Roscoe Martin
Master Chief
Recently completed and interesting project on 2004 Bug Dog chopper. Contacted by an old friend about his sons bike. The bike quit on him and sat parked in weather for period of years. Told me he couldnt find anyone in his area willing to work on the bike and asked if I would be will take a look at it. Knew then that this bike might be a challenge and told him bring it to me. Sad when I seen the bike, the top portion of seat cover had rotted away,etc. Put bike on charger and started in on the electrical system diagnosis. First thing I found was circuit breaker failure, next was the Thunder Heart dead, bike wouldn't crank over, so connected remote starter and starter engaged. Found that wiring harness was installed at factory too tight lower frame area and the wire to oil pressure sensor had broken. Pulled plugs and gave it a drink of marvel mystery oil. Gas capped was froze in place, had use pipe wrench get it off. Amazed find how clean inside tank was, drained fuel and flushed tank. removed checked and clean carb ,it too was in good condition Replaced PCB control board switches on bars. Wanted reduce the odds of another future ignition problem and at same time increase engine performance, so installed S&S Ignition kit ( refer pic). Love this ignition system !! Easy set static timing and modes are easily set with screwdriver. Changed engine oil, fresh set spark plugs, new battery,fresh gas, primed it with couple squirts gas and time start it up. This thing fired up like it was sitting on showroom floor !!. Would set and idle perfectly. Wont bore you with further details of bike service,fluid changes ect. Provided a list of recommendations to owner and number was not let bike set in weather. Sure all Dog owners know that they dont like being exposed for extended periods tome to water and I go so far as to recommend NOT to power wash the bike. Moral to my story these bikes are made of top quality parts ( well, maybe except for electrical systems) and they seem to withstand some really horrible conditions. Love these bikes, great frames, engines and gearbox's