2005 BIGDOG MASTIFF Recalls (8)
- Campaign:
- 05V149000 on 04/13/2005
- Component:
- Power train
- Manufactured:
- 07/31/2004 - 01/21/2005
- Affected:
- 1,418
- Defect:
- On certain motorcycles, the primary drive sprocket nut may back off the engine main shaft.
- Consequence:
- This could cause the primary drive to lock up and cause a crash. this condition could occur without any prior warning.
- Correction:
- Dealers will inspect and replace the drive sprocket nut free of charge. the recall began on may 13, 2005. owners may contact big dog at 316-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 05V432000 on 09/28/2005
- Component:
- Wheels:lugs/nuts/bolts
- Manufactured:
- 09/19/2004 - 05/31/2005
- Affected:
- 3,294
- Defect:
- On certain motorcycles, the rear wheel hub bolts could loosen and back out allowing the hub and brake rotor to detach from the wheel with an associated loss of stopping power.
- Consequence:
- This condition could occur without any prior warning and could result in a crash.
- Correction:
- Dealers will remove, clean and reattach the rear hub bolts free of charge. the recall began on october 14, 2005. owners may contact big dog at 1-312-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 06V019000 on 01/24/2006
- Component:
- Structure:motorcycle kickstand/center stand
- Manufactured:
- 08/07/2003 - 01/12/2006
- Affected:
- 9,726
- Defect:
- On certain motorcycles, the kickstand spring may stretch and detach from the mounting bracket or the kickstand.
- Consequence:
- This will allow the kickstand to deploy into the extended position and cause a crash.
- Correction:
- Dealers will install a new kickstand spring free of charge. the recall began on february 17, 2006. owners may contact big dog at 316-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 06V301000 on 08/08/2006
- Component:
- Electrical system:ignition:module
- Manufactured:
- 09/09/2004 - 07/23/2006
- Affected:
- 2,711
- Defect:
- On certain motorcycles, the ignition modules are oriented within the battery tray in a way that makes the ignition module susceptible to vibration.
- Consequence:
- This susceptibility to vibration may contribute to a stalling condition that could occur without any prior warning and result in a crash.
- Correction:
- Dealers will install a new ignition module mounting system free of charge. the recall began on august 25, 2006. owners may contact big dog at 316-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 06V305000 on 08/10/2006
- Component:
- Electrical system
- Affected:
- 2,101
- Defect:
- On certain motorcycles, the electronic harness control (ehc) module can fail resulting in a total shut down of the vehicle's electronic power.
- Consequence:
- This condition could occur without any prior warning and could result in a crash.
- Correction:
- Dealers will replace the ehc modules free of charge. the recall began on september 19, 2006. owners may contact big dog at 316-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 06V389000 on 10/11/2006
- Component:
- Structure
- Manufactured:
- 09/09/2004 - 04/11/2006
- Affected:
- 2,494
- Defect:
- On certain motorcycles, the long pivot bolt may bend or break during normal operation of the motorcycle.
- Consequence:
- This could potentially cause the rear fender to abrade against the rear tire while the motorcycle is being driven. this condition could occur without any prior warning and could result in a crash.
- Correction:
- Dealers will replace the long pivot bolt and, if necessary, straighten the rear frame side panel. the short left side pivot bolt and pivot shaft may also be replaced free of charge. the recall began on november 1, 2006. owners may contact big dog at 316-267-9121.
- Notes:
- Customers can also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 07V356000 on 08/14/2007
- Component:
- Electrical system:alternator/generator/regulator
- Manufactured:
- 09/09/2004 - 08/09/2005
- Affected:
- 7,611
- Defect:
- On certain motorcycles, a warped bus bar within the voltage regulator can cause a short circuit.
- Consequence:
- This could possibly result in a fire.
- Correction:
- Dealers will replace the existing circuit breaker located between the voltage regulator positive battery lead (b+ lead) and the positive battery terminal with an alternative circuit protection device that will prevent a thermal event if there is a short to ground. the recall began on october 1, 2007. owners may contact big dog at 1-316-219-9129 or email to customer.service@bigdogmotorcycles.com.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
- Campaign:
- 07V580000 on 12/17/2007
- Component:
- Structure:body
- Manufactured:
- 09/09/2004 - 11/29/2007
- Affected:
- 8,061
- Defect:
- On certain motorcycles, the rear fender strut attaching bolts can fail allowing the rear fender to detach from the motorcycle.
- Consequence:
- This could occur without prior warning and could result in an injury or a crash.
- Correction:
- Dealers will remove existing strut bolts and replace with higher tensile strength attaching bolts and updated washers. higher torque values will be observed when installing the replacement fasteners. the recall began on january 21, 2008. owners may contact big dog at 316-267-9121.
- Notes:
- Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
2005 BIGDOG MASTIFF TSBs (23)
- Bulletin:
- 1054
- Component:
- 102000 power train:manual transmission
- Summary:
- Baker 6-speed main shaft snap ring. *sc
- Bulletin:
- 1061
- Component:
- 061000 engine and engine cooling:engine
- Summary:
- 1/2 - 20 inch upper engine mount bolt retention. big dog. *tt
- Bulletin:
- 1055
- Component:
- 113000 electrical system:starter assembly
- Summary:
- Primary drive fluid seeping from the starter housing. *tt
- Bulletin:
- 1056
- Component:
- 063000 engine and engine cooling:exhaust system
- Summary:
- Exhaust end cap resonating rattling noise. *tt
- Bulletin:
- 1058
- Component:
- 116000 electrical system:ignition
- Summary:
- Engine running only on one cylinder and/or damaged ignition coil or ignition module. *tt
- Bulletin:
- 1059
- Component:
- 061110 engine and engine cooling:engine:gasoline:belts and associated pulleys
- Summary:
- Abnormal primary chain noise resulting from displacement of the adjusting shoe 10mm external snap ring retainer. *tt
- Bulletin:
- 143
- Component:
- 101000 power train:clutch assembly
- Summary:
- 05 clutch bearing carrier identification. *ak
- Bulletin:
- 1072
- Component:
- 110000 electrical system
- Summary:
- Inaccurate speedometer operation - vibrations at high speed are causing signal loss to needle from speed sensor. *tt
- Bulletin:
- 1079
- Component:
- 061000 engine and engine cooling:engine
- Summary:
- Upper engine mount screw is loose or missing. *ak
- Bulletin:
- 1075
- Component:
- 110000 electrical system
- Summary:
- Dielectric grease addition to connectors. *tt
- Bulletin:
- 1080
- Component:
- 160000 structure
- Summary:
- Tachometer board replacement - inaccurate tachometer readings or fluctuation in readings due to moisture. *ak
- Bulletin:
- 1078
- Component:
- 110000 electrical system
- Summary:
- Ehc contact improvement procedure (revised). current seal does not allow connector pins to seat properly and moisture may be present in connector. *tt
- Bulletin:
- 1069
- Component:
- 110000 electrical system
- Summary:
- Intermittent printed circuit board operation. *tt
- Bulletin:
- 1077
- Component:
- 121000 exterior lighting:headlights
- Summary:
- Headlamp connector may melt, making bulb replacement difficult. *tt
- Bulletin:
- 1088
- Component:
- 341000 communications:horn assembly
- Summary:
- Horn harness wires may break. *tt
- Bulletin:
- 1090
- Component:
- 100000 power train
- Summary:
- Rough shifting, or noisy transmission caused by loose transmission countershaft screw. *tt
- Bulletin:
- SIL-0001
- Component:
- 355200 equipment:other:owners/service/other manual
- Summary:
- Bigdog motorcycles: this letter highlights the difference between the various electronic harness controllers (ehcs). for models years 2005-2009 motorcycles. *pe
- Bulletin:
- SIL-0008
- Component:
- 355200 equipment:other:owners/service/other manual
- Summary:
- Big dog motorcycle: electrical side cover contact with belt guard. a wire bundle may protrude into the right electrical side cover. *pe
- Bulletin:
- 07V580
- Component:
- 021400 suspension:front:macpherson strut
- Summary:
- Big dog motorcycle: strut bolts replacement. remove strut bolts and install strut bolt kit p/n 243 000010-00. *pe
- Bulletin:
- 07-V-580
- Component:
- 162000 structure:body
- Summary:
- Bigdog motorcycle: rear fender strut bolt remedy. rear fender strut bolts may fail allowing the fender to detach from the motorcycle. *pe
- Bulletin:
- SB-1099
- Component:
- 091100 fuel system, other:storage:tank assembly
- Summary:
- Bigdog motorcycle: fuel tank vent may become flooded with fuel, causing the motorcycle to run poorly due to a fuel mixture that is too rich. *pe
- Bulletin:
- SB-1106
- Component:
- 355200 equipment:other:owners/service/other manual
- Summary:
- Bigdog motorcycle: new primary inspection cover gasket. install new inspection cover gasket on all 2005-2008 big dog motorcycles. *pe
- Bulletin:
- SB-1102
- Component:
- 350000 equipment
- Summary:
- Bigdog motorcycle: hidden shock electrical cover hardware replacement. electrical side covers may crack or break. 243-000011-00 for all models except 2006 k9. 243-000013-00 for 2006 k9 model. *pe
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