright position with an
appropriate motorcycle lift or a block of wood or steel placed
securely under the frame.
3. View the hydraulic fluid through the sight glass. The fluid
should be clear and at a level above the sight glass on the
reservoir. Add hydraulic fluid if necessary, (see Adding
Hydraulic Fluid page 1-13).
4. 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 lever within 3/4” of lever travel. If the brake pedal does
not function as described,
Handbook.
see the motorcycle’s Service
10527
10527
1. LOWER MARK
10551
1-12 6999-0006 Rev. A
Adding Hydraulic Fluid
1. Wipe the area around the reservoir cover clean.
2. Wipe the hydraulic fluid container clean.
3. Remove the reservoir cover, gasket plate, and gasket.
4. Carefully add enough fluid to bring the level above the
sight glass on the reservoir.
5. Reinstall the reservoir gasket, gasket plate, and cover.
WARNING
• Use only DOT 5 hydraulic fluid from a sealed, clean
container. Using the wrong hydraulic fluid, or allowing
contaminants into the hydraulic system, can damage
the system seals, resulting in a system failure and the
rider could lose control of the motorcycle.
• Do not operate any hydraulic system while its reservoir
cover is removed. Fluid could overflow from the reservoir
and cause air to enter the fluid system. Air in the
hydraulic fluid system could cause a system malfunction
and the rider could lose control of the motorcycle.
• Hydraulic fluid can cause irritation to skin and eyes, and
can be harmful if swallowed. If hydraulic fluid is
swallowed, induce vomiting and call a doctor. In case of
contactwithskinoreyes,flushwithwater.
1. RESERVOIR COVER
2. GASKET PLATE
Vehicle Setup
10528
3. GASKET
4. SIGHT GLASS
Rear Wheel Alignment
Notice
Checking the rear wheel alignment involves using the
Excelsior-Henderson rear wheel alignment gauge, part
no. EH-6999-0037.
A skewed rear axle can damage the drive belt, causing it to
fail. Rear wheel alignment is also critical to drive belt tension
and should be checked to make sure the rear wheel is in
proper alignment.
Check Rear Wheel Alignment
1. Place the open end of the rear wheel alignment gauge
over either swing cage pivot bolt.
2. Loosen the pointer thumb screw and slide the pointer
along the rod until pointer tip rests in the center dimple of the
rear axle. Tighten the pointer thumb screw .
3. Move the alignment gauge to the same location on the
other side of the motorcycle. If t he rear axle is the same
distance from the swing cage pivot bolt on both sides of the
motorcycle, the rear wheel is in proper alignment.
1. ALIGNMENT GAUGE
1. ALIGNMENT GAUGE
2. SWING CAGE PIVOT BOLT
10529
10552
3. POINTER
6999-0006 Rev. A 1-13
Vehicle Setup
Adjust Rear Wheel Alignment
Notice
Adjusting the rear wheel alignment involves using the
Excelsior-Henderson rear wheel alignment gauge, part
no. EH-6999-0037.
1. Remove and discard the rear axle cotter pin.
2. Loosen the rear axle castle nut enough to allow the rear
axle to slide back and forth in the swing cage.
3. Place the open end of the rear wheel alignment gauge
over either swing cage pivot bolt.
4. Loosen the pointer thumb screw and slide the pointer
along the rod until pointer tip rests in the center dimple of the
rear axle. Tighten the pointer thumb screw .
5. Move the alignment gauge to the opposite location on the
other side of the motorcycle.
6. Loosen the adjuster jam nuts.
1. COTTER PIN
2. CASTLE NUT
3. ADJUSTERJAM NUT
10553
4. REAR AXLE ADJUSTER
5. ADJUSTER COLLAR
7. Turn the rear axle adjuster in or out until the dimple in the
rear axle aligns with the pointer tip. Make sure the rear axle
adjusters are seated against the adjuster collars.
8. Repeat steps 1-4 on alternate sides of the wheel until the
distance from the swing cage pivot bolt to the rear axle center
dimple is equal on both sides of the motorcycle.
9. Check the drivebelt tension and adjust it if necessary
(see Check Drive Belt Tension page 1-15).
10. Tighten the adjuster jam nuts.
11. Tighten the rear axle castle nut.
Torque: 111 ft-lbs
12. Recheck drive belt tension, and install a new rear axle
cotter pin.
WARNING
Do not reuse a cotter pin because it may fail, causing
the rear wheel to loosen and the rider to lose control of
the motorcycle.
10552
1. ALIGNMENT GAUGE 2. POINTER
10554
1. ADJUSTER JAM NUT 2. CASTLE NUT
10555
1. COTTER PIN
1-14 6999-0006 Rev. A
Drive Belt Tension
Notice
Checking the drive belt tension involves using the
Excelsior-Henderson belt tension gauge, part no.
EH-6999-0038. This procedure can be performed from
either the right or left side of the motorcycle.
Check Drive Belt Tension
1. Mount the motorcycle and bring it to an upright position.
2. Position the small O-ring on the belt tension gauge
directly over the 10 lb. mark on the plunger.
3. Have an assistant complete steps 4–5.
4. 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.
Vehicle Setup
1. SMALL O-RING
2. PLUNGER
1. LOWER BELT GUARD 2. TENSION GAUGE
3. BASE OF BRACKET
4. BODY
5. LARGE O-RING
10556
10469
5. 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.
6. Remove the belt tension gauge and measure the
distance between the base of the tension gauge bracket and
the large O-ring. If the measurement is between 1/4” and 3/
8”, the drive belt tension is correct.
7. Adjust belt tension as necessary.
Adjust Drive Belt T ension
1. Remove and discard the rear axle cotter pin. Loosen the
rear axle castle nut enough to allow the rear axle to slide
back and forth in the swing cage.
2. Turn both rear axle adjusters an equal amount until the
drive belt tension is correct, making sure the adjusters are
firmly seated against the adjuster collars.
3. Tighten the adjuster jam nuts.
4. Tighten the rear axle castle nut.
Torque: 111 ft.-lbs
1. DRIVE BELT
1. COTTER PIN
2. CASTLE NUT
3. ADJUSTERJAM NUT
10035
10553
4. REAR AXLE ADJUSTER
5. ADJUSTER COLLAR
6999-0006 Rev. A 1-15
Vehicle Setup
5. Recheck drive belt tension, and install a new rear axle
cotter pin.
WARNING
Do not reuse a cotter pin because it may fail, causing
the wheel to loosen and the rider to lose control of the
motorcycle.
Engine Oil
The motorcycle comes from the factory filled with the correct
amount of 15W-40 mineral based break-in oil. No additional
oil should be required for starting and road testing the
motorcycle.
The oil level should be checked while the engine is at it’s
normal operating temperature. Since you will be road testing
the motorcycle later in the vehicle setup (consequently
heating the engine to normal operating temperature)
instructions for checking the oil level follow the Road Test.
10555
1. COTTER PIN
Low Fuel Indicator
Check the low fuel indicator before filling the
motorcycle with fuel. There must be less than 1 gallon
of fuel in the tank to actuate the low fuel indicator.
1. Insert the key into the main switch and turn the key to the
unlocked (horizontal) position and remove the key.
2. Turn the main switch to the Acc (Accessories) position.
The low fuel level indicator should illuminate.
3. Turn the main switch to the Off position.
10560
10561
1. UNLOCKED 2. LOW FUEL INDICATOR
1-16 6999-0006 Rev. A
Fuel Tank
Fill the motorcycle with the recommended fuel (see Super X
Specifications page 1-30) and check the fuel system for
leaks.
1. With the motorcycle on the sidestand and on level
ground, remove the right fuel cap.
2. Fill the fuel tank to a level aprox. 3/4” below the bottom of
the fuel filler insert.
WARNING
• Overfilling the fuel tank may cause fuel to overflow
when it expands.
• Fuel may leak from an improperly sealed or tightened
fuel cap. Tighten the fuel cap until you hear one or more
distinct clicks. Be certain the fuel cap is properly sealed
and tightened before starting the engine.
Vehicle Setup
Caution
Fuel can damage painted surfaces and plastic parts.
Wipe spilled fuel immediately from the motorcycle
using a clean, dry, soft cloth.
3. Inspect the fuel hose and its connection to the fuel pump
and to the fuel rail. Check for dampness or stains from
leaking or dried fuel.
10562
1. FUEL FILLER INSE RT 2. FUEL FILL HEIGHT
10563
1. FUEL HOSE 2. FUEL PUMP
Evaporative Control System
(California Only)
Visually inspect all hoses and connections. Make sure all
connections are tight. Also, inspect the evaporative canister
to make sure it has not been damaged.
10564
1. EVAPORATIVE CANISTER
6999-0006 Rev. A 1-17
Vehicle Setup
Electrical Components
Main Switch
1. Insert the key into the main switch and turn the key to the
locked (vertical) position and remove the key.
2. Move the indicator to the On, Acc,andOff positions. All
electrical circuits should remain inactive during this operation.
3. Insert the key into the main switch and turn the key to the
unlocked (horizontal) position and remove the key.
4. With the main switch unlocked and in the Off position, all
electrical circuits should be inactive.
5. Turn the indicator to the Acc position. When the main
switch is unlocked and in the Acc position, all lighting circuits
are energized. You can activate all switch and
button-operated controls except the electric starter button.
10530
1. LOCKED 2. INDICATOR
6. Turn the indicator to the On position. When the main
switch is unlocked and in the On position, all electricalcircuits
are energized including the electric starter button.
Caution
Do not start the engine until all the electrical
components have been checked.
Indicator Lights
There are six indicator lights on the speedometer face.
Check Engine Indicator
1. With the main switch unlocked, turn it to the On
position. Set the engine stop/run switch on the right
handlebar controls to the Run position. The check
engine indicator should illuminate.
2. Set the engine stop/run switch to the Stop position, and
turn the main switch to the Acc position.
1. UNLOCKED
2. OFF POSITION
1. ON POSITION
10531
3. ACC POSITION
10532
10565
1. CHECK ENGINE INDICATOR
1-18 6999-0006 Rev. A
Notice
Check the remainder of the indicator lights with the
mainswitchintheAcc position. When you have
completed these checks return the main switch to the
Off position.
Headlamp High Beam Indicator
1. Set the headlamp dimmer switch to high beam
position. The headlamp high beam indicator should
illuminate.
2. Set the headlamp dimmer switch to the low beam
position.
Vehicle Setup
10601
1. ACC POSITION
Turn Signal Indicator
1. Pushandreleasetheturnsignalswitchtotheright
or left. The turn signal indicator should flash.
2. Push the turn signal switch in toward the handlebar to
cancel the turn signals.
3. Push and release the turn signal switch to the opposite
direction. The turn signal indicator should flash.
4. Push the turn signal switch in toward the handlebar to
cancel the turn signals.
Neutral Indicator
Make sure the transmission is in neutral. The neutral
indicator should be illuminated.
Low Oil Pressure Indicator
The low oil indicator should be illuminated.
10566
1. HIGH BEAM INDICATOR
10567
1. TURN SIGNAL INDICATOR
10568
1. NEUTRAL INDICATOR 2. LOW OIL PRESSURE
6999-0006 Rev. A 1-19
INDICATOR
Vehicle Setup
Low Battery Voltage Indicator
The low battery voltage indicator should not be
illuminated.
Notice
The low battery voltage indicator illuminates only when
the battery voltage drops below the minimum of
10.0 volts (± 1volt).
Instrument Pod Lights
The four instrument pod lights located behind the gauge
faces should be illuminated.
10569
1. LOW BATTERY VOLTAGE INDICATOR
Odometer/Trip Meter
A single, digital display on the speedometer face indicates
either the odometer or the trip meter mileage.
The odometer/trip meter function button toggles the digital
display between the odometer mileage and the trip meter
mileage. The odometer/trip meter function button also resets
the trip meter.
1. All the display digits should be clearly visible and ODO
should appear as part of the display.
2. Press and release the odometer/trip meter function
button. The trip meter display should be clearly visible and
TRIP should appear as part of the display.
3. Press and hold the odometer/trip meter function button
for two seconds. The trip meter display should reset.
10571
1. INSTRUMENT POD LIGHTS
1-20 6999-0006 Rev. A
1. DIGITAL DISPLAY
(ODOMETER MILEAGE)
2. ODOMETER/TRIP METER
FUNCTION BUTTON
10570
3. DIGITAL DISPLAY
(TRIP MILEAGE)
Fuel Gauge
The fuel gauge needle should be at the F mark on the gauge.
Headlamp
1. Check the headlamp to see that it is on.
2. Set the headlamp dimmer switch to the high beam
position. The headlamp brightness should increase.
3. Return the headlamp dimmer switch to the low
beam position. The headlamp brightness should
decrease.
Vehicle Setup
10542
1. FUEL GAUGE
dimmer switch
Turn Signals
1. Movetheturnsignalswitchtotheleft.Thefront
and rear left turn signal lights should flash.
2. Push the turn signal switch in toward the handlebar to
cancel the turn signals.
3. Move the turn signal switch to the right. The front and
rear right turn signal lights should flash.
4. Push the turn signal switch in toward the handlebar to
cancel the turn signals.
Horn
Press and release the horn button. The horn should
respond instantly with a loud and clear sound.
10572
1. HEADLAMP DIMMER SWITCH
10573
1. TURN SIGNAL SWITCH
10574
1. HORN BUTTON
6999-0006 Rev. A 1-21
Vehicle Setup
Emergency Flashers
1. Slide the emergency flasher switch to the left. All
four turn signals should flash.
2. Slide the switch to the right to cancelthe
emergency flashers.
Running Lights
The two amber front running lights and the tail light should be
illuminated. The licence plate light should also be illuminated.
10575
1. EMERGENCY FLASHER SWITCH
Brake Light
1. Apply slight pressure to the front brake lever. The tail light
brightness should increase.
2. Apply slight pressure to the rear brake pedal. The tail
light brightness should increase.
Starting the Engine
The motorcycle has a closed loop, port sequential, fuel
injection system. The system adjusts the fuel mixture and the
ignition timing based on combustion efficiency. The ECM
makes all adjustments necessary forstarting and running the
engine in all temperatures and other ambient conditions.
Usethefollowingproceduretostartthemotorcycleand
check the specific components indicated.
10427
1. RUNNING LIGHTS 2. LICENSE PLATE LIGHT
1. TAIL LIGHT
10602
10533
1-22 6999-0006 Rev. A
Electric Starter
1. Turn the main switch to the On position.
2. Set the engine stop/run switch to the Run position.
You should hear the fuel pump momentarily as it
pressurizes the fuel system.
3. With the transmission in neutral and the throttle in
the closed position, press and hold the electric starter
button for several seconds until the engine starts.
Listen to make sure the electric starter disengages
after the engine starts.
Notice
If the engine does not start within a few seconds after
pressing the starter button, release the button and wait
several seconds. Then press and hold the starter
button again. Hold the starter button for as short a time
as possible to minimize battery drain and avoid over
heating the starter. Do not hold the starter button in for
more than 10 seconds at any time.
Vehicle Setup
Indicator Lights - OFF
After the engine starts the check engine indicator and low oil
pressure indicator should go out.
Engine Idle - Tachometer
1. After the engine starts, the engine should run at a high
idle speed of approximately 1,500 R.P.M.
2. After reaching normal operating temperature, the engine
should run at a normal idle speed of approximately 950
R.P.M.
3. Use the tachometer in the instrument pod to verify the
engine R.P.M., and to make sure the tachometer is
functioning correctly.
1. ELECTRICSTARTER BUTTON
1. CHECK ENGINE
INDICATOR
2. LOW OIL PRESSURE
10577
INDICATOR
10578
1. TACHOMETER
6999-0006 Rev. A 1-23
Vehicle Setup
Engine Stop/Run Switch
1. With the engine running, set the engine stop/run
switch to the Stop position. The engine should stop
running immediately.
2. Turn the main switch to the Off position.
Road Test
During the first 500 miles of operation, critical parts require
special wear-in procedures so they seat and mate properly.
Use the following rules for operation during the road test to
ensure the engine’s long-term performance and durability.
• Vary the engine speed.
• Do not keep a steady engine speed for an extended time.
• Do not exceed 70 m.p.h. during the test ride.
• Select gears that prevent lugging a new engine.
Within these limitations, the engine can be run at speeds up
to 3000 rpm.
10579
1. ENGINE RUN STOP SWITCH
10580
Protective Apparel
We respect your right to make your own choices. However,
we recommend that you wear an approved helmet, eye
protection gloves, boots, and a jacket to prevent or reduce
your chance of injury in case of a fall during the road test.
Some state laws require that you wear an approved helmet,
eye protection, or both. Eye protection reduces the chance
that your vision could be impaired by wind or by airborne
particles and objects.
The combination of your boots and pants should completely
cover your legs, ankles, and feet, protecting you from engine
and exhaust system heat.
Engine Operation
1. Start the engine (see Starting the Engine page 1-22).
2. Allow the engine to idle for about 30 seconds. To prevent
putting the engine under load before the engine oil reaches
all areas requiring lubrication, do not rev the engine or put the
transmission in gear during this period.
3. Twist and release the throttle. The engine should respond
instantaneously.
4. Check for any unusual engine vibration or noise while
running the engine at a variety of different R.P.M’s.
10534
1-24 6999-0006 Rev. A
10580
Clutch Operation
1. With the engine running at idle speed, pull in the front
brake lever (engage brake) and pull in the clutch lever
(disengage clutch).
2. Push the shift lever down until you feel it drop into first
gear.
3. Release the front brake lever.
4. Release the clutch lever as you open the throttle. As the
clutch begins to engage, the motorcycle will begin to move
forward.
5. Pull in the clutch lever, and return the shift lever to
neutral.
6. Release the clutch lever.
7. Repeat steps 1-6 a few times until you are satisfied that
the clutch is fully engaging and disengaging the transmission.
Vehicle Setup
Transmission Operation
The motorcycle is equipped with a five-speed transmission
and a heel-toe shift pedal. T o shift to a higher gear, press
down on the rear pedal with your heel or lift up on the front
pedal with your toe. To shift to a lower gear, press down on
the front pedal with your toe.
1. With the engine running at idle speed and the
transmission in neutral, pull in the front brake lever (engage
brake) and pull in the clutch lever (disengage clutch).
2. Push the shift lever down until you feel it drop into first
gear.
3. Release the front brake lever.
4. Simultaneously release the clutch lever as you open the
throttle. As the clutch engages, the motorcycle will move
forward.
10582
1. GEAR PATTERN
6999-0006 Rev. A 1-25
Vehicle Setup
Upshifting
1. To shift to the next higher gear, accelerate to the
recommended shift point.
2. Close the throttle and pull in the clutch lever.
3. Press down on the rear pedal with your heel or lift up on
the front pedal with your toe, until you feel the transmission
move into the next gear.
4. Release the clutch lever as you apply the throttle.
WARNING
The clutch must be fully disengaged before you attempt
to shift gears. Forced shifting (shifting without the
clutch disengaged) may damage the engine,
transmission, and drive train, causing you to lose
control of the motorcycle.
Downshifting
1. To shift to a lower gear, pull in the clutch leverand close
the throttle.
2. Shift into the next lower gear and release the clutch lever
as you open the throttle.
Upshift
(Acceleration)
Gear Change
1st to 2nd 20 mph
2nd to 3rd 30 mph
3rdto4th 40mph
4thto5th 55mph
1. UPSHIFT POINTS(DURING BREAK-IN)
Upshift
Speed
WARNING
• Downshifting at a speed in excess of the recommended
downshift point may severely damage the transmission
or cause the rear wheel to lose traction. In either case,
you could lose control of the motorcycle. It could also
result in engine damage from running the engine too
fast. Reduce your speed before downshifting and do
not downshift at speeds above the recommended shift
points.
• Downshifting abruptly on wet, rough, loose, or slippery
surfaces can cause the motorcycle to loose traction. This
can cause you to lose control of the motorcycle. When
downshifting on such surfaces, release the clutch lever
very gradually.
• Downshifting in a curve may cause the rear wheel to lose
traction, which could cause you to lose control of the
motorcycle. Downshift before you enter a curve.
1-26 6999-0006 Rev. A
Downshift
(Deceleration)
Gear Change
5thto4th 45mph
4th to 3rd 35 mph
3rd to 2nd 25 mph
2nd to 1st 20 mph
1. DOWNSHIFT POINTS (DURING BREAK-IN)
Downshift
Speed
The transmission should shift upward and downward
smoothly through all the gears.
Run the motorcycle through all of the gears a number of
times, and check for any unusual transmission vibration or
noise while in each gear.
Brake Operation
1. Whileridingthemotorcycle,closethethrottleandapply
the front and rear brakes evenly. Applying slightly more front
brake than rear brake generally gives you the best braking
performance.
2. The front and rear brakes should operate smoothly and
quietly, allowing you to stop the motorcycle safely and quickly.
Vehicle Setup
WARNING
• Applying either brake so strongly that the wheel loses
traction may cause you to lose control of the
motorcycle.
• Braking hard on wet, rough, loose, or slippery surfaces
can cause the motorcycle to loose traction, and you could
lose control of the motorcycle. Apply the brakes lightly on
such surfaces.
• Braking while in a curve can cause you to lose control of
the motorcycle. Brake before entering a curve.
Motorcycle Handling
During the road test, pay special attention to the operation of
the following components:
• Drive Belt - runs quietly and free from excessive vibration
• Front Suspension - moves smoothly, absorbs impacts
without unnecessary friction or sticking
• Rear Suspension - moves smoothly, absorbs impacts
without unnecessary friction or sticking
• Wheels - little or no radial or lateral movement, rotation is
smooth and without interference
6999-0006 Rev. A 1-27
Vehicle Setup
Speedometer/Odometer Function
1. During the road test, make sure the speedometer needle
moves and reacts appropriately to changes in speed.
2. Make sure either the odometer or the trip meter display
advances as you ride.
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 off while
the motorcycle is in the upright position.
3. Rest the motorcycle on the sidestand and on level
ground. Remove the oil filler cap and wipe the dipstick clean.
Reinstall the dipstick and turn the cap clockwise until it seats.
10583
1. SPEEDOMETER 2. ODOMETER DISPLAY
10558
1. FILLER CAP AND
DIPSTICK
4. Remove the dipstick again and note the oil level.
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. Repeat steps 3-4 each time you
adjust the oil level.
If you need to add any oil, use only a 15W-40API-rated SF or
SG grade mineral based oil.
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 the rider losing control of the motorcycle.
10557
1-28 6999-0006 Rev. A
1. ADD MARK
2. MAX. COLD MARK
3. MAX.HOTMARK
Cleaning the Motorcycle
Before washing the motorcycle, make sure the engine and
exhaust pipes are cool.
Wash the motorcycle indoors or in the shade to preventwater
spotting.
1. Rinse off as much dirt as possible with low pressure
water.
Caution
• Do not spray or allow water to come into contact with
electrical components or connectors. Electrical components may be damaged by contact with water.
• Use as little water as possible when washing near the
air cleaner or the exhaust pipe openings. An
excessively wet air cleaner or water in the exhaust
pipes may cause the engine to start and run poorly.
2. Wash the entire motorcycle using a soft cloth or sponge
soaked in a solution of mild detergent and warm water. Apply
minimal pressure as you wash; let the detergent do the
cleaning. Excessive washing pressure may cause dirt, sand,
or other foreign materials on the motorcycle to scratchthe
finish.
3. Rinse the motorcycle with water running at low pressure.
4. Dry all components thoroughly before starting the
engine.
5. Start the engine and let it idle for a few minutes.
6. Make sure the brakes are functioning properly before
riding.
Vehicle Setup
10584
Notice
Excessively wet brake pads or discs may diminish
braking effectiveness. Dry these components
thoroughly before using the motorcycle.
6999-0006 Rev. A 1-29
Vehicle Setup
Super X Specifications
Dimensions
Overalllength.............................92.5"
Overallwidth..............................39.5"
Overallheight.............................52.5"
Saddleheight.............................26.5"
Wheelbase...............................62.9"
Groundclearance...........................5.9"
Weight
Dryweight .............................647lbs
Gross Vehicle Weight Rating
(GVWR).............................1140 lbs
Gross Axle Weight Rating
front.................................394lbs
rear.................................746lbs
Engine
Type..............................50° X-Twin
Numberofcylinders...........................2
Bore....................................3.66"
Stroke...................................4.02"
Displacement..........................85cu.in.
Compressionratio .........................9.2:1
Fuelsystem.........portsequential,closedloopEFI
Startingsystem..........................electric
Lubricationsystem..........pressure,dualscavenge
Aircleaner ...................drypaper/wiremesh
Transmission
Type.....................5speed,constantmesh
Primary reduction system. . . . . . . . wet multi-gear drive
Primaryreductionratio.....................1.75:1
Gearshiftpattern....................1down,4up
Gear ratios:
1st...................................2.53:1
2nd ..................................1.77:1
3rd...................................1.35:1
4th...................................1.00:1
5th...................................0.80:1
Clutch............................wetmulti-disc
Drivebelt ........... highperformancesynchronous
Chassis
Frametype..............tubularsteel,doublecradle
Front suspension . . . . leading link, double strut system
Rearsuspension......adjustable,gaschargedsystem
Casterangle............................... 30°
Trail.....................................6.25"
Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .±43°
Turningradius..............................7.6'
Brakes (diameter X width):
Front . . . 11.5" X 0.236" floating disc, 4 piston caliper
Rear. . . . 11.5" X 0.236" floating disc, 4 piston caliper
Wheels
Type:
Front....................stainlesssteel40spoke
Rear....................stainlesssteel40spoke
Size:
Front................................3.0X16
Rear................................3.5X16
Tires
Type ....................................tube
Size:
Front..............................MT90HB16
Rear..............................MU90HB16
Manufacturer and model . . . . . . ....Dunlop491EliteII
Maximum load:
Front.................................770lbs
Rear.................................930lbs
Air pressure (up to 200 lb. load):
Front.............................36psi(cold)
Rear.............................36psi(cold)
Air pressure (200 lb. – 440 lb. load):
Front.............................36psi(cold)
Rear.............................40psi(cold)
Electrical
Ignition system:
Type.............................inductivecoil
Timing........................... ECM-driven
Spark plug:
.........Excelsior-Henderson
Type
Gap................................0.035in.
Battery ........................... sealed18AH
Generator......................35ampregulator
Light bulbs (voltage, wattage X quantity):
Headlamp . . . . .halogen sealed beam, ANSI #H6024
Runninglight/Frontturnsignal..........ANSI#198
Rearturnsignal.....................ANSI#199
Tail/brakelight......................ANSI#198
Licenseplatelight...................ANSI#193
Speedometer .......................ANSI#161
Tachometer.........................ANSI#74
Fuel gauge. . ........................ANSI#74
Instrument Pod Indicators:
Headlamphighbeam..................ANSI#74
Checkengine........................ANSI#74
Turnsignal..........................ANSI#74
Neutral.............................ANSI#74
Lowoilpressure......................ANSI#74
Lowbatteryvoltage....................... LED
Lowfuel............................ANSI#74
Fuses:
Auxiliarylights........................10amps
Fuelpump...........................10amps
EFI.................................15amps
Lights...............................15amps
Horn................................10amps
Ignition...............................5amps
part no. 3199-0030
1-30 6999-0006 Rev. A
Super X Specifications (continued)
Fluids
Capacities:
Fueltank.............................. 5.75gal
Engineoil(withfilter) ....................... 4qt.
Brakeand clutch fluid . . . . . . . . . . DOT 5 hydraulic fluid
Fuel:
unleaded gasoline only, 92 pump octane minimum
• DO NOT USE GASOLINE CONTAINING
METHANOL. Using gasoline/methanol blends can
result in poor starting and engine operation, and
may damage critical fuel system components.
• Gasoline containing up to 15% MethylTertiary Butyl
Ether (MTBE) can be used.
• Gasoline containing up to 10% Ethanol can be
used.
• Gasoline that has been Reformulated or
Oxygenated can be used.
Engine oil:
Classification................API-ratedSForSG
Viscosity(first500miles)..........15W-40(+40°F)
Viscosity(after500miles).........20W-50(+40°F)
Viscosity (after 500 miles) . . . . .10W-40 (below 40°F)
Vehicle Setup
Caution
Do not combine mineral-base and synthetic oil
in the crankcase at the same time, as this can
cause serious engine damage.
6999-0006 Rev. A 1-31
Vehicle Setup
Super X Torque Specifications
Engine Fasteners:
Sparkplug .............................15ft-lbs
Uppercamcoverscrew...................12ft-lbs
Aircleanercoverscrew ....................8ft-lbs
Aircleanerelementscrew ..................8ft-lbs
Throttlebodybracketscrew.................8ft-lbs
Exhaustflangenut.......................20ft-lbs
Exhaustclamp..........................55ft-lbs
Heatshieldclamp.........................8ft-lbs
Mufflermountingscrew ...................30ft-lbs
Timinggearcoverscrew....................8ft-lbs
Oilfiltercoverscrew.......................8ft-lbs
Oilpumpcoverscrew......................8ft-lbs
Crankcase:
3/8-16 ...............................25ft-lbs
5/16-18..............................18ft-lbs
Oildrainplugs...........................30ft-lbs
Startermotormountingscrew ...............8ft-lbs
Starterterminalnut........................5ft-lbs
Primarydrivecoverscrew ..................8ft-lbs
Primarydrivecoverinsertscrew .............8ft-lbs
Clutchaccesscoverscrew..................8ft-lbs
Chassis Fasteners:
Front engine flange to frame. . . . . . . . . .......20ft-lbs
Front engine brackets to frame:
3/8-16 ...............................35ft-lbs
5/16-18..............................20ft-lbs
Rearenginemountrodtoengine............60ft-lbs
Isolationmounttoengine(front&rear).......55ft-lbs
Isolationmountcapnut ...................50ft-lbs
Footboardsupportscrew..................25ft-lbs
Footboardpivotscrew .....................8ft-lbs
Passengerfootpegpostscrew .............50ft-lbs
Passengerfootpegpivotscrew.............25ft-lbs
Shifterbracketscrew .....................14ft-lbs
Shifterleverpinchscrew....................8ft-lbs
Shifterrodacornnut......................25ft-lbs
Rear brake master cylinder adapter screw. . . . .10 ft-lbs
Rearbrakemastercylinderscrew ...........18ft-lbs
Rearbrakereservoirscrew.................18ft-lbs
Rearbrakepedalpost ....................50ft-lbs
Swing cage pivot:
Bolt................................158ft-lbs
Nut..................................79ft-lbs
Rearshockabsorber .....................72ft-lbs
Batterycoverstrapscrew...................7ft-lbs
Voltageregulatorscrew.................... 7ft-lbs
Rearelectronicscoverscrew............... 7ft-lbs
Electronics/oilfillcoverscrew............... 7ft-lbs
Mainswitchbracketscrew ................. 7ft-lbs
Mainswitchscrew........................ 7ft-lbs
Rearaxlenut.......................... 111ft-lbs
Rearbrakecaliperbracketscrew........... 35ft-lbs
Rearbrakerotorscrew................... 50ft-lbs
Rearsprocketscrew..................... 55ft-lbs
Frontaxlebolt.......................... 79ft-lbs
Frontbrakecaliperbracketscrew........... 35ft-lbs
Frontcaliperrod........................ 30ft-lbs
Frontcaliperrodbracketscrew............. 35ft-lbs
Frontbrakerotorscrew................... 50ft-lbs
Fronthubcapscrew..................... 10ft-lbs
Rockerpivotscrew...................... 25ft-lbs
Rockerpinchscrew...................... 18ft-lbs
Frontstrutpivotshaftscrew ...............55ft-lbs
Frontstrutcapscrew..................... 10ft-lbs
Toptripleclampacornnut................. 25ft-lbs
Handlebarriserpost..................... 50ft-lbs
Handlebarriserscrew.................... 17ft-lbs
Handlebarrisercapscrew ................ 17ft-lbs
Hydraulicreservoirclampscrew............ 10ft-lbs
Hydraulic line banjo bolt . . . . . . ............ 18ft-lbs
Switchclustermountingscrew.............20in-lbs
Throttlecableretainerscrew...............20in-lbs
Headlamp/hornbracketscrew ............. 10ft-lbs
Hornscrew............................22in-lbs
Headlamppostscrew.................... 25ft-lbs
Headlampmountingscrew................ 35ft-lbs
Frontfenderscrew ...................... 35ft-lbs
Instrumentpodmountingscrew............ 12ft-lbs
Fueltankmountingscrew................. 20ft-lbs
Riderseatscrew........................ 18ft-lbs
Tandem seat screw. . . . . . . . . . ............ 18ft-lbs
Rearfendersupportscrew................ 50ft-lbs
Rearfenderscrew....................... 35ft-lbs
Rear fender extension:
Nut................................. 10ft-lbs
Screw................................ 7ft-lbs
Licenseplatebracketscrew................ 7ft-lbs
Taillighthousingscrew.................... 5ft-lbs
Frontbeltguardscrew .................... 7ft-lbs
Rear upper belt guard. . . . . . . . ............ 18ft-lbs
Rearlowerbeltguard..................... 5ft-lbs
1-32 6999-0006 Rev. A
NOTES
Vehicle Setup
6999-0006 Rev. A 1-33
Owner Predelivery 2
NOTES
2-0 6999-0006 Rev. A
2. Owner Predelivery
GeneralInformation..............2-1
VehicleLiteratureKit .............2-2
WARNING - Read Before You Ride
You and Your Motorcycle -
Riding Tips
RiderCourse Pamphlet
Notice of Motorcycle Patents
Dunlop
Rider’s Warranty & Service Records
The Excelsior-Henderson
California Emission Control System
Accessories Limited Warranty
Rider’s Handbook
Limited Warranty
Warranty
.....................2-2
.............2-2
Tire Care Booklet
.................2-3
........................2-4
.................2-4
..........2-3
....2-2
........2-2
..2-3
.......2-4
VisualInspection.................2-5
InstrumentsandControls..........2-5
AdjustRearSuspension...........2-5
Fuses...........................2-6
AdjustOperator’sControls.........2-6
Keys............................2-6
Pre-OperationCheck..............2-6
Break-in&Maintenance ...........2-7
500MileService..................2-7
MotorcycleDustCover ............2-7
General Information
The following information is provided to assist the Dealer Sales Representative. Please use this chapter as a guide to
guarantee delivery of all the necessary items and information associated with the new motorcycle. Helping the new
Owner enjoy their new motorcycle quickly and safely is to everybody’s best interests. The additional time spent with
the new Owner during this orientation builds goodwill and strengthens your relationship.
Both the Dealer Sales Representative and the new Owner should use the spaces provided on the
Vehicle Setup & Predelivery
to indicate completion of each step of the Owner Predelivery process.
Certificate of
6999-0006 Rev. A 2-1
Owner Predelivery
VehicleLiteratureKit
Please open the Literature Kit and discuss each item
individually.
WARNING - Read Before You Ride
This eye catching “Warning Sign” is a friendly reminder,
prompting the new Owner to read all the information provided
in the literature kit. It asks that special attention be given to
information found in the
Rider’s Handbook.
You and Your Motorcycle - Riding Tips
The booklet includes important tips that can help the new
Owner ride safely. It should take an average reader about 30
minutes to read the entire document carefully, and it may be
the most valuable half-hour the new Owner has ever had.
!
10585
RiderCourse
The pamphlet introduces the new Owner to the Motorcycle
Safety Foundation’s
Beginner and the Experienced courses are discussed. The
toll-free
RiderCourse
Pamphlet
RiderCourse
locator number is also provided.
. Information about both the
Notice of Motorcycle Patents
In addition to the patent information on the motorcycle, a
document announcing that certain features of the motorcycle
are protected by various United States Patents is included in
the Literature Kit. Please present this document to the new
Owner.
10586
10587
2-2 6999-0006 Rev. A
Owner Predelivery
Dunlop
In addition to providing tire maintenance and care
information, this booklet contains Dunlop’s Limited Warranty
and Warranty Registration Card.
The Dealer is required to fill in the following areas of the
registration card:
• D.O.T. Tire Identification Numbers
• Dealer’s Address
• Name of Dealer that sold the tire
The new Owner should complete the registration card and
send it to Dunlop to activate the warranty as soon as
possible.
Tire Care Booklet
(enter Excelsior-Henderson Motorcycle Manufacturing
Co.)
Rider’s Warranty & Service Records
This booklet is the business end of the Literature Kit.
It includes:
• The Excelsior-Henderson Limited Warranty
• The Noise Control System Warranty and Regulations
• The Emission Control System Warranty
• The California Emission Control System Warranty
• A service record checklist and note page for each
recommended service interval
• Warranty Transfer and Address Update cards
The Excelsior-Henderson Limited Warranty
Please take the time to explain the following elements of the
Excelsior-Henderson Limited Warranty to the new Owner:
• Warranty period
• Owner obligations
• Warranty duration and transferability
• Exclusions and limitations to the warranty
RIDER'S
WARRANTY &
SERVICE RECORDS
10588
10589
10590
6999-0006 Rev. A 2-3
Owner Predelivery
California Emission Control System Warranty
Dealers delivering motorcycles equipped with the California
Emission Control System, are asked to explain the basic
elements of the California Emission Control System Warranty
to the new Owner.
Accessories Limited Warranty
If you or any of your staff install Excelsior-Henderson brand
accessories on a 1999 model motorcycle prior to delivery,
please discard the ninety (90) day Accessories Limited
Warranty card supplied with the accessory kit.
Attach the twelve (12) month Accessories Limited Warranty
label found in the motorcycle’sLiterature Kit to the inside front
cover of the new Owner’s
Records
booklet.
Rider’s Warranty & Service
California Emission Control System
Warranty Statement
Your Warranty Rights And Obligations
The California Air Resources Board and Excelsior-Henderson, are pleased to explain
the emission control system warranty on your 1999 motorcycle. In California new
motor vehicles must be designed, built and equipped to meet the State's stringent antismog standards. Excelsior-Henderson must warrant the emission control system on your
motorcycle for the periods of time listed below provided there has been no abuse,
neglect or improper maintenance of your motorcycle.
Your emission control system may include parts such as the fuel-injection system, the
ignition system and engine computer. Also included may be hoses, belts, connectors and
other emission-related assemblies.
Where a warrantable condition exists, Excelsior-Henderson will repair your motorcycle
at no cost to you, including diagnosis, parts and labor.
ATTENTION
Authorized Excelsior-Henderson Dealers
If Excelsior-Henderson brand accessories are installed prior to delivery of
a new 1999 model motorcycle, please discard the ninety (90) day
Accessories Limited Warranty card that is included with the accessories.
Attach the following twelve (12) month Accessories Limited Warranty label
to the inside front cover of the Rider's Warranty & Service Records
booklet that will be delivered to the new Owner.
Thank You.
Accessories Limited Warranty
Excelsior-Henderson warrants Excelsior-Henderson brand accessories that are installed by
an authorized Excelsior-Henderson Dealer prior to delivery of a new 1999 model motorcycle
to be free from defects in materials, workmanship, and construction. Should the product fail
due to a defect in material, workmanship, and/or construction, after normal use, Excelsior-
Henderson Motorcycle Manufacturing Company will repair or replace the product, at its
option, at no charge for a period of twelve (12) months after the date of the initial retail
purchase of the motorcycle on which the accessory was installed. The defective product must
be inspected and repaired or replaced by an authorized Excelsior-Henderson Dealer.
Changes, modifications, or alterations to the accessories will not be covered by this warranty.
Product repaired or replaced under this warranty will assume the balance of the original
twelve (12) month warranty period.
If the product includes leather, given the characteristics of full-grain leather, no warranty is
extended for color variations, naturally occurring marks, or other imperfections indigenous to
EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY MAKES NO
OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND, EITHER EXPRESSED
OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
Accessories purchased at any other time (other than at the time of purchase of a new 1999
model motorcycle) are covered by a separate warranty included with the accessories.
EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY
the product.
A PARTICULAR PURPOSE.
805 Hanlon Drive • Belle Plaine, Minnesota 56011 USA
6999-0089 Rev. A
15California Emission Control System Warranty Statement
10591
10603
Rider’s Handbook
The Excelsior-Henderson
Rider’s Handbook
is the new
Owner’s primary reference book. In addition to the
information needed to safely operate and maintain the
motorcycle, it contains a special section of ExcelsiorHenderson history to help familiarize the new Owner with the
brand.
Notice
• All the information you need to complete the remainder
of Owner Predelivery is in the
Rider’s Handbook
Referring to it throughout the orientation familiarizes
the new Owner with the
Rider’s Handbook
strates its practical purpose.
.
and demon-
10535
2-4 6999-0006 Rev. A
Visual Inspection
Make sure the motorcycle is in excellent condition before the
new Owner takes possession. This step should help prevent
Excelsior-Henderson and its Dealer network from incurring
any fraudulent warranty expenses.
Instruments and Controls
Please address the location and demonstrate the operation
of each item described in the
Instruments and Controls
chapters of the
Product Description
Rider’s Handbook
and
Owner Predelivery
10592
.
Adjust Rear Suspension
Help the new Owner experience a great ride right from the
start. Adjust the rear suspension to fit the new Owner’s riding
needs. Refer to the
Instruments and Controls
the
Handbook
for settings and procedures.
Rear Suspension Adjustment
chapterof the
section of
Rider’s
Notice
• This procedure involvesusing the Excelsior-Henderson
rear shock adjusting wrench, part no. EH-6999-0029,
which is designed specifically for changing the preload
adjuster setting.
10593
10594
6999-0006 Rev. A 2-5
Owner Predelivery
Fuses
Before replacing the saddles, point out the location of the
electrical system fuses to the new Owner.
If no suspension adjustments are needed and the saddles
are not removed, all fuse information can be found in the
Electrical Equipment
Rider’s Handbook.
the
section of the
Maintenance
chapter of
Adjust Operator’s Controls
The following items maybe adjusted slightly to improve Rider
comfort:
• Handlebars and mirrors
• Gear shift pedal
• Rear brake pedal
Refer to the
information.
motorcycle’s Service Handbook
for additional
10595
Keys
Before presenting the new Owner with the motorcycle keys,
record the key identification number on the
Vehicle Setup & Predelivery.
The Owner must provide the key identification number when
ordering replacement keys.
Fill in or merely point out the space provided in the
Specifications
the key identification number. Space for recording the vehicle
and engine identification numbers is also provided.
chapter of the
Rider’s Handbook
Certificate of
for recording
Pre-Operation Check
Refer the new Owner to the
Rider’s Handbook
the
checking over the motorcycle before each ride.
Assure the new Owner that with a little practice, this check
will only take a few minutes, and may prevent serious
damage or injury.
Pre-Operation Check
and reinforce the importance of
chapter of
10596
10536
2-6 6999-0006 Rev. A
10597
Break-in & Maintenance
Please inform the new Owner that during the first 500 miles,
critical parts require special wear-in procedures to ensure
long-term performance and durability. Refer to the
During Break-In Period
chapter of the
In addition, regular service is required to keep the motorcycle
in top working condition. Regular service increases the
motorcycle’s durability, safety, and dependability, and
provides greater riding pleasure.
Rider’s Handbook
section of the
Operating and Riding
.
Operating
Owner Predelivery
500 Mile Service
We understand how busy your Service Department can get
during the riding season. Takegood care of the new
Excelsior-Henderson Owner by recommending that they
think ahead, and schedule their first 500 mile break-in
maintenance appointment NOW.
Motorcycle Dust Cover
The dust cover used to ship the motorcycle in the crate is
reusable, and should be given to the new Owner for use until
a more durable cover can be obtained.
10598
10599
10537
10600
6999-0006 Rev. A 2-7
Owner Predelivery
NOTES
2-8 6999-0006 Rev. A
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