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Big Dog Service Bulletins

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

  1. BroadBand

    BroadBand Since late 60's

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    BD Chopper
    Part 2

    2/2/07SIL-0002

    EHC COMMUNICATION ISSUE

    Issued Bulletin Number Description

    4/1/2002 02V-016

    Big Dog Motorcycles, LLC (BDM) has decided that a defect, which relates to motor vehicle

    safety, exists in the rear fender front mounting tabs on certain 1998 and 1999 Pitbull model

    motorcycles.

    The rear fender front mounting tabs securing the rear fender to the frame can fracture, causing

    the rear fender to break away and drop onto the rear tire, resulting in tire damage and unintended braking action. This condition could occur without any prior warning. A recall notice has been sent to the owners of these motorcycles.

    ________________________________________

    12/16/2002 02V-089

    This notice is sent to you regarding requirements set forth by the National Highway Traffic

    Safety Administration (NHTSA). Big Dog Motorcycles, LLC (BDM) had earlier contacted you

    concerning this campaign, which was initially undertaken in April of 2002. The remedy at that

    time involved either replacing the fuel tanks on certain 2002 Model Pitbull, Boxer, Husky, and

    Mastiff motorcycles, or shimming the tanks and remounting them on the subject motorcycles.

    The revised remedy here involves removing the fuel tanks, replacing the mounting grommets and related hardware, and remounting the tanks.

    ________________________________________

    4/1/2002 02V-090

    Big Dog Motorcycles, LLC (BDM) has decided that a defect, which relates to motor vehicle

    safety, exists in the fuel shutoff valve on certain 2001 and 2002 Big Dog motorcycles.

    The fuel valve’s outlet nipple, which the fuel line attaches to, can pull out of the fuel valve

    allowing fuel to exit onto the motor and primary drive. This condition could occur without any

    prior warning.

    ________________________________________

    11/15/2002 02V-285

    Big Dog Motorcycles, LLC (BDM) has determined that a defect, which relates to motor vehicle

    safety, exists in the stainless steel handlebars on certain 2002 Big Dog motorcycles.

    The weld on the handlebar may break, limiting the ability to use the hand controls. This

    condition could occur without any prior warning.

    ________________________________________

    7/15/2003 03V-230

    Big Dog Motorcycles, LLC (BDM) has decided that a defect, which relates to motor vehicle

    safety, exists on certain 2003 Chopper models, on which the fuel tank mount has been

    improperly welded. This can cause the tank to fail with the possibility of fuel spillage. This

    condition could occur without any prior warning.

    ________________________________________

    1/09/2004 03V-535

    Big Dog Motorcycles, L.L.C. (BDM) has determined that a defect, which relates to motor

    vehicle safety, exists on all 2003 and 2004 Chopper models, manufactured with the early version Rolling Thunder frame, on which a stress crack may emerge in the frame. This condition could occur without any prior warning. The frame is designated with an “N” as the first character in the project number, which is stamped on the left side of the steering head opposite the VIN.

    Recently Rolling Thunder has modified its frames in production to correct this situation, so that

    new Choppers being produced today will not be impacted by this recall. Although these new

    modified frames are also identified by the “N” designation, a quick visual inspection will

    confirm if it is a new production frame or an early version subject to recall. Please see the Big

    Dog Motorcycles Dealer website for identification information on the subject frame. Please note that the frames manufactured by Daytec, which are not subject to this recall, are identified by a “T” as the first character in the project number.

    ________________________________________

    4/12/2004 04V-137

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates

    to motor vehicle safety, exists on all 2004 models, manufactured prior to March 17, 2004. The

    rear master cylinder piston may be improperly sized, which could cause the rear brakes to drag

    or lock-up. This condition could occur without any prior warning. At this time Big Dog

    Motorcycles has no reports of any accidents or injuries related to this condition.

    ________________________________________

    4/12/2004 04V-164

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates

    to motor vehicle safety, exists on all 2004 models, manufactured prior to March 27, 2004. A

    screw may become loose in the handlebar control due to the lack of a lock washer, which could

    cause the throttle or front brake control to bind. This condition could occur without any prior

    warning. At this time Big Dog Motorcycles has no reports of any accidents or injuries related to

    this condition.

    ________________________________________

    12/27/2004 04V-523

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates to motor vehicle safety, exists on all 2004 models. The kickstand spring attaching stud may break off allowing the kickstand to deploy into the extended position and cause a crash. This condition could occur without any prior warning. At this time Big Dog Motorcycles has no reports of any accidents or injuries related to this condition.

    ________________________________________

    05-432

    REVISED 2005 WHEEL ASSEMBLIES REMEDY. All 2005 models built on or before June 1, 2005

    ________________________________________

    3/11/2005 05V-052

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates

    to motor vehicle safety, exists on all 2005 models manufactured prior to February 11, 2005. The

    internal voltage regulator in the electronic harness control is susceptible to damage by voltage

    transients in the ignition switch circuit resulting in a total shutdown of the vehicle’s electrical

    system. This condition could occur without any prior warning. At this time Big Dog

    Motorcycles has no reports of any accidents or injuries related to this condition.

    ________________________________________

    4/26/2005 05V-149

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates

    to motor vehicle safety, exists on all 2005 models manufactured prior to January 22, 2005. Some of these motorcycles were built using a 7/8” –14 x 1/2” primary drive sprocket nut. Under

    certain conditions, this sprocket nut could back off the engine main shaft. This condition could

    occur without any prior warning. At this time Big Dog Motorcycles has no reports of any

    accidents or injuries related to this condition.

    ________________________________________

    5/23/2005 05V-233

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that a defect, which relates

    to motor vehicle safety, exists on all 2005 Bulldog models manufactured between March 29,

    2005 and May 12, 2005. The front fender brackets could fail, allowing the front fender to detach and cause a crash. This condition could occur without any prior warning. At this time Big Dog Motorcycles has no reports of any accidents or injuries related to this condition.

    ________________________________________

    4/18/2006 06V-122

    Big Dog Motorcycles, LLC (Big Dog Motorcycles) notified you of the 2005 Bulldog Fender Bracket recall campaign, No. 05V-233, initially undertaken in May of 2005. Big Dog Motorcycles has determined that the replacement front fender brackets remedy provided in this recall may not sufficiently address the defect condition noted in our original defect notice. Accordingly, Big Dog Motorcycles is modifying the remedy in the campaign to include a stronger replacement bracket that it believes will more appropriately address the front mounting issue. Big Dog Motorcycles is also expanding the recall to include all 2005 model year Bulldog motorcycles, including those built subsequent to the production period covered by the original notice.

    ________________________________________

    06V-301

    The purpose of this recall is to correct vibration issues with the ignition module mounting system of the listed models.

    Install Ignition Module Relocation Kit P/N 203-000018-00.

    ________________________________________

    R06V-301

    The purpose of this supplement is to identify potential 2005 models covered under the Ignition Module Relocation Recall, #06V-301, that could experience premature side cover wear when the Ignition Module Relocation Kit is installed. Premature side cover wear is a cosmetic issue that does not pose a safety risk to the rider. The relocation kit is still an adequate remedy for the previously identified safety risk that requires recall #06V-301.

    ________________________________________

    06V-305

    MPORTANT: Replace the EHC of ANY

    Big Dog Motorcycle model having an EHC, P/N 170-000001-00 with clear, gel-type potting material. Remove that EHC and replace with P/N 171-000010-00.

    NOTE: This recall does not affect EHC’s P/N 170-000001-00 with black potting material.

    ________________________________________

    1/16/2006 05E-082

    Big Dog Motorcycles, L.L.C., (Big Dog Motorcycles) has decided that a defect, which relates to

    motor vehicle safety, exists with respect to certain Big Dog Motorcycles’ accessory pillion pads

    when used in combination with Flat Matte, (“primer”) finished motorcycles. The subject pillion

    pads are identified as Part No. BDM230-00195, BDM230-00194, and BDM230-00081. Our

    records indicate that you may have these pillion pads in your inventory, or, you may have primer painted motorcycles in your inventory.

    ________________________________________

    06V-389

    MODELS: All 2005 Bulldog, N-Chopper units and Mastiff; 2006 N-Chopper and Mastiff units manufactured before April 12, 2006.

    SYMPTOM: Right side, long pivot bolts are bending and may break.

    ________________________________________

    07V-355

    BULLDOG TACHOMETER CIRCUIT BOARD IMPROVEMENT INSTRUCTIONS

    IDENTIFICATION: All 2007 Bulldog models that have not had SB-1093 performed.

    ________________________________________

    8/21/2007 07V-356

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that there is a safety defect in the voltage

    regulator installed on certain 2005 and 2006 model motorcycles. Voltage regulators on these motorcycles with a manufacture date code of 04 or 05 may be susceptible to developing a short circuit which, in turn, may result in a fire without prior warning.

    ________________________________________

    8/29/2007 07E-058

    Big Dog Motorcycles, L.L.C. (Big Dog Motorcycles) has determined that there is a potential safety defect in the following sissy bar assemblies:

    223-000001-00 2006 K-9

    223-000001-01 2006 K-9, 2007 K-9, and 2007 Mastiff

    223-000002-00 2006 K-9

    223-000002-01 2006 K-9, 2007 K-9, and 2007 Mastiff

    223-000007-01 2007 K-9, 2007 Mastiff, and 2007 Bulldog

    223-000008-01 2007 K-9, 2007 Mastiff, and 2007 Bulldog
     
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