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POWER TRAIN SYSTEM

2006 MASTIFF

 MAJOR COMPONENTS

28

A

B

C

D

Содержание 2006 Mastiff

Страница 1: ...afety 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 manua...

Страница 2: ...ssenger 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 MAINTEN...

Страница 3: ...d 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...

Страница 4: ...d 4 000 will prolong the life of your new engine AFTER 3 000 MILES Follow the prescribed maintenance schedule located in Section 3 Maintenance and Storage in this manual QUICK START GUIDE PROLONGED ID...

Страница 5: ...information contact a Big Dog Motorcycles Dealer or Authorized Service Center QUICK START GUIDE 2006 MASTIFF GENERAL INFORMATION 2 000 RPM 3 000 RPM 1ST GEAR 19 MPH 23 MPH 2ND GEAR 24 MPH 33 MPH 3RD...

Страница 6: ...hrottle 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 1 500 RPM using the throt...

Страница 7: ...TORCYCLE 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 BATTER...

Страница 8: ...her 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 i...

Страница 9: ...TCH 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 M...

Страница 10: ...ees Front Suspension 41mm Telescopic Tube Length 2 OS Seat Height 24 25 Ground Clearance 4 Wheel Base 77 5 Total Length 103 Front Brake PM 4 Piston Diff Bore Rear Brake PM 4 Piston Front Tire MH120 70...

Страница 11: ...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...

Страница 12: ...DVERSELY 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 RESUL...

Страница 13: ...ou 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 ever...

Страница 14: ...refully 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 r...

Страница 15: ...g 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...

Страница 16: ...after refueling and get to know the range of the motorcycle GENERAL INFORMATION 2006 MASTIFF GENERAL INFORMATION SHOULD ANY ABNORMALITY OCCUR IN THE OPERATION OF YOUR MOTORCYCLE IMMEDIATELY CONTACT A...

Страница 17: ...ntains 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 ign...

Страница 18: ...ark 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 I...

Страница 19: ...rienced 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 BRI...

Страница 20: ...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 im...

Страница 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...

Страница 22: ...2006 MASTIFF 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...

Страница 23: ...ms 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 p...

Страница 24: ...oothly 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...

Страница 25: ...nt 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 t...

Страница 26: ...CUMSTANCES 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 C...

Страница 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...

Страница 28: ...POWER TRAIN SYSTEM 2006 MASTIFF MAJOR COMPONENTS 28 A B C D...

Страница 29: ...lutch 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...

Страница 30: ...ne 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...

Страница 31: ...ch 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 IMP...

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

Страница 33: ...llowing 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...

Страница 34: ...e 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 ap...

Страница 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 electric...

Страница 36: ...rizontal 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 tri...

Страница 37: ...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 F...

Страница 38: ...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 neutr...

Страница 39: ...ometer 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 4 500 RPM the Ye...

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

Страница 41: ...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 BRAI...

Страница 42: ...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...

Страница 43: ...R YOUR HAND PUTTING PRESSURE ON THE FRONT BRAKE LEVER EXCEPT WHEN STOPPING AVOID PROLONGED BRAKE APPLICATION THIS CAN OVERHEAT THE BRAKES AND REDUCE THEIR EFFECTIVENESS If you experience trouble with...

Страница 44: ...FUEL SYSTEM 2006 MASTIFF MAJOR COMPONENTS TANK CAPACITY Main Capacity 3 9 gal Reserve Capacity 0 7 gal Total Capacity 4 6 gal 44 C F D E A B...

Страница 45: ...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...

Страница 46: ...cycle 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 centere...

Страница 47: ...SECTION 3 2006 MASTIFF MAINTENANCE STORAGE 47 MAINTENANCE STORAGE Maintenance Maintenance Log Service Cleaning Storage Trouble Shooting...

Страница 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 OT...

Страница 49: ...uts 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 disp...

Страница 50: ...ing 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 i...

Страница 51: ...ndition 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 Bearin...

Страница 52: ...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 DA...

Страница 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 DOWNLOAD DOWNLOAD DOWNLOAD DOWNLOAD 10 000 MILE MAINTENANCE DATE MILES DEALER COMMENTS 12 500 MILE MAINTEN...

Страница 54: ...ould 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...

Страница 55: ...rnia 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 cleane...

Страница 56: ...y check the oil level while the motorcycle is on the kickstand Proper oil level should be visible within the indicator marks Otherwise the oil level should be checked when the engine is at normal oper...

Страница 57: ...in 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 mountin...

Страница 58: ...every service interval or if there is abnormal 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...

Страница 59: ...the drive train is at normal operating temperature 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...

Страница 60: ...ith 20 oz of lubricant When draining and refilling the transmission lubricant insure that dirt and debris do not enter the transmission case PRIMARY DRIVE LUBRICANT Use a high grade primary drive lubr...

Страница 61: ...rimary lubricant should be changed initially at 500 miles and every 5 000 miles thereafter The drain plug is located under the clutch on the underside of the primary The filler access is the tensioner...

Страница 62: ...o get on rear wheel tire or brake components PRIMARY DRIVE CHAIN INSPECTION The primary drive chain adjustment should be checked initially at 500 miles and every 2 500 miles thereafter A loose primary...

Страница 63: ...HERE IS NOT ENOUGH THREAD ENGAGEMENT FOR PROPER SAFETY AND FUNCTION LENGTH ADJUSTMENTS To increase the length of the shocks after installation loosen the short jam nut and turn the large adjuster nut...

Страница 64: ...ide 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 te...

Страница 65: ...hifting 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...

Страница 66: ...keep the front handlebars in this position 3 Remove the master cylinder lid and visually check for fluid at the undercut inside the reservoir To service the rear brake master cylinder 1 Stand the mot...

Страница 67: ...any electrical system trouble is experienced that might be related to the alternator or voltage regulator contact a Big Dog Motorcycles Dealer or Authorized Service Center BATTERY SERVICING AND INSTA...

Страница 68: ...e 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 ELECTROMAGNETI...

Страница 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 attem...

Страница 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 B...

Страница 71: ...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 no...

Страница 72: ...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...

Страница 73: ...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 su...

Страница 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 opera...

Страница 75: ...T 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...

Страница 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...

Страница 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 mount...

Страница 78: ...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 cha...

Страница 79: ...ficient 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...

Страница 80: ...aminated 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...

Страница 81: ...SECTION 4 2006 MASTIFF WARRANTY 79 WARRANTY Warranty Warranty Transfer...

Страница 82: ...d 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 co...

Страница 83: ...lude but are 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...

Страница 84: ...control of BIG DOG MOTORCYCLES 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...

Страница 85: ...r 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 o...

Страница 86: ...NT 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 S...

Страница 87: ...NG 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 MAI...

Страница 88: ...njection 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 D...

Страница 89: ...lled 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 i...

Страница 90: ...OG 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 ensur...

Страница 91: ...nd 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...

Страница 92: ...e 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 mainten...

Страница 93: ...n 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...

Страница 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 co...

Страница 95: ...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...

Страница 96: ...re 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 D...

Страница 97: ...F 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 compl...

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

Страница 99: ...F 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 compl...

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

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