Big Dog 2006 Chopper Owner'S Manual Download Page 41

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BRAKE SYSTEM

2006 CHOPPER

MAJOR COMPONENTS

FRONT BRAKE COMPONENTS

The front brake is a hydraulic disc type, which

is operated by the hand lever on the right handle bar. It is composed of:

A. FRONT DISC ROTOR

B. FOUR-PISTON CALIPER

C. BRAIDED STAINLESS STEEL LINE

D. 5/8 BORE MASTER CYLINDER & RESERVOIR

REAR BRAKE COMPONENTS

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 MASTER CYLINDER & RESERVOIR

NOTE: THE REAR BRAKE PEDAL IS LOCATED ON THE RIGHT FORWARD

FOOT CONTROL. DO NOT RIDE WITH YOUR FOOT RESTING ON THE BRAKE

PEDAL. THIS WILL CAUSE PREMATURE WEAR OF THE BRAKE PADS AND

CAN REDUCE YOUR BRAKING ABILITY.

Summary of Contents for 2006 Chopper

Page 1: ...cycling safety and pleasure This manual 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 current production information available at the time of printing Big Dog Motorcycles L L C reserves the right to make changes to their motorcycles without notice or obl...

Page 2: ...assenger Weight General 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 Maintenance Maintenance Log Service Cleaning Storage Trouble Shooting 4 WARRANTY 77 Warranty Warranty Transfer 2 ...

Page 3: ...nd you safe when operating 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 operating your motorcycle and enhance rider safety PHONE US 316 267 9121 EMAIL US customerservice bigdogmotorcycles com MAIL US Big Dog Motorcycles 1520 E Douglas Wichita KS 6721...

Page 4: ...and 4000 will prolong the 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 AIRFLOW OVER THE ENGINE WILL CAUSE OVERHEATING AND PERMANENT DAMAGE TO THE ENGINE HEAVY STOP AND GO TRAFFIC AND EXTENDED IDLING SHOULD BE AVOIDED ESPECIALLY DURING THE BREAK IN PE...

Page 5: ...re information contact a 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 GEAR 42 MPH 56 MPH 5TH GEAR 53 MPH 72 MPH 6TH GEAR 62 MPH 81 MPH 5 ...

Page 6: ...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 ...

Page 7: ...OTORCYCLE FOR THE OCCASIONAL 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 UNDER WARRANTY MAY RESULT 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 enrich...

Page 8: ...ther brake applied depressing 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 manually cancel the signal by pressing the same turn signal button By applying both turn signal buttons at the same time both signals will flash hazard lights RIDING THE MOTORCYC...

Page 9: ...D AND THE CLUTCH DISENGAGED 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 SHOULD NOT BE RUN FOR LONG PERIODS AT A CONSTANT RPM VARYING THE RPM WILL HELP THE ENGINE DURING THIS CRUCIAL PERIOD AND PROLONG ENGINE LIFE This QUICK START GUIDE was designed ...

Page 10: ...grees Front Suspension 41mm 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 Tire Pressure F 40psi R 42psi Engine OHV 45 degree V Twin Displacement 117 c i 1916cc Bore x Stroke 4 1 8 x 4 3 8 Compression Ratio 9 6 1 Transmission Baker 6 Speed Primary Drive...

Page 11: ...e the full 17 digit number when ordering 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 ification number is found on the right underside of the case VEHICLE ID NUMBER ENGINE ID NUMBER TRANSMISSION ID NUMBER 11 ...

Page 12: ...ADVERSELY AFFECT MOTORCYCLE 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 ON THE RIM OR SUDDEN TIRE FAILURE INSPECT TIRE TREAD FOR PUNCTURES CUTS BREAKS ETC AT LEAST WEEKLY IF IN DAILY USE OR BEFORE EACH TRIP IF USED ONLY OCCASIONALLY IF THERE IS UNC...

Page 13: ...you should have the tire 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 integrity of the tires each time you ride Be sure to keep tires properly inflated See the information on air pressure in this section for correct cold tire pressure Maximum inf...

Page 14: ...arefully check any approved 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 periodically The addition of accessories and additional weight to the motorcycle can affect the stability handling characteristics and safe operating speed Because Big Dog Motorcyc...

Page 15: ...ng a sidecar 6 Do not tow 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 lighting etc could cause an overloading of printed circuits CARRYING A PASSENGER When carrying a passenger it is your responsibility to instruct them on proper riding procedur...

Page 16: ... after refueling and get to know the 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 SERVICE CENTER FOR CORRECTION OF THE PROBLEM BE SURE ALL EQUIPMENT REQUIRED BY FEDERAL STATE AND LOCAL LAW IS INSTALLED AND IN GOOD OPERATING CONDITION REGULARLY INSPECT...

Page 17: ...ontains carbon monoxide 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 key from the switch when leaving the motorcycle unattended TOWING Do not tow a disabled motorcycle with another vehicle If a disabled motorcycle must be transported load into a t...

Page 18: ...park come to a complete 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 unavoidable face the motorcycle uphill Failure to face the motorcycle uphill while parked could cause the motorcycle to tip over Parking on asphalt during an extremely hot day...

Page 19: ...erienced rider we recommend 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 BEST FOR VISIBILITY IN TRAFFIC ESPECIALLY WHEN DRIVING AT NIGHT OR IN LOW LIGHT CONDITIONS AVOID CLOTHING THAT MAY GET TANGLED IN ANY PART OF THE MOTORCYCLE NEVER WEAR DARK GL...

Page 20: ...s never intended to withstand 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 not attempt to service the suspension Please contact a Big Dog Motorcycles Dealer or Authorized Service Center for any problems with these components REAR SUSPENSION This motorcy...

Page 21: ... MSF New riders as well as experienced 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 you call the national toll free number 800 447 4700 USA only 5 Be sure to keep your motorcycle in proper operating condition in accordance with the maintenance inter...

Page 22: ...2006 CHOPPER MAJOR COMPONENTS 22 MAJOR COMPONENTS Battery Controls Gear Shifter Power Train System Clutch Electrical System Ignition Switch Display Brake System Fuel System Fuel Valve SECTION 2 ...

Page 23: ...al problems contact a Big 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 under the seat or pillion pad and locate the suction release tab Release the suction cups by pulling up on the suction release tabs Remove seat carefully to avoid damage to paint...

Page 24: ...moothly outward to engage 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 signal is operated by the TURN L switch KEEP YOUR FINGERS FROM BETWEEN HAND CONTROL LEVERS AND HANDLEBAR GRIPS OR YOU WILL BLOCK FULL USE OF THE CONTROLS WARNING 24 A B C D ...

Page 25: ...ont brake hand lever is 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 to close it I THROTTLE FRICTION ADJUSTING SCREW Located at the bottom of the throttle grip clamp When used properly it can help reduce rider fatigue Do not use the throttle fric...

Page 26: ...RCUMSTANCES FORCING A SHIFT MAY DAMAGE 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 WARNING 26 6 5 4 3 2 N NEUTRAL SHIFTER FRONT OF MOTORCYCLE ...

Page 27: ... gearshift lever after each 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 raise the shift lever slightly until you feel a slight click If the key is on the green neutral indicator light will stay on after you release the pressure on the shift lever ...

Page 28: ...POWER TRAIN SYSTEM 2006 CHOPPER MAJOR COMPONENTS 28 A B C D ...

Page 29: ...clutch C BAKER 6 SPEED TRANSMISSION 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 varying speeds and conditions Proper gear selection while riding will enhance your enjoyment safety and help to ensure longevity of the engine D RIGHT SIDE BELT DRIVEN FINAL DRI...

Page 30: ...ine The clutch is manually 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 clutch lever partially compressed 2 When shifting gears make sure the throttle is closed before you engage or disengage the clutch 3 Keep your fingers from between the clutch hand...

Page 31: ...tch cable has too much slack the clutch 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 CAUSE CLUTCH PLATES CLUTCH PUSH RODS AND CLUTCH THROW OUT BEARINGS TO OVERHEAT AND OR WARP CLUTCH REPAIRS AND ADJUSTMENTS ARE A SERIOUS MATTER AND SHOULD ONLY BE PER...

Page 32: ...ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS 32 A B C D H I J G K F E ...

Page 33: ...ollowing 1 STARTING A BATTERY 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 SIGNALS ADJUSTING THE IGNITION TIMING ON THE CHOPPER IS NOT POSSIBLE TIMING IS DETERMINED BY THE CRANK SENSOR AND THE IGNITION MODULE CALIBRATES THE FIRING SEQUENCE DO NOT ATTEMP...

Page 34: ...he headlight to low beam 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 switches simultaneously and can be deactivated by applying either turn signal 8 With the engine not running the hazard lights can be activated by applying both turn signals bu...

Page 35: ... Center 1 Engine does not 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 to take your motorcycle to a Big Dog Motorcycles Dealer or Authorized Service Center They have the parts equipment and training to diagnose the problem and make the necessary r...

Page 36: ...orizontal or ON position the following 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 defaults to low beam annunciator lights tail tag and running lights front and rear COIL COVER IGNITION SIWTCH IGNITION KEY OFF IGNITION KEY ON The ignition switch activate...

Page 37: ...Y NOT COME BACK ON IMMEDIATELY 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 WARNING After shutting down the engine always turn the switch to the OFF position If you leave the ignition ON the lights will run down the battery To prevent theft always lock t...

Page 38: ...s low oil pressure when 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 familiar with shifting D HIGH BEAM LIGHT The blue indicator light is lit when the headlight is switched to the High position E RIGHT TURN INDICATOR LIGHT The yellow turn indicator wi...

Page 39: ...odometer G TACHOMETER The 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 illuminate and at 6000 RPM the Red LED s will illuminate as rev limiting engages IF THE OIL PRESSURE INDICATOR LIGHT FAILS TO GO OFF WITHIN THREE TO FIVE SECONDS AFTER STARTING IMMEDI...

Page 40: ...BRAKE SYSTEM 2006 CHOPPER MAJOR COMPONENTS 40 A B C F H D E G ...

Page 41: ...R CYLINDER RESERVOIR REAR BRAKE COMPONENTS 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 MASTER CYLINDER RESERVOIR NOTE THE REAR BRAKE PEDAL IS LOCATED ON THE RIGHT FORWARD FOOT CONTROL DO NOT RIDE WITH YOUR FOOT RESTING ON THE BRAKE PEDAL THIS WILL CA...

Page 42: ...SE LOSS OF CONTROL UNDER 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 fluid reservoirs to be kept full of DOT5 brake fluid Having adequate wear surface on the brake pads is equally important Remember brake fluid level will drop slightly as the bra...

Page 43: ...KE PEDAL OR YOUR HAND PUTTING 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 system have it inspected by a Big Dog Motorcycles Dealer or Authorized Service Center You can also refer to the Troubleshooting section for help 43 ...

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 ...

Page 45: ...r filter see Section 3 D 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 the enrichener lever for cold starting Push down the enrichener lever to close as the engine begins to warm F THROTTLE GRIP AND CABLES The throttle grip and cables are connecte...

Page 46: ...rcycle difficult to start FUEL ON Turn 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 FUEL VALVE 2006 CHOPPER MAJOR COMPONENTS IN THE FUEL ON POSITION FUEL ENTERS THE VALVE FROM APPROXIMATELY ONE INCH ABOVE THE BOTTOM OF THE TANK THE RESERVE POSITION...

Page 47: ...SECTION 3 2006 CHOPPER MAINTENANCE STORAGE 47 MAINTENANCE STORAGE Maintenance Maintenance Log Service Cleaning Storage Trouble Shooting ...

Page 48: ... S WARRANTY IN EFFECT IF 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 SUFFICIENT TO PROVE THAT THE REQUIRED MAINTENANCE WAS PERFORMED AT THE PROPER INTERVAL ACCORDING TO THE MAINTAINENCE LOG LOCATED IN THIS SECTION Prior to delivery of this new motorc...

Page 49: ...cuts 2 Brakes steering and 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 Cables for fraying or crimping and free operation 8 Engine oil primary chaincase and transmission fluid to maintain proper levels 9 Headlamp tail lamp brake lamp and directional l...

Page 50: ...cing may be required To 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 new motorcycle s warranty in effect If you or someone other than a Big Dog Motorcycles Dealer or Authorized Service Center performs the required service you must continuously ...

Page 51: ...Condition front rear Fluid Lines oil 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 bracket Rear Swingarm pivot arm pivot shaft nut and shocks Electrical Components and Switches Spark Plugs Inspect torque of all fasteners excluding engine head bolts Whee...

Page 52: ... 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 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS 2 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS 5 000 MILE MAINTENANCE DATE MILES DEALER COMMENTS 7 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS R Replace I Inspect clean adjust repair or replace if necessary ...

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 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 DEALER COMMENTS 15 000 MILE MAINTENANCE DATE MILES DEALER COMMENTS 17 500 MILE MAINTENANCE DATE MILES DEALER COMMENTS ...

Page 54: ... could occur resulting in 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 6 Disconnect the battery s negative cable to avoid accidental start up of the motorcycle or injuries 7 When running the engine adequate ventilation is imperative in preventing ...

Page 55: ...ornia models are equipped 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 air filter from the air cleaner back plate 3 Tap the filter on a flat surface to dislodge any large embedded dirt particles Use low pressure air 15 psi or below to clean the fil...

Page 56: ...d when the engine is at normal operating 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 avoid overfilling the oil tank 2006 CHOPPER MAINTENANCE STORAGE 54 DO NOT CHECK OIL LEVEL WITH THE MOTORCYCLE ON THE SIDE STAND THE MOTORCYCLE MUST BE IN THE UPRIGH...

Page 57: ... located at the rear of 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 contact surface on the oil filter mounting bracket 5 Apply a thin film of clean motor oil to the oil filter gasket and mounting bracket surface 6 Screw the filter onto the mountin...

Page 58: ...bnormal lifter noise Use 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 spring to reinstall with the filter screen or the filter screen will not be able to perform its function WINTER LUBRICATION The oil change interval in winter should be shorter tha...

Page 59: ...emperature 1 Turn the engine 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 wipe excess oil off and reinsert until threads on dipstick and filler neck align DO NOT THREAD 3 Remove the dipstick and take the reading The lubricant level should be between...

Page 60: ...ure that dirt and debris 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 and level 2 Remove screws and washers that secure the inspection cover Remove inspection cover 3 Primary lubricant should be at the bottom of the clutch diaphragm spring This i...

Page 61: ...ged 1 Remove the primary tensioner inspection 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 with 32 oz of lubricant For routine maintenance purposes with bike upright and level the proper fluid level can be visually checked by looking for partial oil coverag...

Page 62: ...USTABLE REAR SHOCKS Your 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 of the eye assembly A paper clip of short length of wire can be used in checking the hole When inserted the wire should not go in more than 1 8 inch DO NOT ADJUST THE EYES OUT S...

Page 63: ...stallation 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 ...

Page 64: ...side stand with anti seize 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 factory and should be checked along with pulley wear at the 500 mile service and each 2 500 miles thereafter Inspect the belt for signs of excessive wear tears cracks and missing ...

Page 65: ...shifting FRONT AND REAR 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 inspection may be necessary Visual inspection of brake pads can be made without removing the caliper by viewing the lower area of each caliper with the aid of a flashlight If brake pad...

Page 66: ...rcut inside the reservoir To service 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 IN YOUR BIG DOG MOTORCYCLES BRAKE SYSTEM THE FRONT WHEEL MASTER CYLINDER IS LOCATED BESIDE THE FRONT BRAKE HAND LEVER CARBURETOR CONTROLS The throttle control and ...

Page 67: ...ternator or voltage regulator 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 cleaned and torqued to 60 in lbs every 2 500 miles To service the battery 1 Remove the seat 2 Disconnect battery cables negative first positive last 3 Clean the cable connectors a...

Page 68: ...ve battery charger CONNECTING 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 THE ACCESSORY PLUG WIRES WILL CAUSE IGNITION ISSUES SPARK PLUG PLUG WIRE INSPECTION AND REPLACEMENT Inspect and or replace the spark plugs at 500 miles and every 2 500 miles th...

Page 69: ...lacing a halogen bulb never 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 it is still hot TURN SIGNALS The turn signals for this motorcycle are designed for brighter illumination and longevity Substitution with any other type or brand of turn signal ...

Page 70: ... RUN WELL UNTIL DRY START 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 MATERIALS MAY REDUCE BRAKING EFFICIENCY GENERAL CLEANING Care should be taken to keep your new motorcycle clean to inhibit rust and corrosion Chrome and aluminum parts must be...

Page 71: ...p your paint looking its best 1 DO NOT 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 inside If it must remain outdoors make sure to keep it protected with a high quality motorcycle cover Over time wind rain and daily exposure to sunlight all take the...

Page 72: ...g or travel gear on your 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 THE PAINTED SURFACES AS THIS CAN DAMAGE THE PAINT STORAGE Proper long term storage is important for trouble free operation of your motorcycle If you do not wish to perform the...

Page 73: ...e motorcycle for 1 2 minutes 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 If the motorcycle is to be covered use a material such as light canvas that will breathe Plastic materials trap condensation against the surfaces of your motorcycle FUEL IS FL...

Page 74: ...ttery 4 Start the engine 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 smoothness through full turning radius 9 Check tire pressure 10 Check all electrical equipment including turn signals headlight low and high beam brake light and horn 11 Check fo...

Page 75: ...RT 1 Fuel valve turned off 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 condition and shorting 7 Throttle held open when enrichener is used 8 Loose or corroded wire or cable connection s at coil HARD TO START 1 Throttle held open when enrichener used 2 F...

Page 76: ... condition or partially fouled 2 Spark 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 battery terminals or coils 6 Intermittent short circuit due to damaged wire insulation 7 Water or dirt in fuel system 8 Fuel vent system plugged 9 Air leak in intake...

Page 77: ... Heavy carbon deposit from 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 Wheels and or tires damaged or out of balance 4 Vehicle not properly aligned 5 Final drive belt badly worn 6 Primary drive chain badly worn or links tight as a result of insufficien...

Page 78: ...h rod cover washers etc 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 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 Malfunctio...

Page 79: ...fficient clutch spring attitude 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 TRANSMISSION JUMPS OUT OF GEAR 1 Shifter rod improperly adjusted 2 Shifter fork bent inside transmission 3 Worn shifter clutch gears in transmission 2006 CHOPPER MAINTENANCE STORAGE...

Page 80: ...taminated brake pad disc 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 Insufficient hand lever or rear pedal free play 7 Master or caliper pistons worn 2006 CHOPPER MAINTENANCE STORAGE 78 ...

Page 81: ...SECTION 4 2006 CHOPPER WARRANTY 79 WARRANTY Warranty Warranty Transfer ...

Page 82: ...ed The term of this Manufacturer 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 sale at retail on the date it is first placed in service Warranty services will be performed within a reasonable time after notification of a claim subject to inspection and fa...

Page 83: ...re not limited to the following 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 filters fluids or other maintenance items tires finish on polished metal exhaust discoloration squeaks chirps or rattles 2 Damage caused by exceeding manufacturer s recommended weigh...

Page 84: ...nd BIG DOG MOTORCYCLES control 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 use of wrong lubricants blockage or the failure to maintain proper levels of lubricants or any breakdown resulting from failure to protect vehicle from further damage when brea...

Page 85: ...ler or another vehicle or 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 or route work 10 Any breakdowns that occur to your vehicle outside the United States or Canada 11 Damage caused by failure to follow recommended BIG DOG MOTORCYCLES engine break...

Page 86: ...ENT OF A MECHANICAL BREAKDOWN To obtain 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 MOTORCYCLES 1520 E Douglas Wichita KS 67214 Follow these procedures 1 Use all reasonable means to protect your motorcycle from further damage that may result from continue...

Page 87: ...ING OUT OF THE OPERATION 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 MOTORCYCLE IS EXPRESSLY EXCLUDED THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE THE PROVISIONS OF THIS PARAGRAPH DO NOT APPLY TO SALES MA...

Page 88: ...injection system the ignition 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 repair your motorcycle at no cost to you including diagnosis parts and labor LIMITED WARRANTY ON EMISSION CONTROL SYSTEM BIG DOG MOTORCYCLES warrants that each new BIG DOG MOTORCY...

Page 89: ...olled vehicles fuel vapor 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 emission related parts may vary from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts Emission Control...

Page 90: ...DOG MOTORCYCLES recommends 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 all scheduled maintenance You are responsible for presenting your motorcycle to a BIG DOG MOTORCYCLES dealer as soon as a problem exists The warranty repairs should be completed ...

Page 91: ...and necessary maintenance to all covered 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 or unapproved modifications 1 The OWNER must keep a maintenance log validated by the servicing dealer and keep receipts and work orders showing the date mileage and...

Page 92: ...le 2 Modification to the 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 Big Dog Motorcycles Dealer or Authorized Service Center REPORTING SAFETY DEFECTS Required by the National Highway Traffic Safety Administration NHTSA If you believe that your v...

Page 93: ...on program before exercising 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 rights or seeking remedies under certain state consumer laws and lemon law statutes These requirements vary from state to state and are independent of the requirements of the federa...

Page 94: ... claim with the BBB OWNER 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 all repair orders and any other documentation to support OWNER S claim s BIG DOG MOTORCYCLES shall have ten 10 days from the receipt of written notice from the BBB that OWNER ha...

Page 95: ...ce regarding arbitration 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 by OWNER in a separate document furnished to OWNER at the time of sale entitled Notice of Warranty Dispute Resolution Program and is set forth in its entirety in this WARRANTY...

Page 96: ...ore you are eligible for remedies these 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 provide your name address phone number vehicle model vehicle identification number date of purchase current odometer reading the name of your BIG DOG MOTORCYCLES Deale...

Page 97: ...FF o PITBULL o RIDGEBACK 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 form does not diminish your warranty rights 2006 CHOPPER WARRANTY TRAMSFER ...

Page 98: ...Please mail this Warranty Transfer to Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 ...

Page 99: ...FF o PITBULL o RIDGEBACK 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 form does not diminish your warranty rights 2006 CHOPPER WARRANTY TRANSFER ...

Page 100: ...Please mail this Warranty Transfer to Big Dog Motorcycles 1520 E Douglas Wichita KS 67214 ...

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Big Dog 2006 Chopper, Owner'S Manual

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