Excelsior-HENDERSON HCX 1999, Service Handbook

Page: 317 / 474

10. CLUTCH
6999-0003 7/15/99
10-1
SERVICE INFORMATION
GENERAL
The Super X

motorcycle incorporates the use of a hydraulically actuated wet clutch. The clutch system includes the
clutch master cylinder, the clutch slave cylinder, and the clutch assembly. The 14 mm. bore master cylinder assembly
incorporates the fluid reservoir and is located on the left end of the handlebar. The slave cylinder is mounted to the
outer primary drive cover directly over the clutch assembly. The clutch is a multi-plate wet design residing between
the inner and outer primary drive covers.
Caution
• Cleanliness is essential when servicing hydraulic clutch components. Always ensure hands, tools, and work
surfaces are clean to avoid contamination.
• Use only DOT 5 (silicone based) hydraulic fluid from a sealed clean container. Using the wrong hydraulic
fluid, or allowing contaminants into the hydraulic system can damage brake system componants.
• Do not use mineral based products to clean clutch cylinder parts. Use only denatured alcohol, DOT 5 hydrau-
lic fluid, or a solvent specifically recommended for brake/clutch systems for cleaning these parts.
WARNING
• Wear eye protection when removing or installing retaining rings. Retain rings can slip and cause serious eye
injury. To avoid injury when removing or installing retaining rings, always use the correct size and type retaining
ring pliers and be sure the tips are not worn or damaged.
• To avoid blowing debris into your eyes and face, wear eye and face protection when working with compressed
air.
SERVICE INFORMATION . . . . . . . . . 10-1
TROUBLESHOOTING . . . . . . . . . . . . 10-2
BLEEDING CLUTCH SYSTEM . . . . . 10-3
ADJUSTING CLUTCH FREEPLAY . . 10-4
MASTER CYLINDER . . . . . . . . . . . . . 10-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 10-4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 10-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . 10-5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 10-6
INSTALLATION . . . . . . . . . . . . . . . . . . . 10-7
SLAVE CYLINDER . . . . . . . . . . . . . . .10-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 10-7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 10-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . 10-9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 10-9
INSTALLATION . . . . . . . . . . . . . . . . . . 10-10
CLUTCH . . . . . . . . . . . . . . . . . . . . . .10-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . 10-10
DISASSEMBLY . . . . . . . . . . . . . . . . . . 10-11
INSPECTION . . . . . . . . . . . . . . . . . . . . 10-12
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 10-14
INSTALLATION . . . . . . . . . . . . . . . . . . 10-16