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Big Dog 2006 Chopper Owner's Manual

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2006 CHOPPER OWNER’S MANUAL
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Summary of Contents for Big Dog 2006 Chopper

  • Page 1 2006 CHOPPER OWNER’S MANUAL WARNING...
  • Page 2 TABLE OF CONTENTS SECTION PAGE 1. GENERAL INFORMATION ..............4 2. MAJOR COMPONENTS ..............22 3. MAINTENANCE & STORAGE ............47 4. WARRANTY..................77...
  • Page 3 HOW TO USE THIS MANUAL MAINTENANCE RIDING TIP WARNING CONTACT US...
  • Page 4 QUICK START GUIDE WARNING INITIAL BREAK-IN FIRST 3000 MILES AFTER 3000 MILES 2006 CHOPPER GENERAL INFORMATION...
  • Page 5 QUICK START GUIDE RPM TO MPH CONVERSION 2006 CHOPPER GENERAL INFORMATION...
  • Page 6 QUICK START GUIDE COLD STARTING PROCEDURE IMPORTANT: 2006 CHOPPER GENERAL INFORMATION...
  • Page 7 QUICK START GUIDE NOTE: HOT ENGINE START 2006 CHOPPER GENERAL INFORMATION...
  • Page 8 QUICK START GUIDE SHUTTING DOWN SHIFTING INTO NEUTRAL TURN SIGNALS RIDING THE MOTORCYCLE 2006 CHOPPER GENERAL INFORMATION...
  • Page 9 QUICK START GUIDE NOTE: NOTE: 2006 CHOPPER GENERAL INFORMATION...
  • Page 10 SPECIFICATIONS 2006 CHOPPER GENERAL INFORMATION...

  • Page 11: Vehicle Identification

    VEHICLE IDENTIFICATION VEHICLE ID NUMBER ENGINE ID NUMBER TRANSMISSION ID NUMBER 2006 CHOPPER GENERAL INFORMATION...
  • Page 12 TIRES WARNING 2006 CHOPPER GENERAL INFORMATION...
  • Page 13 TIRES CUTS AND ABRASIONS TIRE INTEGRITY AIR PRESSURE RECOMMENDATIONS REAR: 42 PSI FRONT: 40 PSI 2006 CHOPPER GENERAL INFORMATION...
  • Page 14 CARGO AND PASSENGER WEIGHT WARNING CARRYING TRAVEL GEAR 2006 CHOPPER GENERAL INFORMATION...
  • Page 15 CARGO AND PASSENGER WEIGHT CARRYING A PASSENGER WARNING 2006 CHOPPER GENERAL INFORMATION...

  • Page 16: General Information

    GENERAL INFORMATION WARNING FUELING 2006 CHOPPER GENERAL INFORMATION...
  • Page 17 GENERAL INFORMATION HEAT EXHAUST HAZARDS SECURITY TOWING LOANING TO OTHERS 2006 CHOPPER GENERAL INFORMATION...
  • Page 18 GENERAL INFORMATION ROAD CONDITIONS PARKING WARNING 2006 CHOPPER GENERAL INFORMATION...
  • Page 19 GENERAL INFORMATION GOOD JUDGMENT SAFE SPEED RIDING TIP 2006 CHOPPER GENERAL INFORMATION...
  • Page 20 GENERAL INFORMATION FRAME CONSTRUCTION FRONT SUSPENSION REAR SUSPENSION 2006 CHOPPER GENERAL INFORMATION...
  • Page 21 GENERAL INFORMATION 2006 CHOPPER GENERAL INFORMATION...

  • Page 22: Major Components

    SECTION 2 MAJOR COMPONENTS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 23 BATTERY BATTERY SEAT REMOVAL WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 24 CONTROLS A. CLUTCH HAND LEVER B. HEAD LAMP HIGH/LOW SWITCH C. HORN SWITCH D. LEFT TURN SIGNAL WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 25 CONTROLS E. ELECTRIC STARTER SWITCH F. ENGINE STOP SWITCH G. FRONT BRAKE HAND LEVER H. THROTTLE CONTROL GRIP I. THROTTLE FRICTION ADJUSTING SCREW J. RIGHT TURN SIGNAL 2006 CHOPPER MAJOR COMPONENTS...
  • Page 26 GEAR SHIFTER WARNING GEAR SHIFTER 2006 CHOPPER MAJOR COMPONENTS...
  • Page 27 GEAR SHIFTER 2006 CHOPPER MAJOR COMPONENTS...
  • Page 28 POWER TRAIN SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 29 POWER TRAIN SYSTEM SYSTEM COMPONENTS A. V-TWIN, 117 CUBIC-INCH, FOUR-STROKE ENGINE B. CHAIN DRIVEN PRIMARY DRIVE C. BAKER 6-SPEED TRANSMISSION D. RIGHT SIDE BELT DRIVEN FINAL DRIVE 2006 CHOPPER MAJOR COMPONENTS...
  • Page 30 CLUTCH MANUAL, MULTI-PLATE CLUTCH 2006 CHOPPER MAJOR COMPONENTS...
  • Page 31 CLUTCH CLUTCH ADJUSTMENTS WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 32 ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 33 A. BATTERY; B. STARTING MOTOR 2. CHARGING C. IGNITION SYSTEM; D. ENGINE OFF RUN SWITCH; E. ELECTRONIC HARNESS; F. SPARK PLUGS 3. IGNITION G. ALTERNATOR; H. VOLTAGE REGULATOR 4. LIGHTING I. HEADLIGHT; J. TAIL LIGHT; K. TURN SIGNALS WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 34 ELECTRICAL SYSTEM 2006 ELECTRONIC DEVICES AND THEIR DEFAULTS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 35 ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS...

  • Page 36: Ignition Switch

    IGNITION SWITCH IGNITION KEY OFF IGNITION KEY ON COIL COVER & IGNITION SIWTCH SWITCH POSITIONS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 37 IGNITION SWITCH WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 38 DISPLAY WARNING A. LEFT TURN INDICATOR LIGHT B. OIL INDICATOR LIGHT C. TRANSMISSION NEUTRAL LIGHT D. HIGH BEAM LIGHT TACHOMETER E. RIGHT TURN INDICATOR LIGHT 2006 CHOPPER MAJOR COMPONENTS...
  • Page 39 DISPLAY F. SPEEDOMETER/ODOMETER G.TACHOMETER WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 40 BRAKE SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 41 B. FOUR-PISTON CALIPER C. BRAIDED STAINLESS STEEL LINE D. 5/8” BORE MASTER CYLINDER & RESERVOIR REAR BRAKE COMPONENTS E. REAR DISC ROTOR F. FOUR-PISTON CALIPER G. BRAIDED STAINLESS STEEL LINE H. 5/8” BORE MASTER CYLINDER & RESERVOIR 2006 CHOPPER MAJOR COMPONENTS...
  • Page 42 BRAKE SYSTEM FOR NORMAL BRAKING WARNING MAINTAINING BRAKE SYSTEM INTEGRITY 2006 CHOPPER MAJOR COMPONENTS...
  • Page 43 BRAKE SYSTEM WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 44 FUEL SYSTEM TANK CAPACITY Main Capacity 3.4 gal Reserve Capacity .4 gal Total Capacity 3.8 gal 2006 CHOPPER MAJOR COMPONENTS...
  • Page 45 FUEL SYSTEM A. FUEL TANK B. FUEL VALVE C. CARBURETOR D. FUEL LINE E. ENRICHENER F. THROTTLE GRIP AND CABLES 2006 CHOPPER MAJOR COMPONENTS...
  • Page 46 FUEL VALVE FUEL VALVE FUEL ON FUEL OFF FUEL RESERVE 2006 CHOPPER MAJOR COMPONENTS...

  • Page 47: Maintenance & Storage

    SECTION 3 MAINTENANCE & STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 48 MAINTENANCE WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 49 MAINTENANCE GENERAL INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 50 MAINTENANCE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 51 MAINTENANCE LOG...
  • Page 54 SERVICE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 55 SERVICE AIR FILTER 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 56 SERVICE FUEL TANK STRAINER WARNING CHECK OIL LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 57 SERVICE ENGINE OIL CHANGING ENGINE OIL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 58 SERVICE ENGINE OIL FILTER TAPPET OIL FILTER SCREEN WINTER LUBRICATION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 59 SERVICE TRANSMISSION LUBRICANT CHECKING TRANSMISSION LUBRICANT LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 60 SERVICE CHANGING TRANSMISSION LUBRICANT PRIMARY DRIVE LUBRICANT CHECKING PRIMARY DRIVE LUBRICANT LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 61 SERVICE C H A N G I N G P R I M A R Y D R I V E LUBRICANT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 62 SERVICE PRIMARY DRIVE CHAIN INSPECTION ADJUSTABLE REAR SHOCKS WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 63 SERVICE LENGTH ADJUSTMENTS 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 64 SERVICE FRONT FORK OIL LUBRICATION DRIVE BELT INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 65 SERVICE SHIFTER LINKAGE ADJUSTMENT FRONT AND REAR BRAKE INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 66 SERVICE BRAKE LINE AND MASTER CYLINDER INSPECTION AND SERVICING CARBURETOR CONTROLS CLUTCH CABLE INSPECTION AND ADJUSTMENT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 67 SERVICE ALTERNATOR CHARGING RATE AND VOLTAGE REGULATOR BATTERY SERVICING AND INSTALLATION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 68 SERVICE WARNING SPARK PLUG/PLUG WIRE INSPECTION AND REPLACEMENT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 69 SERVICE HEADLIGHT REPLACEMENT TURN SIGNALS 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 70 CLEANING WARNING GENERAL CLEANING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 71 CLEANING CHROME LEATHER PAINT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 72 CLEANING WARNING STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 73 STORAGE PREPARING YOUR MOTORCYCLE FOR STORAGE WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 74 STORAGE REMOVING YOUR MOTORCYCLE FROM STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 75 TROUBLE-SHOOTING TROUBLE-SHOOTING GUIDE ENGINE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 76 TROUBLE-SHOOTING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 77 TROUBLE-SHOOTING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 78 TROUBLE-SHOOTING LUBRICATION SYSTEM ELECTRICAL SYSTEM 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 79 TROUBLE-SHOOTING CLUTCH SYSTEM TRANSMISSION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 80 TROUBLE-SHOOTING BRAKES 2006 CHOPPER MAINTENANCE & STORAGE...

  • Page 81: Warranty

    SECTION 4 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 82 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 83 WARRANTY TRANSFER OF WARRANTY PARTS AND LABOR NOT COVERED 2006 CHOPPER 2006 CHOPPER WARRANTY WARRANTY...
  • Page 84 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 85 WARRANTY LIMIT OF LIABILITY 2006 CHOPPER WARRANTY...
  • Page 86 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 87 WARRANTY LEGAL RIGHTS 2006 CHOPPER WARRANTY...
  • Page 88 WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS LIMITED WARRANTY ON EMISSION CONTROL SYSTEM 2006 CHOPPER WARRANTY...
  • Page 89 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 90 WARRANTY LIMITATIONS UNDER EMISSION CONTROL SYSTEM WARRANTY 2006 CHOPPER WARRANTY...
  • Page 91 WARRANTY OWNER’S WARRANTY RESPONSIBILITIES 2006 CHOPPER WARRANTY...
  • Page 92 WARRANTY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED REPORTING SAFETY DEFECTS 2006 CHOPPER WARRANTY...
  • Page 93 WARRANTY NOTICE OF WARRANTY DISPUTE RESOLUTION PROGRAM 2006 CHOPPER WARRANTY...
  • Page 94 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 95 WARRANTY STATE WARRANTY ENFORCEMENT LAWS 2006 CHOPPER WARRANTY...
  • Page 96 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 97 WARRANTY TRANSFER 2006 CHOPPER WARRANTY TRAMSFER...
  • Page 99 WARRANTY TRANSFER 2006 CHOPPER WARRANTY TRANSFER...