2005 BIGDOG CHOPPER DT Recalls (4)

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:
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.

2005 BIGDOG CHOPPER DT TSBs (21)

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:
1081
Component:
102000 power train:manual transmission
Summary:
Shifting difficulty caused by loose transmission countershaft screw. *ak
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-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:
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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