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

  • Page 1 All manuals and user guides at all-guides.com 2006 CHOPPER OWNER’S MANUAL WARNING...
  • Page 2 All manuals and user guides at all-guides.com TABLE OF CONTENTS SECTION PAGE 1. GENERAL INFORMATION ..............4 2. MAJOR COMPONENTS ..............22 3. MAINTENANCE & STORAGE ............47 4. WARRANTY..................77...
  • Page 3 All manuals and user guides at all-guides.com HOW TO USE THIS MANUAL MAINTENANCE RIDING TIP WARNING CONTACT US...
  • Page 4 All manuals and user guides at all-guides.com QUICK START GUIDE WARNING INITIAL BREAK-IN FIRST 3000 MILES AFTER 3000 MILES 2006 CHOPPER GENERAL INFORMATION...
  • Page 5 All manuals and user guides at all-guides.com QUICK START GUIDE RPM TO MPH CONVERSION 2006 CHOPPER GENERAL INFORMATION...
  • Page 6 All manuals and user guides at all-guides.com QUICK START GUIDE COLD STARTING PROCEDURE IMPORTANT: 2006 CHOPPER GENERAL INFORMATION...
  • Page 7 All manuals and user guides at all-guides.com QUICK START GUIDE NOTE: HOT ENGINE START 2006 CHOPPER GENERAL INFORMATION...
  • Page 8 All manuals and user guides at all-guides.com QUICK START GUIDE SHUTTING DOWN SHIFTING INTO NEUTRAL TURN SIGNALS RIDING THE MOTORCYCLE 2006 CHOPPER GENERAL INFORMATION...
  • Page 9 All manuals and user guides at all-guides.com QUICK START GUIDE NOTE: NOTE: 2006 CHOPPER GENERAL INFORMATION...
  • Page 10 All manuals and user guides at all-guides.com SPECIFICATIONS 2006 CHOPPER GENERAL INFORMATION...
  • Page 11 All manuals and user guides at all-guides.com VEHICLE IDENTIFICATION VEHICLE ID NUMBER ENGINE ID NUMBER TRANSMISSION ID NUMBER 2006 CHOPPER GENERAL INFORMATION...
  • Page 12 All manuals and user guides at all-guides.com TIRES WARNING 2006 CHOPPER GENERAL INFORMATION...
  • Page 13 All manuals and user guides at all-guides.com TIRES CUTS AND ABRASIONS TIRE INTEGRITY AIR PRESSURE RECOMMENDATIONS REAR: 42 PSI FRONT: 40 PSI 2006 CHOPPER GENERAL INFORMATION...
  • Page 14 All manuals and user guides at all-guides.com CARGO AND PASSENGER WEIGHT WARNING CARRYING TRAVEL GEAR 2006 CHOPPER GENERAL INFORMATION...
  • Page 15 All manuals and user guides at all-guides.com CARGO AND PASSENGER WEIGHT CARRYING A PASSENGER WARNING 2006 CHOPPER GENERAL INFORMATION...
  • Page 16: General Information

    All manuals and user guides at all-guides.com GENERAL INFORMATION WARNING FUELING 2006 CHOPPER GENERAL INFORMATION...
  • Page 17 All manuals and user guides at all-guides.com GENERAL INFORMATION HEAT EXHAUST HAZARDS SECURITY TOWING LOANING TO OTHERS 2006 CHOPPER GENERAL INFORMATION...
  • Page 18 All manuals and user guides at all-guides.com GENERAL INFORMATION ROAD CONDITIONS PARKING WARNING 2006 CHOPPER GENERAL INFORMATION...
  • Page 19 All manuals and user guides at all-guides.com GENERAL INFORMATION GOOD JUDGMENT SAFE SPEED RIDING TIP 2006 CHOPPER GENERAL INFORMATION...
  • Page 20 All manuals and user guides at all-guides.com GENERAL INFORMATION FRAME CONSTRUCTION FRONT SUSPENSION REAR SUSPENSION 2006 CHOPPER GENERAL INFORMATION...
  • Page 21 All manuals and user guides at all-guides.com GENERAL INFORMATION 2006 CHOPPER GENERAL INFORMATION...
  • Page 22: Major Components

    All manuals and user guides at all-guides.com SECTION 2 MAJOR COMPONENTS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 23 All manuals and user guides at all-guides.com BATTERY BATTERY SEAT REMOVAL WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 24 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com GEAR SHIFTER WARNING GEAR SHIFTER 2006 CHOPPER MAJOR COMPONENTS...
  • Page 27 All manuals and user guides at all-guides.com GEAR SHIFTER 2006 CHOPPER MAJOR COMPONENTS...
  • Page 28 All manuals and user guides at all-guides.com POWER TRAIN SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 29 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com CLUTCH MANUAL, MULTI-PLATE CLUTCH 2006 CHOPPER MAJOR COMPONENTS...
  • Page 31 All manuals and user guides at all-guides.com CLUTCH CLUTCH ADJUSTMENTS WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 32 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 33 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM 1. STARTING 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.
  • Page 34 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM 2006 ELECTRONIC DEVICES AND THEIR DEFAULTS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 35 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 36 All manuals and user guides at all-guides.com IGNITION SWITCH COIL COVER & IGNITION SIWTCH IGNITION KEY OFF IGNITION KEY ON SWITCH POSITIONS 2006 CHOPPER MAJOR COMPONENTS...
  • Page 37 All manuals and user guides at all-guides.com IGNITION SWITCH WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 38 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com DISPLAY F. SPEEDOMETER/ODOMETER G.TACHOMETER WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 40 All manuals and user guides at all-guides.com BRAKE SYSTEM 2006 CHOPPER MAJOR COMPONENTS...
  • Page 41 All manuals and user guides at all-guides.com BRAKE SYSTEM FRONT BRAKE COMPONENTS A. FRONT DISC ROTOR 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.
  • Page 42 All manuals and user guides at all-guides.com BRAKE SYSTEM FOR NORMAL BRAKING WARNING MAINTAINING BRAKE SYSTEM INTEGRITY 2006 CHOPPER MAJOR COMPONENTS...
  • Page 43 All manuals and user guides at all-guides.com BRAKE SYSTEM WARNING 2006 CHOPPER MAJOR COMPONENTS...
  • Page 44 All manuals and user guides at all-guides.com FUEL SYSTEM TANK CAPACITY Main Capacity 3.4 gal Reserve Capacity .4 gal Total Capacity 3.8 gal 2006 CHOPPER MAJOR COMPONENTS...
  • Page 45 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com FUEL VALVE FUEL VALVE FUEL ON FUEL OFF FUEL RESERVE 2006 CHOPPER MAJOR COMPONENTS...
  • Page 47: Maintenance & Storage

    All manuals and user guides at all-guides.com SECTION 3 MAINTENANCE & STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 48 All manuals and user guides at all-guides.com MAINTENANCE WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 49 All manuals and user guides at all-guides.com MAINTENANCE GENERAL INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 50 All manuals and user guides at all-guides.com MAINTENANCE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 51 All manuals and user guides at all-guides.com MAINTENANCE LOG...
  • Page 52 All manuals and user guides at all-guides.com...
  • Page 53 All manuals and user guides at all-guides.com...
  • Page 54 All manuals and user guides at all-guides.com SERVICE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 55 All manuals and user guides at all-guides.com SERVICE AIR FILTER 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 56 All manuals and user guides at all-guides.com SERVICE FUEL TANK STRAINER WARNING CHECK OIL LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 57 All manuals and user guides at all-guides.com SERVICE ENGINE OIL CHANGING ENGINE OIL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 58 All manuals and user guides at all-guides.com SERVICE ENGINE OIL FILTER TAPPET OIL FILTER SCREEN WINTER LUBRICATION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 59 All manuals and user guides at all-guides.com SERVICE TRANSMISSION LUBRICANT CHECKING TRANSMISSION LUBRICANT LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 60 All manuals and user guides at all-guides.com SERVICE CHANGING TRANSMISSION LUBRICANT PRIMARY DRIVE LUBRICANT CHECKING PRIMARY DRIVE LUBRICANT LEVEL 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 61 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com SERVICE PRIMARY DRIVE CHAIN INSPECTION ADJUSTABLE REAR SHOCKS WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 63 All manuals and user guides at all-guides.com SERVICE LENGTH ADJUSTMENTS 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 64 All manuals and user guides at all-guides.com SERVICE FRONT FORK OIL LUBRICATION DRIVE BELT INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 65 All manuals and user guides at all-guides.com SERVICE SHIFTER LINKAGE ADJUSTMENT FRONT AND REAR BRAKE INSPECTION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 66 All manuals and user guides at all-guides.com SERVICE BRAKE LINE AND MASTER CYLINDER INSPECTION AND SERVICING CARBURETOR CONTROLS CLUTCH CABLE INSPECTION AND ADJUSTMENT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 67 All manuals and user guides at all-guides.com SERVICE ALTERNATOR CHARGING RATE AND VOLTAGE REGULATOR BATTERY SERVICING AND INSTALLATION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 68 All manuals and user guides at all-guides.com SERVICE WARNING SPARK PLUG/PLUG WIRE INSPECTION AND REPLACEMENT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 69 All manuals and user guides at all-guides.com SERVICE HEADLIGHT REPLACEMENT TURN SIGNALS 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 70 All manuals and user guides at all-guides.com CLEANING WARNING GENERAL CLEANING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 71 All manuals and user guides at all-guides.com CLEANING CHROME LEATHER PAINT 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 72 All manuals and user guides at all-guides.com CLEANING WARNING STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 73 All manuals and user guides at all-guides.com STORAGE PREPARING YOUR MOTORCYCLE FOR STORAGE WARNING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 74 All manuals and user guides at all-guides.com STORAGE REMOVING YOUR MOTORCYCLE FROM STORAGE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 75 All manuals and user guides at all-guides.com TROUBLE-SHOOTING TROUBLE-SHOOTING GUIDE ENGINE 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 76 All manuals and user guides at all-guides.com TROUBLE-SHOOTING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 77 All manuals and user guides at all-guides.com TROUBLE-SHOOTING 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 78 All manuals and user guides at all-guides.com TROUBLE-SHOOTING LUBRICATION SYSTEM ELECTRICAL SYSTEM 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 79 All manuals and user guides at all-guides.com TROUBLE-SHOOTING CLUTCH SYSTEM TRANSMISSION 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 80 All manuals and user guides at all-guides.com TROUBLE-SHOOTING BRAKES 2006 CHOPPER MAINTENANCE & STORAGE...
  • Page 81: Warranty

    All manuals and user guides at all-guides.com SECTION 4 WARRANTY 2006 CHOPPER WARRANTY...
  • Page 82 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 83 All manuals and user guides at all-guides.com WARRANTY TRANSFER OF WARRANTY PARTS AND LABOR NOT COVERED 2006 CHOPPER 2006 CHOPPER WARRANTY WARRANTY...
  • Page 84 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 85 All manuals and user guides at all-guides.com WARRANTY LIMIT OF LIABILITY 2006 CHOPPER WARRANTY...
  • Page 86 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 87 All manuals and user guides at all-guides.com WARRANTY LEGAL RIGHTS 2006 CHOPPER WARRANTY...
  • Page 88 All manuals and user guides at all-guides.com WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS LIMITED WARRANTY ON EMISSION CONTROL SYSTEM 2006 CHOPPER WARRANTY...
  • Page 89 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 90 All manuals and user guides at all-guides.com WARRANTY LIMITATIONS UNDER EMISSION CONTROL SYSTEM WARRANTY 2006 CHOPPER WARRANTY...
  • Page 91 All manuals and user guides at all-guides.com WARRANTY OWNER’S WARRANTY RESPONSIBILITIES 2006 CHOPPER WARRANTY...
  • Page 92 All manuals and user guides at all-guides.com WARRANTY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED REPORTING SAFETY DEFECTS 2006 CHOPPER WARRANTY...
  • Page 93 All manuals and user guides at all-guides.com WARRANTY NOTICE OF WARRANTY DISPUTE RESOLUTION PROGRAM 2006 CHOPPER WARRANTY...
  • Page 94 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 95 All manuals and user guides at all-guides.com WARRANTY STATE WARRANTY ENFORCEMENT LAWS 2006 CHOPPER WARRANTY...
  • Page 96 All manuals and user guides at all-guides.com WARRANTY 2006 CHOPPER WARRANTY...
  • Page 97 All manuals and user guides at all-guides.com WARRANTY TRANSFER 2006 CHOPPER WARRANTY TRAMSFER...
  • Page 98 All manuals and user guides at all-guides.com...
  • Page 99 All manuals and user guides at all-guides.com WARRANTY TRANSFER 2006 CHOPPER WARRANTY TRANSFER...
  • Page 100 All manuals and user guides at all-guides.com...