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COLD STARTING PROCEDURE FOR CARBURETED MODELS:

Make certain the bike is in neutral.
Turn fuel petcock to the ON position.
Turn ignition switch to the ON position.
Depress handlebar ENGINE STOP switch to the RUN position.
Prime the motor with two twists of the throttle.
Lift up on carburetor enrichener half way.

Depress start button for no more than five seconds at a time until the engine starts.

Keep the engine running at fast idle or 1500 RPM using the throttle.
Depress the enrichener back to the pre-start position when the engine has achieved a constant 

and steady speed.

If the enrichener is left in the starting position, the spark plugs will foul, causing poor engine per-

formance and / or failed engine start.

Allow engine to warm approximately one to two minutes before riding.

NOTE: A battery discharges up to 2% per day when idle. If your motorcycle is not ridden for ap-

proximately for a month, the battery may not have sufficient charge to start your motorcycle. 

Big Bear Choppers does not recommend using a standard automotive battery charger as battery 

failure is not covered under warranty.

HOT ENGINE START:

Use the same procedure as cold start. Do not prime the engine with two (2) twists of the throttle 

and do not engage the carburetor enrichener.

SHUTTING DOWN:

Use the ENGINE STOP SWITCH on the right handlebar to shut off the engine. Turn the ignition key 

switch to the “OFF” position. Turn the fuel petcock to the “OFF” position.

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Summary of Contents for Chopper 2009

Page 1: ...UNDERSTAND THE MATERIAL BEFORE YOU RIDE YOUR NEW BIG BEAR CHOPPER MOTORCYCLE YOUR BBC MOTORCYCLE IS A THING OF BEAUTY BUT MORE IT S A MACHINE THAT REQUIRES YOUR ATTENTION EVERY NOW AND THEN FOR OPTIMU...

Page 2: ...2 3 Electrical System 2 4 Fuel System SECTION 3 Maintenance Storage 3 0 Inspection Overview 3 1 Fluids Inspection 3 2 Wheel Tire Inspection 3 3 General Inspection 3 4 Drivetrain Overview 3 5 Trouble S...

Page 3: ...rmance and pleasure of riding your Big Bear Chopper We want to acquaint you with your Big Bear Chopper components We want to advise you of the break in procedure to obtain maximum life of your Big Bea...

Page 4: ...described may not be standard on your bike but is on another The information in this manual is based on the most current production information available at the time of printing Big Bear American Mad...

Page 5: ...nd on the top righthand side of the case ENGINE IDENTIFICATION NUMBER TRANSMISSION IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER VIN stamped 17 digit number located between the regulator and eng...

Page 6: ...AIL __________________________ VEHICLE IDENTIFICATION NUMBER VIN stamped 17 digit number located between the regulator and engine on the front engine mount of the frame YEAR MODEL OF YOUR BIKE________...

Page 7: ...foul causing poor engine per formance and or failed engine start Allow engine to warm approximately one to two minutes before riding NOTE A battery discharges up to 2 per day when idle If your motorcy...

Page 8: ...tes before riding NOTE A battery discharges up to 2 per day when idle If your motorcycle is not ridden for ap proximately for a month the battery may not have sufficient charge to start your motorcycl...

Page 9: ...ROL During the break in period of your new motorcycle figure out the relationship of the clutch and the throttle Try not to over rev the engine especially when shifting Do not speed shift or shift wit...

Page 10: ...up to you to help protect that investment It is your the owner responsibility not to exceed the maximum RPMs during the break in period FIRST 3000 MILES Do not rev higher than 4000 RPM at any time in...

Page 11: ...nditions Different motorcycles ride different from each other Even though you might be riding for 3 decades and you have the need for speed be conserva tive on the throttle and in your riding style We...

Page 12: ...ng at night or in low light times Please do not wear clothing that may get tangled in any part of the bike other vehicles or surrounding objects or that hinder the operation of the controls Never wear...

Page 13: ...mbination of accessories you must be respon sible for safe operation of the motorcycle when operating with accessories or carrying additional weight The following guidelines should be used when equipp...

Page 14: ...d take them to heart 3 Enroll in a Certified Rider Training Course 4 Be sure to keep your Big Bear Chopper in proper riding condition that follows the maintenance intervals chart in this owner s manua...

Page 15: ...on the ENGINE STOP SWITCH before pressing the START SWITCH F RIGHT TURN SIGNAL The right turn signal is operated by the TURN R switch G ENGINE STOP SWITCH The engine stop switch turns the ignition on...

Page 16: ...her gear change can be made Neutral position is between first and second gear To shift into neutral from first gear raise the shift lever slightly until you feel a slight click To shift to neutral fro...

Page 17: ...life of your bike s clutch If the clutch cable is too tight the clutch plates will not fully engage and will cause the clutch to slip If the clutch cable has too much slack the clutch will not comple...

Page 18: ...he bakes and reduce their power If you experience trouble with your brake system have it inspected by an authorized Big Bear Choppers Dealer FOR BIG BEAR CHOPPERS SPRINGER FRONTENDS Be advised with a...

Page 19: ...ave any electrical problems IGNITION Adjusting the ignition timing on your Big Bear Chopper without proper knowledge could lead to engine damage and void your warranty If your bike exhibits any of the...

Page 20: ...wly and when you re done fueling tighten the gas cap until it is not loose Do not over tighten it Refuel in a well ventilated area with the engine turned off Do not smoke or allow open flames or spark...

Page 21: ...s stopped in the ON position FUEL RESERVE Turn the lever until it has stopped in the RES position In the Fuel ON position fuel enters the petcock from about one inch above the bottom of the tank The r...

Page 22: ...ently between the regular service intervals to determine if ad ditional maintenance is necessary The following items should be checked regularly 1 Tires Check for correct pressure abrasions or cuts 2...

Page 23: ...oil is needed depending on model TRANSMISSION LUBRICANT The transmission lubricant level should be checked monthly Big Bear Choppers recommends 80 90W GL5 V Twin motorcycle transmission lubricant Harl...

Page 24: ...r Choppers Dealer BRAKE FLUID LEVELS Check brake fluid levels at least every 5000 miles or annually Check the fluid in both the front and rear master cylinder reservoirs Use only DOT5 brake fluid for...

Page 25: ...uncertain of the tire integrity have your tires inspected by an authorized Big Bear Chop pers Dealer WHEEL INTEGRITY Your aluminum wheels should be checked regularly for dents or cracks TIRE INTEGRITY...

Page 26: ...e shift rod eyelets must remain in a vertical position to one another If the eyelets are not aligned vertically linkage may bind causing difficult shifting DRIVE BELT INSPECTION The rear drive belt te...

Page 27: ...ills or heavy traffic inspect the pads more often Visual inspection of brake pads can be made without removing the caliper by viewing the lower area of each caliper with a flashlight If brake pad mate...

Page 28: ...ient cranking power to start the motorcycle Use a motorcycle specific charger SPARK PLUG PLUG WIRE INSPECTION AND REPLACEMENT Inspect and or replace the spark plugs at the 500 mile mark then every 2 5...

Page 29: ...open belt drive is an option TRANSMISSION The transmission delivers the power it receives from the primary drive to the rear wheel by the final drive belt or chain The transmission also allows the en...

Page 30: ...ed 2 Fuel tank vent plugged or carburetor fuel line closed off restricting fuel flow 3 Spark plugs in bad condition 4 Loose wire or cable connection s at one of the battery terminals or at coil 5 Spar...

Page 31: ...vy carbon deposit from lugging the engine 6 Ignition timing retarded or overly advanced 7 Carburetor set too lean For Carbureted only 8 No air flow over engine stopping in traffic EXCESSIVE VIBRATION...

Page 32: ...OR CHARGE RATE IS BELOW NORMAL 1 Weak battery 2 Excessive use of add on accessories 3 Loose or corroded connections 4 Extensive periods of idling or low speed riding 5 Malfunction in charging system C...

Page 33: ...ylinder low on fluid 2 Air bubbles in the hydraulic system 3 Contaminated brake pad disc 4 Brake pads badly worn 1 16 in minimum lining thickness 5 Brake discs badly worn or warped 6 Brake fades becau...

Page 34: ...ts assuring you competent service However Big Bear Choppers is not liable for any actions or claims any shop or dealership may make You must always keep your receipts logs and other documentation to p...

Page 35: ...clutch cables 17 Inspect operation of throttle and enrichener controls 18 Check tire pressure and inspect for wear and damage 19 Check rear swing arm pivot nut for proper torque 20 Check all operation...

Page 36: ...ent 13 Inspect brake pads and discs for wear 14 Inspect brake fluid reservoir level and condition 15 Inspect oil lines and brake system for leaks 16 Lubricate brake and clutch levers and throttle and...

Page 37: ...t brake pads and discs for wear 14 Inspect brake fluid reservoir level and condition 15 Inspect oil lines and brake system for leaks 16 Lubricate brake and clutch levers and throttle and clutch cables...

Page 38: ...ar brake pedal and front lever adjustment 14 Inspect brake pads and discs for wear 15 Inspect brake fluid reservoir level and condition 16 Inspect oil lines and brake system for leaks 17 Lubricate bra...

Page 39: ...l and front lever adjustment 13 Inspect brake pads and discs for wear 14 Inspect brake fluid reservoir level and condition 15 Inspect oil lines and brake system for leaks 16 Lubricate brake and clutch...

Page 40: ...pads and discs for wear 14 Inspect brake fluid reservoir level and condition 15 Inspect oil lines and brake system for leaks 16 Lubricate brake and clutch levers and throttle and clutch cables 17 Insp...

Page 41: ...trap condensation against the surfaces of your bike Do not store the bike with gasoline in the tank inside your home or garage if there are open flames pilot lights sparks or electric motors present...

Page 42: ...r bike with cool water when the paint has been heated by direct sunlight This can break the bond between the paint and the metal surface Do not apply power wash directly on the painted surfaces as thi...

Page 43: ...ear Choppers brand of wheels and pulleys are warranted for the duration of 1 year and is transferable 9 If your motorcycle was contracted to Big Bear Choppers to build upon spec Big Bear Choppers will...

Page 44: ...t does not have a valid manufacturer s VIN or title branded as salvage junk rebuilt totaled or flood damaged Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot...

Page 45: ...nd other emission related assemblies Where a warrantable condition exists BIG BEAR CHOPPERS will repair your motorcycle at no cost to you including diagnosis parts and labor LIMITED WARRANTY ON EMISSI...

Page 46: ...IG BEAR CHOPPERS is limited solely to the remedying of defects in material or workmanship by BEAR CHOPPERS or an au thorized BEAR CHOPPERS Dealer at their place of business during customary business h...

Page 47: ...rinciples If OWNER accepts the arbitrator s decision BIG BEAR CHOPPERS will be bound to abide by the decision and comply with its terms subject to any limited right of review that may be provided by s...

Page 48: ..._________________________________________________ __________________________________________________________________________________________ ___________________________________________________________...

Page 49: ...lass II motorcycles 170 to 279 cc for a period of use of five 5 years or 18 000 kilometers 11 185 miles whichever first occurs Class III motorcycles 280 cc and larger for a period of use of five 5 yea...

Page 50: ...l tank fuel injection system spark advance mechanism crankcase breather air cutoff valves fuel tank cap for evaporative emission controlled vehicles oil filler cap pressure control valve fuel vapor se...

Page 51: ...ON HOW LONG AN IMPLIED WAR RANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU C No dealer is authorized to modify this Limited Emission Control System Warranty IV LEGAL RIGHTS THIS WARRANTY GIV...

Page 52: ......

Page 53: ...azard Health disorders from contact with oil What can happen Although it is extremely unlikely repeated contact of your skin by oil can cause serious health problems including cancer How to avoid the...

Page 54: ...e with your mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes get professional medical help immediately If gasoline spills on your skin wash...

Page 55: ...A loose or improperly attached part can come loose and jam a wheel or suspension or steering causing loss of control and an accident Improperly installed parts causing engine failure or seizure of the...

Page 56: ...the hazard Observe all load limits in this manual Never exceed the gross vehicle weight limits given on the weight label Concerning the GTX model never carry more than 10 pounds in your saddlebags Do...

Page 57: ...inflated over inflated or improper tires can cause a reduction in controllability or even loss of control of your motorcycle This can of course lead to a serious accident with potential serious injury...

Page 58: ...ntial hazard Working on the motorcycle when it is hot What can happen Many parts of the motorcycle including the exhaust pipe and muffler engine transmission and brakes become very hot during normal o...

Page 59: ...rear brakes for proper operation Ensure that both brakes function properly by rid ing slowly and braking gently as you first move off If you suspect any problem with the brakes contact your dealer bef...

Page 60: ...n cause instability which can lead to an accident and subsequent serious injury or death How to avoid the hazard Every time before you ride check the steering head for looseness excessive tightness or...

Page 61: ...rcycle on flat level paved surfaces only WARNING Potential hazard Injuring some part of your body with a rotating part What can happen Parts of your body can be caught in or between rotating parts on...

Page 62: ...atteries even the sealed type contain highly corrosive poisonous acid Contact with this acid can be destructive to any part of your vehicle that it touches and deadly if swallowed Contact with your sk...

Page 63: ...accessories such as racks trunks saddlebags etc Observe the accessories manufacturer and your motorcycle manufactur er s recommendation for loading Always ensure that accessories are properly and sec...

Page 64: ...o clean them Have your motorcycle dealer replace the pads before you ride your motorcycle WARNING Potential hazard Electrical fire or other damage to your motorcycle or injury to yourself What can hap...

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