Big Dog Motorcycles CHOPPER 2006 Owner'S Manual Download Page 63

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SERVICE

2006 CHOPPER

MAINTENANCE & STORAGE

LENGTH ADJUSTMENTS

To increase the length of the shocks after installation,

loosen the short jam nut and turn the large adjuster nut counterclockwise. The range of

the adjustment is approximately 12 full turns. Alternate between each shock a little at a

time and make sure that they are even. Both adjuster nuts should be flush against the

shock body seal head at the same time.

All manuals and user guides at all-guides.com

Summary of Contents for CHOPPER 2006

Page 1: ...ual is designed to go with the motorcycle should you decide to sell it in order to provide history and additional information to the next owner The information in this manual is based on the most curr...

Page 2: ...Information 2 MAJOR COMPONENTS 22 Battery Controls Gear Shifter Power Train System Clutch Electrical System Ignition Switch Display Brake System Fuel System Fuel Valve 3 MAINTENANCE STORAGE 47 Mainten...

Page 3: ...ng the motorcycle Emphasize areas or improper procedures that could result in mechanical damage or jeopardize your personal safety Improve the longevity and performance of your motorcycle Useful in op...

Page 4: ...e life of your new engine AFTER 3000 MILES Follow the prescribed maintenance schedule located in Section 3 Maintenance and Storage in this manual QUICK START GUIDE PROLONGED IDLING WITH INADEQUATE AIR...

Page 5: ...Big Dog Motorcycles Dealer or Authorized Service Center QUICK START GUIDE 2006 CHOPPER GENERAL INFORMATION 2000 RPM 3000 RPM 1ST GEAR 19 MPH 23 MPH 2ND GEAR 24 MPH 33 MPH 3RD GEAR 33 MPH 47 MPH 4TH G...

Page 6: ...hener 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 t...

Page 7: ...ONAL RIDER BIG DOG MOTORCYCLES RECOMMENDS USING A TRICKLE CHARGER BDM250 00004 BIG DOG MOTORCYCLES DOES NOT RECOMMEND USING A STANDARD AUTOMOTIVE BATTERY CHARGER AS EARLY BATTERY FAILURE NOT COVERED U...

Page 8: ...ssing the appropriate signal switch will activate that signal continuously until the motorcycle is put in gear Once in gear and brakes are released the turn signal will cancel in 10 seconds You can ma...

Page 9: ...GED SPECIAL ATTENTION MUST BE GIVEN WHEN OPERATING IN FIRST AND SECOND GEAR AS IT IS VERY EASY TO EXCEED ENGINE MAXIMUM RPM DURING ACCELERATION NOTE DURING THE INITIAL BREAK IN PERIOD THE MOTORCYCLE S...

Page 10: ...1mm Telescopic Tube Length 10 OS Seat Height 25 Ground Clearance 4 5 Wheel Base 77 5 Total Length 104 Front Brake PM 4 Piston Diff Bore Rear Brake PM 4 Piston Front Tire MH90 21 Rear Tire 250 40 18 Ti...

Page 11: ...ring parts or making any inquiries about the motorcycle Example VIN 5J11YBJ116W000004 The engine identification number can be located on the upper left of the engine case The transmission ident ificat...

Page 12: ...CLE STABILITY TIRE SIZES ARE MOLDED ON THE TIRE SIDEWALL IMPROPER TIRE INFLATION WILL CAUSE ABNORMAL TREAD WEAR AND COULD RESULT IN UNSTABLE HANDLING UNDER INFLATION COULD RESULT IN THE TIRE SLIPPING...

Page 13: ...replaced TIRE INTEGRITY Maintaining tire integrity cannot be stressed enough Because the traction of your motorcycle is directly related to the condition of the tires make every effort to ensure the...

Page 14: ...ved accessories for the maximum weight capacities Luggage racks are designed for light weight items only Do not overload racks Be sure cargo is secure and will not shift while riding Recheck load peri...

Page 15: ...w a trailer with your motorcycle under any circumstance 7 Modifications and or additional electrical equipment are not recommended Any alterations of the 2006 electrical system turn signals additional...

Page 16: ...range of the motorcycle GENERAL INFORMATION 2006 CHOPPER GENERAL INFORMATION SHOULD ANY ABNORMALITY OCCUR IN THE OPERATION OF YOUR MOTORCYCLE IMMEDIATELY CONTACT A BIG DOG MOTORCYCLES DEALER OR SERVI...

Page 17: ...gas Do not inhale exhaust fumes and NEVER run the engine in a closed space like a closed garage or indoors SECURITY In order to protect the motorcycle against theft lock the ignition and remove the ke...

Page 18: ...stop put the transmission in neutral shut the engine off turn off ignition remove key turn fuel off and use the side stand to support the motorcycle Park on solid level ground If parking on a slope is...

Page 19: ...end that you take a certified course on motorcycle riding MAKE SURE YOU ARE WEARING A D O T APPROVED HELMET EYE PROTECTION CLOTHING AND FOOTGEAR SUITED FOR MOTORCYCLE RIDING BRIGHT OR LIGHT COLORS ARE...

Page 20: ...stand FRONT SUSPENSION This motorcycle uses conventional telescopic front fork assemblies The front suspension is vital to the motorcycle s handling Broken or worn parts need immediate attention Do no...

Page 21: ...ed riders will benefit from successfully completing a riding course In many states completing a riding course could lower your insurance premium For more information about a MSF training course near y...

Page 22: ...OMPONENTS 22 MAJOR COMPONENTS Battery Controls Gear Shifter Power Train System Clutch Electrical System Ignition Switch Display Brake System Fuel System Fuel Valve SECTION 2 All manuals and user guide...

Page 23: ...g Dog Motorcycles Dealer or Authorized Service Center If you do not ride frequently Big Dog Motorcycles recommends using a Trickle Charger BDM250 00004 SEAT REMOVAL To remove the seat place fingers un...

Page 24: ...e clutch B HEAD LAMP HIGH LOW SWITCH The head lamp switch controls the head lamp high and low beams C HORN SWITCH The horn is operated by depressing the horn switch D LEFT TURN SIGNAL The left turn si...

Page 25: ...operated with the right hand Pull the lever in towards the handlebar grip to engage the front brake H THROTTLE CONTROL GRIP Turn the control grip counter clockwise to open the throttle and clockwise t...

Page 26: ...GE THE SHIFT LEVER OR THE PRIMARY DRIVE TRAIN DO NOT RIDE WITH YOUR FOOT ON THE GEAR SHIFTER WHEN UP SHIFTING OR DOWNSHIFTING THE THROTTLE SHOULD BE CLOSED AND THE CLUTCH FULLY DISENGAGED GEAR SHIFTER...

Page 27: ...ach gear change and allow the lever to return to its central position before another gear change can be made The neutral position is between first and second gear To shift into neutral from first gear...

Page 28: ...POWER TRAIN SYSTEM 2006 CHOPPER MAJOR COMPONENTS 28 A B C D All manuals and user guides at all guides com...

Page 29: ...RANSMISSION The transmission delivers the power it receives from the engine to the rear wheel via the final drive belt The transmission also allows the engine to operate within its limitations under v...

Page 30: ...ly operated through a lever mounted on the left side handlebar The life of the clutch can be greatly prolonged by following these simple guidelines 1 Resist the urge to ride the clutch holding the clu...

Page 31: ...tch will not completely release This may cause hard shifting vehicle creep overheating and warping of the clutch plates and may make finding neutral difficult AN IMPROPERLY ADJUSTED CLUTCH CABLE CAN C...

Page 32: ...ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS 32 A B C D H I J G K F E All manuals and user guides at all guides com...

Page 33: ...TTERY B STARTING MOTOR 2 CHARGING C IGNITION SYSTEM D ENGINE OFF RUN SWITCH E ELECTRONIC HARNESS F SPARK PLUGS 3 IGNITION G ALTERNATOR H VOLTAGE REGULATOR 4 LIGHTING I HEADLIGHT J TAIL LIGHT K TURN SI...

Page 34: ...for the next time ignition switch is turned on 6 Ignition switch off returns the run stop switch on the right handlebar to the stop position 7 Hazard lights are activated by applying both turn signal...

Page 35: ...t start or difficulty in starting 2 Starter kickback 3 Poor running at low speeds 4 Poor running or low power at high speeds 5 Knocking or abnormal engine noise For any electrical problems it is best...

Page 36: ...ng will occur A Speedo self test display mode one to three seconds calibrated pulse count four to six seconds elapse time accumulated time seven seconds odometer trip mode B Power up headlight default...

Page 37: ...IATELY DUE TO RETAINED OIL PRESSURE DO NOT MODIFY THE LIGHT SWITCH WIRING TO CIRCUMVENT THE AUTOMATIC ON HEADLIGHT FEATURE HIGH VISIBILITY IS AN IMPORTANT SAFETY CONSIDERATION FOR MOTORCYCLE RIDERS WA...

Page 38: ...lit This light will come on when the ignition is on and off when minimum engine oil pressure is reached C TRANSMISSION NEUTRAL LIGHT The green indicator will help you find neutral as you become famili...

Page 39: ...e Tachometer registers in 500 RPM Revolutions Per Minute increments If the engine falls below 900 RPM all LED s will flash warning the rider of engine lugging At 4500 RPM the Yellow LED s will illumin...

Page 40: ...BRAKE SYSTEM 2006 CHOPPER MAJOR COMPONENTS 40 A B C F H D E G All manuals and user guides at all guides com...

Page 41: ...ONENTS The rear brake is a hydraulic disc type which is operated by the pedal on the right foot rest It is composed of E REAR DISC ROTOR F FOUR PISTON CALIPER G BRAIDED STAINLESS STEEL LINE H 5 8 BORE...

Page 42: ...EXTREME BRAKING ALWAYS LEAVE YOURSELF ENOUGH ROOM TO STOP WITHOUT LOSS OF CONTROL MAINTAINING BRAKE SYSTEM INTEGRITY Keeping the braking system performance at its best requires both master cylinder f...

Page 43: ...TTING PRESSURE ON THE FRONT BRAKE LEVER EXCEPT WHEN STOPPING AVOID PROLONGED BRAKE APPLICATION THIS CAN OVERHEAT THE BAKES AND REDUCE THEIR EFFECTIVENESS If you experience trouble with the brake syste...

Page 44: ...FUEL SYSTEM 2006 CHOPPER MAJOR COMPONENTS TANK CAPACITY Main Capacity 3 4 gal Reserve Capacity 4 gal Total Capacity 3 8 gal 44 C F D E A B All manuals and user guides at all guides com...

Page 45: ...FUEL LINE E ENRICHENER Facilitates cold starting by creating a richer than normal fuel condition The enrichener lever is positioned on the top of the carburetor behind the air filter housing Lift up...

Page 46: ...rn the lever until it has stopped in the ON position FUEL OFF Turn the lever until it has stopped in the OFF position FUEL RESERVE Turn the lever until it is centered between the ON and OFF positions...

Page 47: ...SECTION 3 2006 CHOPPER MAINTENANCE STORAGE 47 MAINTENANCE STORAGE Maintenance Maintenance Log Service Cleaning Storage Trouble Shooting All manuals and user guides at all guides com...

Page 48: ...YOU OR SOMEONE OTHER THAN A BIG DOG MOTORCYCLES DEALER OR AUTHORIZED SERVICE CENTER PERFORMS THE REQUIRED SERVICE YOU MUST CONTINUOUSLY MAINTAIN AND RETAIN RECEIPTS LOGS AND OTHER DOCUMENTATION SUFFI...

Page 49: ...nd throttle for responsiveness 3 Drive belt for condition 4 Brake fluid for level and condition 5 Brake lines and fittings for leaks 6 Brake pads and discs for excessive or disproportionate wear 7 Cab...

Page 50: ...determine specific recommendations for servicing your motorcycle consult your Big Dog Motorcycles Dealer or Authorized Service Center Remember maintenance at regular intervals is required to keep your...

Page 51: ...brake fuel Brake and Clutch Levers and Cables including throttle cables Throttle and Enrichener Controls Fuel Valve and Fuel Filter Screen Tires Steering Head Bearings fork stem and upper fork bracke...

Page 52: ...I I I I I I I I I I I DOWNLOAD DOWNLOAD DOWNLOAD DOWNLOAD 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS 2 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS 5 000 MILE MAINTENANCE DATE MILES DEALER CO...

Page 53: ...I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I DOWNLOAD DOWNLOAD DOWNLOAD DOWNLOAD 10 000 MILE MAINTENANCE DATE MILES DEALER COMMENTS 12 500 MILE MAINTENANCE DATE MILES DEALE...

Page 54: ...n a possible malfunction 4 Any oil solvent or grease on the floor can cause slips that could result in injuries 5 The engine must not be running while attempting any maintenance or service operations...

Page 55: ...d with a charcoal impregnated air filter For servicing follow the dry paper filter procedure 1 Remove the three Phillips screws attaching the air cleaner cover to the air cleaner back plate 2 Remove a...

Page 56: ...ting temperature setting upright and level First remove the seat then remove the oil cap by unscrewing counterclockwise The oil level should be just below the bottom of the filler neck Use caution to...

Page 57: ...the oil tank 2 Remove the threaded drain plug and allow oil to drain completely 3 Clean debris from the drain plug and reinstall Do not drain the crankcase 4 Remove the oil filter clean the gasket con...

Page 58: ...caution when cleaning so not to damage the filter screen when removing There is a spring under the filter screen cap to hold the filter screen in place Take care when removing that you retain the spr...

Page 59: ...gine off and position the motorcycle upright and level Leave the motorcycle in this position for a short period allowing the lubricant level to equalize 2 Remove the threaded dipstick see illustration...

Page 60: ...do not enter the transmission case PRIMARY DRIVE LUBRICANT Use a high grade primary drive lubricant designed for a wet clutch CHECKING PRIMARY DRIVE LUBRICANT LEVEL 1 Position the motorcycle upright...

Page 61: ...nspection cover screws cover and drain plug allowing the lubricant to drain Inspect and clean the magnetic drain plug Install the drain plug and tighten to 10 ft lbs torque Do not over tighten Fill wi...

Page 62: ...motorcycle adjustable rear shock feature is limited to 5 8 inch at the shock and approximately 1 3 4 inch at the seat A checking hole is drilled into the eye to indicate the maximum extended length o...

Page 63: ...ort jam nut and turn the large adjuster nut counterclockwise The range of the adjustment is approximately 12 full turns Alternate between each shock a little at a time and make sure that they are even...

Page 64: ...ze every 2 500 miles 4 All control pivot points may be lubricated regularly especially after driving in wet weather or after washing DRIVE BELT INSPECTION The rear drive belt tension is set at the fac...

Page 65: ...BRAKE INSPECTION Initially check your front and rear brakes at 500 miles then every 2 500 miles thereafter If you ride under adverse conditions like steep hills or heavy traffic more frequent inspecti...

Page 66: ...the rear brake master cylinder 1 Stand the motorcycle upright and level 2 Remove the master cylinder cover and visually check for fluid at the undercut inside the reservoir USE ONLY DOT 5 BRAKE FLUID...

Page 67: ...lator contact a Big Dog Motorcycles Dealer or Authorized Service Center BATTERY SERVICING AND INSTALLATION This motorcycle is equipped with a maintenance free battery Battery connections should be cle...

Page 68: ...CTING CABLES TO THE WRONG BATTERY TERMINALS CAN CAUSE SERIOUS DAMAGE TO THE MOTORCYCLE S ELECTRICAL SYSTEM DO NOT INSTALL ACCESSORY PLUG WIRES NEON TAYLOR ETC THE ELECTROMAGNETIC INTERFACE NOISE FROM...

Page 69: ...ver touch the glass portion with your bare fingers Oil contamination will reduce bulb life Always wrap the bulb in clean paper or a clean dry cloth during handling Do not attempt to remove bulb while...

Page 70: ...T THE ENGINE IMMEDIATELY AFTER WASHING AND BE SURE THE BRAKES AND ENGINE ARE OPERATING PROPERLY BEFORE RIDING DO NOT GET ANY CLEANERS WAXES POLISHES OR OTHER COMPOUNDS ON YOUR BRAKE COMPONENTS FOREIGN...

Page 71: ...OT APPLY ANY WAX PRODUCT FOR THE FIRST 90 DAYS DO NOT USE SILICONE BASED WAXES POLISHES OR CLEANERS 2 DO NOT APPLY ANY WAX PRODUCT EVER TO TO A MATTE FINISH 3 When not riding your motorcycle keep it i...

Page 72: ...paint DO NOT WASH YOUR MOTORCYCLE 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...

Page 73: ...utes to circulate the fresh oil and give the stabilizer a chance to reach the carburetor 4 Check condition of the drive belt 5 Inflate tires to proper pressure 6 Wash painted surfaces 7 Remove battery...

Page 74: ...and run until it reaches normal operating temperature Then turn off the engine 5 Check the oil level 6 Check the transmission lubricant level 7 Check controls for proper operation 8 Check steering sm...

Page 75: ...ff low fuel requires the fuel valve to be turned to reserve 2 Fuel tank empty 3 Engine flooded with fuel 4 Fouled spark plugs 5 Fuel valve clogged 6 Spark plug cable connections loose or in bad condit...

Page 76: ...rk plug cables in bad condition or have become detached check both ends of each spark plug cable 3 Spark plug gap too close or too wide 4 Battery nearly discharged 5 Damaged wire loose connection at b...

Page 77: ...om lugging engine 6 Carburetor set too lean 7 No air flow over engine i e stopped in traffic EXCESSIVE VIBRATION 1 Front or rear engine mounting bolts loose 2 Transmission mounting bolts loose 3 Wheel...

Page 78: ...3 Restricted oil return line to tank ELECTRICAL SYSTEM ALTERNATOR DOES NOT CHARGE 1 Regulator not grounded or defective 2 Engine ground wire loose or broken 3 Malfunction in charging system ALTERNATOR...

Page 79: ...ttitude CLUTCH CHATTERS 1 Friction disc or steel discs worn or warped TRANSMISSION HARD TO SHIFT 1 Transmission shifting mechanism needs adjustment 2 Bent shifter fork 3 Clutch out of adjustment TRANS...

Page 80: ...4 Brake pads badly worn 1 16 in minimum lining thickness 5 Brake discs badly worn or warped 6 Brake fades because of heat build up due to a Excessive braking riding the brakes b Brake pads dragging c...

Page 81: ...SECTION 4 2006 CHOPPER WARRANTY 79 WARRANTY Warranty Warranty Transfer All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 82: ...facturer s Limited Warranty shall begin on the date the motorcycle is delivered to the first retail purchaser or if the motorcycle is placed into service as a demonstrator or company vehicle prior to...

Page 83: ...llowing 1 Batteries drive belt brake pads light bulbs throttle cables choke cable and clutch control cable fasteners and connectors including but not limited to bolts clips nuts pins and screws filter...

Page 84: ...ontrol 5 Any damage and or breakdown caused by negligence lack of scheduled maintenance improper servicing or repairs performed by owner or an unauthorized repair facility for any breakdown caused by...

Page 85: ...r object or is used as a commercial unit or is used for rental taxi or shuttle delivery construction job site activities hauling police or emergency service off road use racing or competitive riding o...

Page 86: ...ain performance under this Manufacturer s Limited Warranty OWNER must either return the motorcycle at OWNER S expense to a Big Dog Motorcycles Dealer or Authorized Service Center or to BIG DOG MOTORCY...

Page 87: ...MAINTENANCE OR USE OF YOUR VEHICLE PHYSICAL DAMAGE PROPERTY DAMAGE LOSS OF USE OF THE MOTORCYCLE LOSS OF TIME INCONVENIENCE AND COMMERCIAL LOSS RESULTING FROM THE OPERATION MAINTENANCE OR USE OF THE...

Page 88: ...ition system catalytic converter and engine computer Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists BIG DOG MOTORCYCLES will rep...

Page 89: ...r separator canister ignition coil ignition wires and spark plugs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emi...

Page 90: ...ds that you retain all receipts covering maintenance on your motorcycle but BIG DOG MOTORCYCLES cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of al...

Page 91: ...ered components As the motorcycle OWNER you should be aware that BIG DOG MOTORCYCLES will void your warranty coverage if your motorcycle or a part has failed due to abuse neglect improper maintenance...

Page 92: ...air intake breather or replacement with a type that increases the noise level above the current standard Big Dog Motorcycles recommends that any noise related repair or maintenance be performed by a...

Page 93: ...sing rights or seeking remedies under the federal Magnuson Moss Warranty Act 15 U S C 2301 et seq OWNER may be required to resort to this alternative dispute resolution program before exercising right...

Page 94: ...R shall provide at a minimum the following information make and model vehicle identification number date of purchase place of purchase current odometer reading a list of all complaints and a copy of a...

Page 95: ...established in accordance with the Rules of the Better Business Bureau to settle any Warranty disputes that may arise with OWNER S BIG DOG MOTORCYCLES motorcycle is set forth in part and acknowledged...

Page 96: ...ese laws provide Your written notification should be sent to BIG DOG MOTORCYCLES Attn Warranty Dept 1520 E Douglas Avenue Wichita KS 67214 NOTE When writing to BIG DOG MOTORCYCLES you will need to pro...

Page 97: ...DEALERSHIP DATE OF PURCHASE MILES AT PURCHASE PURCHASE PRICE IGNITION KEY MAIL TO Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 California residents only failure to complete and return this for...

Page 98: ...Please mail this Warranty Transfer to Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 All manuals and user guides at all guides com...

Page 99: ...DEALERSHIP DATE OF PURCHASE MILES AT PURCHASE PURCHASE PRICE IGNITION KEY MAIL TO Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 California residents only failure to complete and return this for...

Page 100: ...Please mail this Warranty Transfer to Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 All manuals and user guides at all guides com...

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