Bigdog CHOPPER recalls by model year

Reported: 2003-06-23 (June 23, 2003) · Model years: 2003

ON CERTAIN MOTORCYCLES, THE FUEL TANK MOUNT MAY HAVE BEEN IMPROPERLY WELDED. THIS CAN CAUSE THE TANK TO FAIL WITH THE POSSIBILITY OF FUEL SPILLAGE.

Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REMOVE THE FUEL TANK AND SHIP IT TO BIG DOG FOR REPAIR. BIG DOG WILL RE-WELD THE MOUNT, REPAIR THE PAINT, AND RETURN IT BACK TO THE DEALER FOR RE-INSTALLATION. OWNER NOTIFICATION BEGAN ON JULY 31, 2003. OWNERS SHOULD CONTACT BIG DOG AT 1-316-219-6584.

Reported: 2003-12-18 (December 18, 2003) · Model years: 2003, 2004

ON CERTAIN MOTORCYCLES ASSEMBLED WITH AN EARLY VERSION ROLLING THUNDER FRAME, A STRESS CRACK COULD EMERGE IN THE FRAME.

Consequence: THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPAIR THE FRAME. OWNER NOTIFICATION BEGAN JANUARY 15, 2004. OWNERS SHOULD CONTACT BIG DOG AT 1-316-267-9121.

Reported: 2004-11-02 (November 2, 2004) · Model years: 2003, 2004

ON CERTAIN MOTORCYCLES, THE KICKSTAND SPRING ATTACHING STUD MAY BREAK OFF ALLOWING THE KICKSTAND TO DEPLOY INTO THE EXTENDED POSITION.

Consequence: IF THE KICKSTAND DEPLOYS, IT COULD CAUSE A CRASH WITHOUT PRIOR WARNING.

Remedy: DEALERS WILL INSPECT AND INSTALL A NEW KICKSTAND UNIT. THE RECALL BEGAN ON DECEMBER 20, 2004. OWNERS SHOULD CONTACT BIG DOG AT 316-267-9121.

Reported: 2004-03-23 (March 23, 2004) · Model years: 2004

ON CERTAIN MOTORCYCLES, THE PISTON IN THE REAR MASTER CYLINDER MAY HAVE BEEN IMPROPERLY SIZED, WHICH COULD CAUSE THE REAR BRAKES TO DRAG OR LOCKUP.

Consequence: THIS COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REMOVE THE PISTON FROM THE REAR MASTER CYLINDER AND REPLACE IT WITH A NEW PISTON. OWNER NOTIFICATION BEGAN ON APRIL 12, 2004. OWNERS SHOULD CONTACT BIG DOG AT 1-316-267-9121.

Reported: 2004-04-06 (April 6, 2004) · Model years: 2004

ON CERTAIN MOTORCYCLES, A SCREW MAY BECOME LOOSE IN THE HANDLEBAR CONTROL DUE TO THE LACK OF A LOCK WASHER AND LOCTITE.

Consequence: THIS COULD CAUSE THE THROTTLE OR FRONT BRAKE CONTROL TO BIND, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A LOCK WASHER AND LOCTITE. OWNER NOTIFICATION BEGAN ON APRIL 12, 2004. OWNERS SHOULD CONTACT BIG DOG AT 1-316-219-7006.

Reported: 2006-01-25 (January 25, 2006) · Model years: 2004, 2005, 2006

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.

Remedy: 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.

Reported: 2005-04-14 (April 14, 2005) · Model years: 2005

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.

Remedy: 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.

Reported: 2005-09-28 (September 28, 2005) · Model years: 2005

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.

Remedy: 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.

Reported: 2006-08-09 (August 9, 2006) · Model years: 2005, 2006

ON CERTAIN MOTORCYCLES, THE IGNITION MODULES ARE ORIENTED WITHIN THE BATTERY TRAY IN A WAY THAT MAKES THE IGNITION MODULE SUSCEPTIBLE TO VIBRATION.

Consequence: THIS SUSCEPTIBILITY TO VIBRATION MAY CONTRIBUTE TO A STALLING CONDITION THAT COULD OCCUR WITHOUT ANY PRIOR WARNING AND RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A NEW IGNITION MODULE MOUNTING SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 25, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2006-08-11 (August 11, 2006) · Model years: 2005, 2006

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.

Remedy: 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.

Reported: 2006-10-12 (October 12, 2006) · Model years: 2005, 2006

ON CERTAIN MOTORCYCLES, THE LONG PIVOT BOLT MAY BEND OR BREAK DURING NORMAL OPERATION OF THE MOTORCYCLE.

Consequence: THIS COULD POTENTIALLY CAUSE THE REAR FENDER TO ABRADE AGAINST THE REAR TIRE WHILE THE MOTORCYCLE IS BEING DRIVEN. THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING AND COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE LONG PIVOT BOLT AND, IF NECESSARY, STRAIGHTEN THE REAR FRAME SIDE PANEL. THE SHORT LEFT SIDE PIVOT BOLT AND PIVOT SHAFT MAY ALSO BE REPLACED FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 1, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2007-12-18 (December 18, 2007) · Model years: 2005, 2006, 2007

ON CERTAIN MOTORCYCLES, THE REAR FENDER STRUT ATTACHING BOLTS CAN FAIL ALLOWING THE REAR FENDER TO DETACH FROM THE MOTORCYCLE.

Consequence: THIS COULD OCCUR WITHOUT PRIOR WARNING AND COULD RESULT IN AN INJURY OR A CRASH.

Remedy: DEALERS WILL REMOVE EXISTING STRUT BOLTS AND REPLACE WITH HIGHER TENSILE STRENGTH ATTACHING BOLTS AND UPDATED WASHERS. HIGHER TORQUE VALUES WILL BE OBSERVED WHEN INSTALLING THE REPLACEMENT FASTENERS. THE RECALL BEGAN ON JANUARY 21, 2008. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2007-08-08 (August 8, 2007) · Model years: 2006

ON CERTAIN MOTORCYCLES, A WARPED BUS BAR WITHIN THE VOLTAGE REGULATOR CAN CAUSE A SHORT CIRCUIT.

Consequence: THIS COULD POSSIBLY RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE EXISTING CIRCUIT BREAKER LOCATED BETWEEN THE VOLTAGE REGULATOR POSITIVE BATTERY LEAD (B+ LEAD) AND THE POSITIVE BATTERY TERMINAL WITH AN ALTERNATIVE CIRCUIT PROTECTION DEVICE THAT WILL PREVENT A THERMAL EVENT IF THERE IS A SHORT TO GROUND. THE RECALL BEGAN ON OCTOBER 1, 2007. OWNERS MAY CONTACT BIG DOG AT 1-316-219-9129 OR EMAIL TO CUSTOMER.SERVICE@BIGDOGMOTORCYCLES.COM.