2005 Big Dog Chopper Technical Service Bulletins

24 technical service bulletins (TSBs) are on record for the 2005 Big Dog Chopper. TSBs are notes manufacturers send to dealers about repair procedures for issues seen in the field. They are not recalls and do not by themselves mean a vehicle has a fault.

• 10026469Oct 30, 2008Suspension. Big dog motorcycle: strut bolts replacement. Remove strut bolts and install strut bolt kit p/n 243 000010-00.
• 10026442May 11, 2008Equipment. Big dog motorcycle: electrical side cover contact with belt guard. A wire bundle may protrude into the right electrical side cover.
• 10026833Apr 18, 2008Equipment. Bigdog motorcycle: new primary inspection cover gasket. Install new inspection cover gasket on all 2005-2008 big dog motorcycles.
• 10026428Apr 18, 2008Equipment. Bigdog motorcycles: this letter highlights the difference between the various electronic harness controllers (ehcs). For models years 2005-2009 motorcycles.
• 10027045Apr 11, 2008Equipment. Bigdog motorcycle: hidden shock electrical cover hardware replacement. Electrical side covers may crack or break. 243-000011-00 for all models except 2006 k9. 243-000013-00 for 2006 k9 model.
• 10026614Jan 14, 2008Body and structure. Bigdog motorcycle: rear fender strut bolt remedy. Rear fender strut bolts may fail allowing the fender to detach from the motorcycle.
• 10026832Jan 11, 2008Fuel system. 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.
• 10023092May 18, 2007Vehicle speed control. Bigdog motorcycles - revised speedometer and mount.
• 10020064Nov 3, 2006Electrical system. Intermittent printed circuit board operation.
• 10020374Aug 25, 2006Transmission and drivetrain. Rough shifting, or noisy transmission caused by loose transmission countershaft screw.
• 10020152Jun 30, 2006Electrical system. Horn harness wires may break.
• 10020045Jun 23, 2006Electrical system. Ehc contact improvement procedure (revised). Current seal does not allow connector pins to seat properly and moisture may be present in connector.
• 10020065Jun 16, 2006Exterior lighting. Headlamp connector may melt, making bulb replacement difficult.
• 10015923Jun 2, 2006Transmission and drivetrain. Baker 6-speed main shaft snap ring.
• 10019909May 3, 2006Electrical system. Dielectric grease addition to connectors.
• 10019984Apr 27, 2006Body and structure. Tachometer board replacement - inaccurate tachometer readings or fluctuation in readings due to moisture.
• 10019776Apr 13, 2006Engine cooling. Upper engine mount screw is loose or missing.
• 10018991Mar 27, 2006Electrical system. Inaccurate speedometer operation - vibrations at high speed are causing signal loss to needle from speed sensor.
• 10017598Sep 10, 2005Engine cooling. Abnormal primary chain noise resulting from displacement of the adjusting shoe 10mm external snap ring retainer.
• 10016969Sep 10, 2005Engine cooling. 1/2 - 20 inch upper engine mount bolt retention. Big dog.
• 10017597Aug 22, 2005Electrical system. Engine running only on one cylinder and/or damaged ignition coil or ignition module.
• 10018960Aug 2, 2005Transmission and drivetrain. 05 clutch bearing carrier identification.
• 10017596Jul 10, 2005Engine cooling. Exhaust end cap resonating rattling noise.
• 10017541Jul 10, 2005Electrical system. Primary drive fluid seeping from the starter housing.

← All problems reported for the 2005 Big Dog Chopper