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Excelsior-HENDERSON Super X 1999 Handbook

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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 Manufacturing Company. All rights reserved. Excelsior-Henderson , the X & Bar logo,
Super X, and Rider's Handbook are trademarks of the Excelsior-Henderson Motorcycle Manufacturing Company. Dunlop is a registered
trademark of the Dunlop Tire Corporation. RiderCourse is a registered trademark of the Motorcycle Safety Foundation.
6999-0006 Rev. A
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6999-0006 Rev. A

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Summary of Contents for Excelsior-HENDERSON Super X 1999

  • Page 1 Copyright© 1999 Excelsior-Henderson Motorcycle Manufacturing Company. All rights reserved. Excelsior-Henderson , the X & Bar logo, Super X, and Rider’s Handbook are trademarks of the Excelsior-Henderson Motorcycle Manufacturing Company. Dunlop is a registered trademark of the Dunlop Tire Corporation. RiderCourse is a registered trademark of the Motorcycle Safety Foundation.
  • Page 2 Introduction Dealer Support This Handbook has been prepared exclusively for the North/Northeast Regional Sales Excelsior-Henderson™ Dealer Network, and is designed to be used with the Excelsior-Henderson PH 1-612-873-7032 Certificate of Vehicle Setup & Predelivery (document FAX 1-612-873-7030 part no. 6999-0067).
  • Page 3 Vehicle Setup 10539 Super X™ - left side view 1. HORN 7. LEFT HANDLEBAR 13. LEFT REAR TURN SIGNAL 19. SIDESTAND 2. HEADLAMP CONTROLS 14. TAIL LIGHT 20. RIDER FOOTREST 3. FRONT LEFT TURN SIGNAL/ 8. INSTRUMENT POD 15. REAR AXLE ADJUSTER 21.

  • Page 4: Table Of Contents

    1. Vehicle Setup General Information ....1-2 Drive Belt Tension ....1-15 Moving the Crate ....1-2 Check Drive Belt Tension .

  • Page 5: 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 removed from the truck or trailer, the crate may be lifted by fork lift from either side or the end marked “Fork This End”.

  • Page 6: Opening The Crate

    Vehicle Setup 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.

  • Page 7: Initial Motorcycle Inspection

    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. 10513 Initial Motorcycle Inspection 1.

  • Page 8: Sidestand

    Vehicle Setup 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.
  • Page 9 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...

  • Page 10: Charge Battery

    Vehicle Setup 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. Notice Battery Charging *Time of Charge Type Rate Using 1 Amp Charger You can quick charge the battery with a constant current charger.

  • Page 11: Install Battery

    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.

  • Page 12: Tires

    Vehicle Setup 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.

  • Page 13: Fork Lock

    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.

  • Page 14: Adjust Throttle Freeplay

    Vehicle Setup 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”...

  • Page 15: Clutch

    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”...

  • Page 16: Adding Hydraulic Fluid

    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.

  • Page 17: Adjust Rear Wheel Alignment

    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.

  • Page 18: Drive Belt Tension

    Vehicle Setup 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. 10556 1. SMALL O-RING 3.

  • Page 19: Engine Oil

    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. 10555 1.

  • Page 20: Fuel Tank

    Vehicle Setup 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.

  • Page 21: Electrical Components

    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, and Off positions. All electrical circuits should remain inactive during this operation. 10530 1.
  • Page 22 Vehicle Setup Notice Check the remainder of the indicator lights with the main switch in the Acc position. When you have completed these checks return the main switch to the Off position. 10601 1. ACC POSITION Headlamp High Beam Indicator 1.

  • Page 23: Instrument Pod Lights

    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 (± 1 volt). 10569 1. LOW BATTERY VOLTAGE INDICATOR Instrument Pod Lights The four instrument pod lights located behind the gauge faces should be illuminated.

  • Page 24: Fuel Gauge

    Vehicle Setup Fuel Gauge The fuel gauge needle should be at the F mark on the gauge. 10542 1. FUEL GAUGE Headlamp 1. Check the headlamp to see that it is on. 2. Set the headlamp dimmer switch to the high beam position.

  • Page 25: Emergency Flashers

    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 cancel the emergency flashers. 10575 1. EMERGENCY FLASHER SWITCH Running Lights The two amber front running lights and the tail light should be illuminated.

  • Page 26: Electric Starter

    Vehicle Setup 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.

  • Page 27: Engine Stop/Run Switch

    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. 10579 1. ENGINE RUN STOP SWITCH Road Test During the first 500 miles of operation, critical parts require special wear-in procedures so they seat and mate properly.

  • Page 28: Clutch Operation

    Vehicle Setup 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.
  • Page 29 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.

  • Page 30: Brake Operation

    Vehicle Setup 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.

  • Page 31: Speedometer/Odometer Function

    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. 10583 1. SPEEDOMETER 2.

  • Page 32: Cleaning The Motorcycle

    Vehicle Setup 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 prevent water spotting. 1. Rinse off as much dirt as possible with low pressure water.

  • Page 33: Super X Specifications

    Type ..... 5 speed, constant mesh Type ..Excelsior-Henderson part no. 3199-0030 Primary reduction system.
  • Page 34 Vehicle Setup Super X Specifications (continued) Fluids Capacities: Engine oil: Fuel tank ......5.75 gal Classification .

  • Page 35: Super X Torque Specifications

    Vehicle Setup Super X Torque Specifications Engine Fasteners: Spark plug ......15 ft-lbs Voltage regulator screw.
  • Page 36 Vehicle Setup NOTES 1-33 6999-0006 Rev. A...
  • Page 37 Owner Predelivery NOTES 6999-0006 Rev. A...
  • Page 38 500 Mile Service ....2-7 The Excelsior-Henderson Limited Warranty ....2-3 Motorcycle Dust Cover .

  • Page 39: Vehicle Literature Kit

    Owner Predelivery Vehicle Literature Kit 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.

  • Page 40: Dunlop Tire Care Booklet

    • Warranty Transfer and Address Update cards 10589 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 •...

  • Page 41: California Emission Control System Warranty

    Owner’s Rider’s Warranty & Service 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- Records booklet.

  • Page 42: Visual Inspection

    Owner Predelivery 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. 10592 Instruments and Controls Please address the location and demonstrate the operation of each item described in the Product Description and Instruments and Controls chapters of the Rider’s Handbook .

  • Page 43: Fuses

    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 section of the Maintenance chapter of the Rider’s Handbook.

  • Page 44: Break-In & Maintenance

    500 Mile Service We understand how busy your Service Department can get during the riding season. Take good care of the new Excelsior-Henderson Owner by recommending that they think ahead, and schedule their first 500 mile break-in maintenance appointment NOW.
  • Page 45 Owner Predelivery NOTES 6999-0006 Rev. A...

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