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Technical Service Bulletins of the 2004 Bigdog Chopper

There have been 10 technical service bulletins issued for the 2004 Bigdog Chopper.

1 2004 Bigdog Chopper tank assembly TSB (Bulletin SB-1099)

Bulletin Date: Jan. 11, 2008
Component: Tank assembly.
Bulletin 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.
Vehicles covered in this TSB:
2002 Bigdog BDM, 2003 Bigdog BDM, 2005 Bigdog Big Dog, 2006 Bigdog Big Dog, 2002 Bigdog Boxer, 2003 Bigdog Boxer, 2004 Bigdog Boxer, 2002 Bigdog Bull Dog, 2000 Bigdog Bulldog, 2001 Bigdog Bulldog, 2002 Bigdog Bulldog, 2003 Bigdog Bulldog, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2007 Bigdog Bulldog, 2008 Bigdog Bulldog, 2003 Bigdog Chopper, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2007 Bigdog Chopper, 2008 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2005 Bigdog Dt Chopper, 2002 Bigdog Husky, 2006 Bigdog K-9, 2007 Bigdog K-9, 2008 Bigdog K-9, 2005 Bigdog K9, 2006 Bigdog K9, 2007 Bigdog K9, 2008 Bigdog K9, 2002 Bigdog Mastiff, 2003 Bigdog Mastiff, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 2007 Bigdog Mastiff, 2008 Bigdog Mastiff, 2002 Bigdog Motorcycle, 2005 Bigdog Mutt, 2006 Bigdog Mutt, 2007 Bigdog Mutt, 2008 Bigdog Mutt, 2005 Bigdog N-chopper, 1997 Bigdog Pitbull, 1998 Bigdog Pitbull, 1999 Bigdog Pitbull, 2000 Bigdog Pitbull, 2001 Bigdog Pitbull, 2002 Bigdog Pitbull, 2003 Bigdog Pitbull, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2007 Bigdog Pitbull, 2008 Bigdog Pitbull, 2003 Bigdog Ridgeback, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2007 Bigdog Ridgeback, 2008 Bigdog Ridgeback, 2005 Bigdog Rolling Thunder, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

2 2004 Bigdog Chopper horn assembly TSB (Bulletin 1088)

Bulletin Date: Jun. 30, 2006
Component: Horn assembly.
Bulletin Summary: Horn harness wires may break.
Vehicles covered in this TSB:
2002 Bigdog BDM, 2003 Bigdog BDM, 2002 Bigdog Boxer, 2003 Bigdog Boxer, 2004 Bigdog Boxer, 2002 Bigdog Bull Dog, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2003 Bigdog Chopper, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2002 Bigdog Husky, 2006 Bigdog K-9, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 1998 Bigdog Pitbull, 1999 Bigdog Pitbull, 2002 Bigdog Pitbull, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

3 2004 Bigdog Chopper electrical system TSB (Bulletin 1078)

Bulletin Date: Jun. 23, 2006
Component: Electrical system.
Bulletin Summary: Ehc contact improvement procedure (revised). Current seal does not allow connector pins to seat properly and moisture may be present in connector.
Vehicles covered in this TSB:
2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2006 Bigdog K-9, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

4 2004 Bigdog Chopper headlights TSB (Bulletin 1077)

Bulletin Date: Jun. 16, 2006
Component: Headlights.
Bulletin Summary: Headlamp connector may melt, making bulb replacement difficult.
Vehicles covered in this TSB:
2005 Bigdog Big Dog, 2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2006 Bigdog K-9, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

5 2004 Bigdog Chopper electrical system TSB (Bulletin 1075)

Bulletin Date: May. 3, 2006
Component: Electrical system.
Bulletin Summary: Dielectric grease addition to connectors.
Vehicles covered in this TSB:
2005 Big Bear Choppers Venom Chopper, 2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2006 Bigdog K-9, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

6 2004 Bigdog Chopper structure TSB (Bulletin 1080)

Bulletin Date: Apr. 27, 2006
Component: Structure.
Bulletin Summary: Tachometer board replacement - inaccurate tachometer readings or fluctuation in readings due to moisture.
Vehicles covered in this TSB:
2005 Bigdog Big Dog, 2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2005 Bigdog Bulldog, 2006 Bigdog Bulldog, 2004 Bigdog Chopper, 2005 Bigdog Chopper, 2006 Bigdog Chopper, 2005 Bigdog Chopper Dt, 2004 Bigdog Daytec Chopper, 2006 Bigdog K-9, 2004 Bigdog Mastiff, 2005 Bigdog Mastiff, 2006 Bigdog Mastiff, 2004 Bigdog Pitbull, 2005 Bigdog Pitbull, 2006 Bigdog Pitbull, 2004 Bigdog Ridgeback, 2005 Bigdog Ridgeback, 2006 Bigdog Ridgeback, 2004 Bigdog T Chopper, 2005 Bigdog T Chopper.

7 2004 Bigdog Chopper structure body TSB (Bulletin 1046)

Bulletin Date: Oct. 25, 2004
Component: Structure body.
Bulletin Summary: Fork dust cover o-ring nonconformance. O-ring is displaced from o-ring groove.
Vehicles covered in this TSB:
2004 Bigdog Chopper, 2004 Bigdog Ridgeback.

8 2004 Bigdog Chopper engine gasoline belts and associated pulleys TSB (Bulletin 1044)

Bulletin Date: Sep. 30, 2004
Component: Engine gasoline belts and associated pulleys.
Bulletin Summary: Belt and chassis issues. Drive belt noise,drive belt ratcheting, swing arm to frame contact. Bigdog service bulletin w/t attachments a-h. Various models including 2003 big dog pitbull, ridgeback and daytec chopper.
Vehicles covered in this TSB:
2003 Bigdog Chopper, 2004 Bigdog Chopper, 2004 Bigdog Daytec Chopper, 2003 Bigdog Mastiff, 2004 Bigdog Mastiff, 2004 Bigdog Pitbull, 2004 Bigdog Ridgeback, Unknown Unknown.

9 2004 Bigdog Chopper electrical system TSB (Bulletin 1042)

Bulletin Date: Sep. 15, 2004
Component: Electrical system.
Bulletin Summary: Ehc replacement. Incorrect electrical component installation resulting in a damaged ehc.
Vehicles covered in this TSB:
2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2004 Bigdog Chopper, 2004 Bigdog Daytec Chopper, 2004 Bigdog Mastiff, 2004 Bigdog Pitbull, 2004 Bigdog Ridgeback.

10 2004 Bigdog Chopper motorcycle kickstand/centerstand TSB (Bulletin 1039)

Bulletin Date: Jul. 12, 2004
Component: Motorcycle kickstand/centerstand.
Bulletin Summary: Kickstand spring stud fracture. All bigdog 2004 models.
Vehicles covered in this TSB:
2004 Bigdog Boxer, 2004 Bigdog Bulldog, 2004 Bigdog Chopper, 2004 Bigdog Daytec Chopper, 2004 Bigdog Mastiff, 2004 Bigdog Pitbull, 2004 Bigdog Ridgeback.





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