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Big Dog Service Bulletins

Discussion in 'Help Wanted' started by Th3InfamousI, Feb 27, 2017.

  1. Butch Cassidy

    Butch Cassidy Member

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    I sure could use the SB-1012 .... I am having issues ...
    If you can. Thanks
     
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  2. Th3InfamousI

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    Absolutely! But it's not much..just says clean sensor. haha

    [​IMG]



    Sent from my 2PS64 using Tapatalk
     
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  3. TapioK

    TapioK Well-Known Member
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    I have 3rd speedo on mail....for -08! I gave up and got Dakota digital, even when I don't like the look of that. I hope it works longer than year.
     
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  4. Butch Cassidy

    Butch Cassidy Member

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    :/ damn...
     
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  5. TapioK

    TapioK Well-Known Member
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    I wonder if my -03 has any of those done.... It was just standing there on the factory all those years after all
     
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  6. Th3InfamousI

    Supporting Member

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    Nope probably not a single damn one! Haha

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  7. Matheny 514

    Matheny 514 Active Member
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    That's an excellent find! I'd love to come across one of those. :old2:
     
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  8. TapioK

    TapioK Well-Known Member
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    So I will know when the frame breaks, struts give up, tank and speedo fells off, primary starts leaking and starter eats shit! Starter is actually acting strange once in the while, have to open it next time I go to Finland. BTW does -03 have a HD starter?
     
    #28 TapioK, Feb 28, 2017
    Last edited: Feb 28, 2017
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  9. Th3InfamousI

    Supporting Member

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    Yep any old Harley Big Twin starter will work. Stock one is 1.75KW

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  10. Matheny 514

    Matheny 514 Active Member
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    It would definitely be great if this was in PDF form to download. :old2:
     
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  11. Th3InfamousI

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    Haha well here's your frame bulletin.

    Also, if it happens I've attached the form to fill out...you can then hang it on your refrigerator. Lol

    Oh and don't forget about the fuel tank mount defect.

    [​IMG]

    [​IMG]

    [​IMG]

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  12. Biker Babe

    Biker Babe Queen Bee
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    Awww...this takes me back
     
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  13. Th3InfamousI

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    I combed through it tonight - I had a few PM's with people interested in some of the service bulletins, some I was never aware (Ex. 2005 Ridgeback Seat Issue). Most of the rest of us only saw the Safety mandatory ones. This is a neat little piece of history for us Die Hard Big Dog Folks. I will try and get this into PDF for reference for everyone.

    At this point most people probably have addressed most of the issues anyways wether indirectly or directly. But if anyone ever wants to know exactly the BDM recommended fixes they can find it in here.
     
  14. Th3InfamousI

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    If I gave away all my secrets I'd have nothing left to offer..haha.

    Unfortunately this only covers bulletins through 2007. I assume there was probably a few more later 08-10 that I don't have - Would be cool if we can complete the documentation somehow. I believe the more documentation that we can shore up for Big Dog Owners is a benefit to us all who still love the brand and there is quite a few of us who willing want to throw our legs over anything else.

    As I am typing this Im on my PC I am usually on phone. The computer just reminded me My Join Date is Sept 2009, I joined after I saw my first Big Dog it was a Pitbull 02 I think and knew I needed to have one, I was 24. I went home checked out Big Dog Bikes and knew I needed Ridgeback, black and chome. I went to Dream Machines here in Dallas and told the sales guy, black ridgeback he never called me back I think he thought I was a young kid, some bullshit tire kicker...I remember how much I was making in Salary back then and I still not sure how I pulled it off..ahah. I got lucky that Rent was really cheap as the economy was in the shitter. I also started dating a girl who moved in with me so my cheap rent was cut in half and I was getting laid. It was a win-win.

    I kept searching and found one at the dream machines in Austin. I was actually kind of mad the guy in Dallas didn't calle me to tell me their sister store had one. I sold off my CBR600 then bought my first one before I turned 25. I had my girlfriend drive me to Austin and I met her parents for the first time as they lived down there. I rolled up to her parents place on my brand new chopper at 25 years old...haha. I will never forget that.
     
    #34 Th3InfamousI, Feb 28, 2017
    Last edited: Feb 28, 2017
  15. Biker Babe

    Biker Babe Queen Bee
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    Love the story. Now that you mention it, my forum join day was the 29th of this month, 9 years ago. Back then, part of my job was taking the service writer's notes, including all these service bulletins, and entering them online with Big Dog.
     
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  16. Th3InfamousI

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    Haha..well we are glad to have you here Kathy.

    The forum has changed quite a bit in my 8 years here but I think we can all say we have had the honor of meeting some very wonderful people and many of us have made some life long friends. At the end of the day I think everyone here just wants to help get someone back on the road which is about all you can ask from a friend.

    Cheers to that

    Sent from my 2PS64 using Tapatalk
     
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  17. TapioK

    TapioK Well-Known Member
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    Trying to figure if I am lucky or not. Seems like my struts are not about to break, but frame is.
     
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  18. Th3InfamousI

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    Struts there was a recall in 03 too lol

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  19. TapioK

    TapioK Well-Known Member
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    Yep, for the other frame! remember, DT and RT big difference! DT frame holds, but rest falls apart, RT frame falls apart but rest is OK! Except electronics, starter, speedo and some other minor parts
     
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  20. BroadBand

    BroadBand Since late 60's

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    What I could find, for cross reference: part 1


    SERVICE BULLETINS

    Issued Bulletin Number Description

    10/1/01 SB1001

    2001 Mastiff

    ________________________________________

    10/1/01 SB1002

    2000 & 2001 Pitbulls

    ________________________________________

    10/1/01 SB1003

    Mid 1999 Husky XT and Bulldog

    ________________________________________

    10/1/01 SB1004

    TP MOTOR BREAK IN PROCEDURE

    ________________________________________

    10/1/01 SB1005

    2000, 2001 and 2002 BIG DOG MOTORCYCLES: TIMING PROCEDURE

    ________________________________________

    10/1/01 SB1006

    ALL 2001 BIG DOG MOTORCYCLES MODELS : COIL PROCEDURE

    ________________________________________

    10/1/01 SB1007

    ALL 2000 and 2001 BIG DOG MOTORCYCLES MODELS : CLUTCH ADJUSTMENT

    ________________________________________

    10/1/01 SB1008

    MID-2000 and EARLY 2001 BIG DOG MOTORCYCLES MODELS : IGNITION SWITCH REPLACEMENT

    ________________________________________

    10/1/01 SB1009

    1999 and 2000 BIG DOG MOTORCYCLES WITH PROJECT NUMBERS 1030 THROUGH 2947 : IGNITION MODULE UPDATE

    ________________________________________

    10/1/01 SB1010

    2001 MASTIFF : MASTIFF COMPENSATOR NUTS

    ________________________________________

    10/1/01 SB1011

    ALL 2001 BIG DOG MOTORCYCLES MODELS : BATTERY CONNECTION / BATTERY BOLT UPGRADE

    ________________________________________

    10/1/01 SB1012

    ALL 2001, 2002 and 2003 BIG DOG MOTORCYCLES MODELS : SPEEDOMETER MALFUNCTION

    ________________________________________

    10/1/01 SB1013

    ALL 1999 and 2000 BIG DOG MOTORCYCLES MODELS : PRIMARY GASKET UPGRADE

    ________________________________________

    10/1/01 SB1014

    2000 and 2001 BOXER, WOLF and VINTAGE SPORT MODELS : FIBERGLASS REAR FENDER TURN SIGNAL SUPPORT

    ________________________________________

    10/1/01 SB1015

    2001 HUSKY, BOXER, BULLDOG and PROSPORT MODELS : FIBERGLASS REAR FENDER BACKING PLATE

    ________________________________________

    10/1/01 SB1016

    ALL 1999 and 2000 WOLF, BULLDOG, HUSKY and PITBULL : HORN MOUNTING BRACKET

    ________________________________________

    10/1/01 SB1017

    2000 and 2001 WOLF, BULLDOG, VINTAGE SPORT, PROSPORT : TAIL LIGHT ELECTRICAL SPIKE ADVISORY

    ________________________________________

    10/1/01 SB1018

    SOME 2001 and 2002 BIG DOG MOTORCYCLES WITH TP ENGINES : TP MOTOR ENGINE-TO-PRIMARY LEAK

    ________________________________________

    10/1/01 SB1019

    2001 BIG DOG MOTORCYCLES WITH TP MOTORS AND S&S CARBS WITH A SINGLE INSULATOR BLOCK BETWEEN THE CARBERATOR AND MANIFOLD

    ________________________________________

    1/18/02 SB1020

    ALL TP MOTORS : TP HEAD AND CYLINDER GASKET SURFACES

    ________________________________________

    3/15/02 SB1021

    ALL 2001 and 2002 BIG DOG MOTORCYCLES : BENT MAINSHAFT ADVISORY

    ________________________________________

    3/15/02 SB1022

    2002 BOXER, BULLDOG, HUSKY, MASTIFF, PROSPORT and WOLF : SEAT FASTENER UPDATE

    ________________________________________

    11/1/02 SB1023A

    All Big Dog motorcycles equipped with “Total Performance” (TP) engines : HEAD OR BASE GASKET OIL SEEPAGE - TP ENGINES

    ________________________________________

    11/1/02 SB1024

    2003 Big Dog Choppers (Projects N3001 through N3077) : SWINGARM CONTACT WITH REAR FENDER

    ________________________________________

    11/1/02 SB1025

    2003 Big Dog Choppers (Projects N3001 through N3083) : CHOPPER FRONT FORK ADJUSTMENT

    ________________________________________

    11/1/02 SB1026

    2003 Big Dog Mastiff (M3002 – M3084) and Chopper (N3001 – N3091) : DRIVE UNIT ALIGNMENT

    ________________________________________

    10/1/03 SB1028

    2003 Big Dog Choppers (with Project Numbers N and T) : 2003 CHOPPER TANK MOUNT UPGRADE

    ________________________________________

    10/1/03 SB1029

    2003 Big Dog Mastiff and PitBull : 2003 DASH REINFORCEMENT

    ________________________________________

    10/1/03 SB1030

    All 2003 models : 2003 SPEEDOMETER SENSORS

    ________________________________________

    10/1/03 SB1031

    2003 Big Dog Choppers with Daytec Frames (Projects T3001 – T3132) : DAYTEC CHOPPER STRUTS

    ________________________________________

    10/1/03 SB1032

    2003 Models with the exception of Boxer : 2003 INNER PRIMARY LEAK

    ________________________________________

    11/1/03 SB1033

    2002 and 2003 Boxer : 2002 & 2003 BOXER TAG BRACKET UPGRADE

    ________________________________________

    3/1/04SB1034

    All 2004 Models built prior to November 1, 2003. : 2004 FRONT BRAKE MASTER CYLINDER COVER

    GASKET SEALING

    ________________________________________

    3/1/04SB1035

    Early 2004 models, all 2003 models, and late production 2002 5-speed models with left

    side drive. : LEFT SIDE DRIVE 2ND GEAR SHIFTING ENGAGEMENT

    ________________________________________

    5/15/04 SB1036

    All 2003 Models when installing optional compression releases. : ADDING ELECTRONIC SOLENOID COMPRESSION RELEASES

    ________________________________________

    7/12/04 SB1037

    2004 Pitbull (H4001 through H4252) and Ridgeback (R4001 through R4715) : RE-ROUTING 2004 REAR FENDER WIRE HARNESS

    ________________________________________

    7/12/04 SB1038

    All 2004 Models : 2004 FRONT MASTER CYLINDER SEEPAGE

    ________________________________________

    7/12/04 SB1040

    All 2004 Models : WATER SEEPAGE INTO CONNECTOR 23/24

    ________________________________________

    9/15/04 SB1042

    All 2004 Models : EHC REPLACEMENT

    ________________________________________

    9/15/04 SB1043

    All model engine cases except full polish : ENGINE CASE DISCOLORATION

    ________________________________________

    9/30/04 SB1044

    2003 and 2004 models with 250 rear tires. Pitbull, Ridgeback, Mastiff, Chopper and Daytec Chopper : Problem – Belt and Chassis Issues

    ________________________________________

    9/30/04 SB1044A

    2003 and 2004 models with 250 rear tires. : Attachment A

    ________________________________________

    9/30/04 SB1044B

    2003 and 2004 with 250 rear tires. : Attachment B

    ________________________________________

    9/30/04 SB1044C

    2003 and 2004 with 250 rear tires. : Attachment C

    ________________________________________

    9/30/04 SB1044D

    2003 and 2004 models with 250 rear tires. : Attachment D

    ________________________________________

    9/30/04 SB1044E

    2003 and 2004 models with 250 rear tires. : Attachment E

    ________________________________________

    9/30/04 SB1044F

    2003 and 2004 models with 250 rear tires. : Attachment F

    ________________________________________

    9/30/04 SB1044G

    2003 and 2004 models with 250 rear tires. : Attachment G

    ________________________________________

    9/30/04 SB1044H

    2003 and 2004 models with 250 rear tires. : Attachment H

    ________________________________________

    10/25/04 SB1045

    All models with PM calipers utilizing BDM180-00139 brake pads. : Brake Pad / Rotor - Inspection and Replacement

    ________________________________________

    10/15/04 SB1046

    2004 Ridgeback with BDM130-00144 fork assembly / 2004 N & T Choppers with BDM130-00145 fork assembly : Fork Dust Cover O-ring Nonconformance

    ________________________________________

    11/5/04 SB1048

    2005 Models shipped prior to 11/01/04 : Problem – Tachometer Printed Circuit Board (PCB) Failures

    ________________________________________

    12/1/04 SB1049

    All 2004 – 2005 models : Issue – Headlight Circuit Failure Due to Aftermarket Lamp Installation and

    Misdiagnosis of Cause

    ________________________________________

    12/15/04 SB1050

    2005 Mastiff models limited to project numbers M5001 to M5064 : Throttle Cable – Fuel Tank Contact

    ________________________________________

    1/15/05 SB1052

    2003 and 2004 models : Starter Troubleshooting

    ________________________________________

    9/23/05 SB1054

    All 2005 and 2006 models manufactured prior to 8 AUG 2005. : Clutch Slippage

    ________________________________________

    6/2/06SB1054A

    2005 models produced before 15 JAN 2005, up to and including transmission case number W124030. : BAKER 6-SPEED MAINSHAFT SNAP RING

    ________________________________________

    7/10/05 SB1056

    All 2005 models : Exhaust End Cap Resonating Rattling Noise

    ________________________________________

    7/10/05 SB1057

    All : Loctite® Product Improvement

    ________________________________________

    8/22/05 SB1058

    All 2005 models produced with a BD4019-05A, BD4019-05B harness, 3/8/2005

    date code : IGNITION COIL HARNESS DISCONNECT

    ________________________________________

    9/10/05 SB1059

    2005 models manufactured before July 8, 2005. : PRIMARY CHAIN TENSIONER SHOE RETAINER REPLACEMENT

    ________________________________________

    9/10/05 SB1060

    2005 Ridgeback : SEAT PAN CONTACT WITH BATTERY

    ________________________________________

    9/23/05 SB1062

    All 2005 Balance-Drive Systems. : Primary Venting and Sealing

    ________________________________________

    9/23/05 SB1063

    All 2005 models with stock exhaust. : Muffler Separation at Inlet Pipes

    ________________________________________

    3/27/06 SB1065A

    All 2005 models and 2006 models built through 23 MAR 2006. : REVISED CLUTCH PUSHROD REPLACEMENT

    ________________________________________

    12/8/05 SB1067

    All 2006 Ridgeback and K-9 Models produced on or before 17 OCT 2005. : WIRING HARNESS WEAR UNDER FUEL TANK

    ________________________________________

    12/15/05 SB1068

    MULTIPLE MODELS / YEARS : ENGINE CRANKCASE OIL SEEPAGE

    ________________________________________

    11/3/06 SB1069A

    All 2005 models and early production 2006 models produced on or before 26 SEP 2005.: REVISED INTERMITTENT PRINTED CIRCUIT BOARD OPERATION

    ________________________________________

    1/4/06SB1070

    All 2006 Ridgeback models assembled after 1 SEP 2005 and shipped before 4 JAN 2006. (Clutch cable is routed underneath the backbone and to the inside of the downtube.) Models assembled before 1 SEP 2005 are not affected. : CLUTCH CABLE GUIDE REPLACEMENT

    ________________________________________

    12/21/05 SB1071

    2006 Ridgeback and K-9 models. : RIDGEBACK AND K-9 TANK INSTALLATION

    ________________________________________

    1/12/06 SB1073

    All hidden-shock models with Mean Mother exhaust pipes installed. : MEAN MOTHER EXHAUST BRACKETS

    ________________________________________

    4/27/06 SB1074

    All 2005 model year motorcycles and all 2006 model year motorcycles produced

    on or before 16 FEB 2006. : PRIMARY CHAIN ALIGNMENT

    ________________________________________

    5/3/06SB1075

    All 2004, 2005, and 2006 models. : DIELECTRIC GREASE ADDITION TO CONNECTORS

    ________________________________________

    4/13/06 SB1076A

    All 2005 and 2006 models with stock exhaust pipes installed. : REVISED MUFFLER HEAT SHIELD SHIMS

    6/16/06 SB1077

    All 2004 and 2005 models, and 2006 models produced on or before 30 MAR 2006. : HEADLIGHT HARNESS MELTING

    ________________________________________

    4/3/06SB1078

    All 2004, 2005 and 2006 models built through 22 MAR 2006. : EHC CONTACT IMPROVEMENT

    ________________________________________

    11/10/06 SB1079A

    All 2005 models.: REVISED UPPER ENGINE MOUNT SCREW RETENTION

    ________________________________________

    6/30/06 SB1082A

    2006 and 2007 Big Dog Motorcycles. : PRIMARY INSPECTION COVER SEALING IMPROVEMENT

    ________________________________________

    6/23/06 SB1083

    2006 BDM K-9 models, serial number YB60001 through YB60014. : SWINGARM PAINT CHIPPING

    ________________________________________

    6/2/06SB1084

    All 2005 and later Balance-Drive Transmissions. : BAKER TRANSMISSION SERIAL NUMBER CODES

    ________________________________________

    6/30/06 SB1086

    2006 Big Dog Motorcycles. : SETTING PRIMARY CHAIN TENSION

    ________________________________________

    8/4/06SB1087

    All 2007 K-9 units listed (See Attachment A). : 2007 K-9 SIDE COVER REINFORCEMENT EDGE TRIM

    ________________________________________

    7/28/06 SB1088A

    2004, 2005 and 2006 Big Dog Motorcycles. : HORN HARNESS WIRE REINFORCEMENT

    ________________________________________

    8/4/06SB1089

    All 2004 and 2005 models, and all 2006 models built on or before 31 MAY 2006. : HANDLEBAR BUSHINGS REPLACEMENT

    ________________________________________

    8/25/06 SB1090

    All 2005 and 2006 models produced on or before 22 JUL 2006. : COUNTERSHAFT WASHER REPLACEMENT

    ________________________________________

    9/8/06SB1091

    All 2004, 2005, 2006 models, and all 2007 models produced on or before 31 AUG 2006. : TACHOMETER CIRCUIT BOARD AND/OR MOISTURE SEAL REPLACEMENT

    ________________________________________

    5/18/07 SB1092

    BULLDOG – All 2005 and 2007 Models. / CHOPPER – All 2005, 2006 and 2007 Models. / MASTIFF and PITBULL – All 2006 and 2007 Models. / RIDGEBACK – All 2005 and 2006 Models. / K-9 – All 2006 and 2007 Models. : REVISED SPEEDOMETER AND MOUNT

    ________________________________________

    5/23/07 SB1093

    All 2007 Bulldog models. : TACHOMETER RING IMPROVEMENT

    ________________________________________

    10/12/07 SB1097

    All 2007 and 2008 EFI models built on or before 10 OCT 2007 : SPARK PLUG WIRE REPLACEMENT

    ________________________________________

    2/2/07SIL-0001

    SERVICE INFORMATION LETTER - CURRENT EHC INFORMATION SHEET

    ________________________________________
     
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