EXCELSIOR HENDERSON HCX 1999 Manuals

Manuals and User Guides for EXCELSIOR HENDERSON HCX 1999. We have 1 EXCELSIOR HENDERSON HCX 1999 manual available for free PDF download: Service Handbook

EXCELSIOR HENDERSON HCX 1999 Service Handbook

EXCELSIOR HENDERSON HCX 1999 Service Handbook (474 pages)

Brand: EXCELSIOR HENDERSON | Category: Motorcycle | Size: 24 MB

Table of Contents

Table of Contents

6
- Service Information
  4
  - Replacement Parts
    4
  - Table of Contents
    6
- Routine Maintenance
  8
- Routine Maintenance
  9
  - Troubleshooting
    10
  - Maintenance Intervals
    10
  - Engine Oil
    11
  - Air Filter Element
    11
  - Drive Belt
    11
    
    Check Tension
    12
    
    Adjust Tension
    12
  - Throttle Cables
    13
  - Fuel Hose/Rail
    13
  - Emission Control System
    13
  - Oxygen Sensor
    14
  - Hydraulic Controls
    14
    
    Fluid Level
    14
    
    Levers and Pedal
    14
    
    Brake Pads
    15
  - Spark Plugs
    15
  - Steering Head Bearings
    15
  - Battery
    15
  - Tires
    16
  - Wheels and Spokes
    16
  - Sidestand
    16
  - Nuts/Bolts/Fasteners
    16
  - Road Test
    17
2. Body/Exhaust

23
- Body/Exhaust
  23
- Troubleshooting
  
  24
- Fuel Tank
  
  25
  - Draining
    26
  - Removal
    28
  - Installation
    29
- Saddle
  
  25
  - Removal
    25
  - Installation
    25
- Front Fender
  
  30
  - Removal
    30
  - Installation
    32
- Rear Fender
  
  32
  - Removal
    32
  - Installation
    33
- Exhaust System
  
  33
  - Removal
    33
  - Inspection
    35
  - Installation
    35
3. Lubrication System

39
- Lubrication System
  39
- Troubleshooting
  
  40
- Oil Pressure Pump
  
  41
  - Oil Pressure Test
    41
  - Removal
    42
  - Disassembly
    42
  - Inspection
    43
  - Assembly
    44
  - Installation
    45
- Oil Pressure Switch
  
  41
- Oil Scavenge Pump
  
  45
  - Removal
    45
  - Disassembly
    46
  - Inspection
    46
  - Assembly
    47
  - Installation
    48
- Crankcase Reed Valve
  
  48
  - Removal
    48
  - Engine Control System
    51
    
    System Operation
    54
    
    Fuel Injectors
    186
    
    Throttle Control
    188
    
    Air Cleaner
    189
    
    Throttle Body
    190
    
    Tilt Switch
    200
  - Engine Removal/Installation
    207
    
    Engine Installation
    212
    
    Oil Filter
    228
6. Cylinder Head/Cam Drive

247
- Cylinder Head/Cam Drive
  247
  - Troubleshooting
    249
  - Compression Test
    250
  - Cylinder Head/Cam Drive
    251
    
    Removal
    251
    
    Disassembly
    254
  - Inspection
    255
  - Valve Guide Replacement
    263
  - Valve Seat Refacing
    264
  - Assembly
    266
  - Camshaft/Gear Replacement
    267
  - Installation
    267
  - Cylinder Timing
    268
- Service Information
  249
7. Cylinder/Piston

275
- Service Information
  
  275
  - Cylinder/Piston
    275
- Troubleshooting
  
  277
- Cylinder
  
  278
  - Removal
    278
  - Inspection
    279
  - Measurement
    281
  - Deglazing
    282
  - Boring
    283
- Pistons
  
  284
  - Removal
    284
  - Installation
    289
  - Crankcase/Crankshaft
    293
9. Primary Drive

309
- Primary Drive
  309
- Outer Primary Cover
  
  310
  - Disassembly
    310
  - Removal
    310
  - Assembly
    311
  - Inspection
    311
  - Installation
    311
- Troubleshooting
  
  310
- Torsional Compensator
  
  312
  - Removal
    312
  - Inspection
    313
  - Installation
    314
- Inner Primary Cover
  
  314
  - Removal
    314
  - Inspection
    315
  - Installation
    315
10. Clutch

317
- Troubleshooting
  
  318
- Bleeding Clutch System
  
  319
- Master Cylinder
  
  320
  - Removal
    320
  - Disassembly
    321
  - Inspection
    321
  - Assembly
    322
  - Installation
    323
- Adjusting Clutch Freeplay
  
  320
- Slave Cylinder
  
  323
  - Removal
    323
  - Disassembly
    324
  - Inspection
    325
  - Assembly
    325
  - Installation
    326
- Clutch
  
  326
  - Removal
    326
  - Disassembly
    327
  - Inspection
    328
  - Assembly
    330
  - Installation
    332
11. Transmission

335
- Service Information
  
  336
- Troubleshooting
  
  336
- Gear Shifter
  
  337
  - Removal
    337
  - Disassembly
    337
  - Inspection
    337
  - Assembly
    338
  - Installation
    338
- Transmission
  
  339
  - Removal
    339
  - Disassembly
    339
  - Inspection
    341
  - Assembly
    344
  - Installation
    347
- Output Sprocket
  
  348
  - Removal
    348
  - Inspection
    349
  - Installation
    349
- Final Drive Belt
  
  350
  - Removal
    350
  - Installation
    351
12. Wheels

353
- Service Information
  
  354
- Troubleshooting
  
  354
- Front Wheel
  
  355
  - Removal
    355
  - Inspection
    355
  - Disassembly
    356
  - Assembly
    357
  - Installation
    358
- Rear Wheel
  
  358
  - Removal
    358
  - Inspection
    359
  - Disassembly
    360
  - Assembly
    361
  - Installation
    362
  - Alignment
    363
- Lacing Wheel
  
  364
- Truing Wheel
  
  366
- Tires & Inner Tubes
  
  368
  - Removal
    369
  - Installation
    370
  - Radial Runout
    371
  - Laterial Runout
    371
- Wheel Balance
  
  372
13. Front Suspension/Steering

375
- Service Information
  
  375
  - 13. Front Suspension/Steering
    375
- Troubleshooting
  
  376
- Handlebar
  
  377
  - Removal
    377
  - Inspection
    377
  - Installation
    378
- Struts
  
  379
  - Removal
    379
  - Disassembly
    381
  - Inspection
    381
  - Assembly
    383
  - Installation
    383
- Fork
  
  385
  - Removal
    385
  - Inspection
    386
  - Installation
    388
- Steering Head Bearings
  
  389
  - Inspection
    389
  - Removal
    389
  - Installation
    390
  - 14. Rear Suspension
    393
    
    Shock Absorber
    394
15. Brakes

401
- Troubleshooting
  
  402
- Bleeding Brake System
  
  403
- Front Master Cylinder
  
  404
  - Removal
    404
  - Disassembly
    404
  - Inspection
    405
  - Assembly
    405
  - Installation
    406
- Front Caliper
  
  407
  - Pad Replacement
    407
  - Removal
    408
  - Disassembly
    408
  - Inspection
    409
  - Assembly
    410
  - Installation
    411
- Rear Master Cylinder
  
  411
  - Removal
    411
  - Disassembly
    412
  - Inspection
    413
  - Assembly
    413
  - Installation
    414
- Rear Caliper
  
  415
  - Pad Replacement
    415
  - Removal
    416
  - Disassembly
    416
  - Inspection
    417
  - Assembly
    418
  - Installation
    419
16. Battery/Charging System

421
- Troubleshooting
  
  422
- Battery
  
  423
  - Removal
    423
  - Inspection
    423
  - Testing
    423
  - Charging
    424
  - Installation
    424
- Charging System Tests
  
  425
  - Regulated Voltage
    425
  - Alternator Output
    425
  - Alternator Stator
    426
  - Current Leakage
    426
  - Current Balance
    426
- Alternator
  
  427
  - Rotor Removal
    427
  - Rotor Inspection
    428
  - Rotor Installation
    428
  - Stator Removal
    429
  - Stator Inspection
    429
  - Stator Installation
    429
- Voltage Regulator
  
  429
  - Removal
    429
  - Installation
    430
17. Starter

433
- Troubleshooting
  
  434
- Starter Motor
  
  435
  - Current Draw Test
    435
  - Removal
    435
  - Disassembly
    435
  - Inspection
    436
  - Assembly
    437
  - Installation
    438
- Starter Relay
  
  438
  - Onboard Test
    438
  - Removal
    438
  - Inspection
    439
  - Installation
    439
- Starter Drive
  
  439
  - Removal
    439
  - Inspection
    440
  - Installation
    441
18. Lights/Gauges/Switches

445
- Service Information
  
  446
- Troubleshooting
  
  447
- Right Handlebar Control
  
  448
  - Removal
    448
  - Inspection
    449
  - Installation
    450
- Left Handlebar Control
  
  451
  - Removal
    451
  - Inspection
    452
  - Installation
    453
- Main Switch
  
  453
  - Removal
    453
  - Inspection
    454
  - Installation
    455
- Front Brake Switch
  
  455
  - Removal
    455
  - Inspection
    455
- Rear Brake Switch
  
  456
  - Removal
    456
  - Inspection
    456
  - Installation
    456
- Headlamp
  
  456
  - Bulb Replacement
    456
  - Removal
    457
  - Installation
    458
- Tail Lamp
  
  458
  - Bulb Replacement
    458
  - Removal
    458
- Turn Signal Control Module18-15
  
  459
  - Installation
    459
  - Removal
    459
  - Installation
    460
- Turn Signal Lamps
  
  460
  - Bulb Replacement
    460
  - Front Turn Signal
    461
  - Rear Turn Signals
    462
- Horn
  
  463
  - Removal
    463
  - Installation
    463
- Neutral Switch
  
  464
  - Onboard Test
    464
  - Removal
    464
  - Inspection
    464
  - Installation
    465
- Oil Pressure Switch
  
  465
  - Removal
    465
  - Inspection
    466
  - Installation
    466
- Instrument Cluster
  
  466
  - Removal
    466
  - Bulb Replacement
    467
  - Inspection
    467
  - Installation
    467
- Main Breaker
  
  468
  - Removal
    468
  - Installation
    468
- Fuses
  
  469
  - Replacement
    469
- Relays
  
  469
  - Removal
    470
  - Inspection
    470
  - Continuity Test
    471
  - Installation
    471
  - 19. Wiring Schematic
    473

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