Big Bear Chopper 2009 Owner's Manual
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Big Bear Chopper 2009 Owner's Manual

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BIG BEAR CHOPPERS STRONGLY RECOMMENDS THAT
YOU READ AND UNDERSTAND THE MATERIAL BEFORE
YOU RIDE YOUR NEW BIG BEAR CHOPPER MOTORCYCLE.
YOUR BBC MOTORCYCLE IS A THING OF BEAUTY, BUT
MORE, IT'S A MACHINE THAT REQUIRES YOUR ATTENTION
EVERY NOW AND THEN FOR OPTIMUM MOTORCYCLE LIFE,
PERFORMANCE AND SAFETY.
Version 7/30/08

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Summary of Contents for Big Bear Chopper 2009

  • Page 1 BIG BEAR CHOPPERS STRONGLY RECOMMENDS THAT YOU READ AND UNDERSTAND THE MATERIAL BEFORE YOU RIDE YOUR NEW BIG BEAR CHOPPER MOTORCYCLE. YOUR BBC MOTORCYCLE IS A THING OF BEAUTY, BUT MORE, IT’S A MACHINE THAT REQUIRES YOUR ATTENTION EVERY NOW AND THEN FOR OPTIMUM MOTORCYCLE LIFE, PERFORMANCE AND SAFETY.
  • Page 2 SECTION 1 General Information 1.0 Warranty Registration 3.3 General Inspection 1.1 Starting Your Bike 3.4 Drivetrain Overview 1.2 Initial Break-in Procedure 3.5 Trouble Shooting 1.3 Vehicle Identification 3.6 Maintenance Overview 1.4 General Safety Tips 3.7 Maintenance Schedule 1.5 Kit BIkes and Rolling Chassis 3.8 Maintenance Records 3.9 Storage SECTION 2 Major Components...
  • Page 3 These instructions were put together for the safety, performance and pleasure of riding your Big Bear Chopper. We want to acquaint you with your Big Bear Chopper components. We want to advise you of the break-in procedure to obtain maximum life of your Big Bear Chopper.
  • Page 4 The information in this manual is based on the most current production information available at the time of printing. Big Bear American Made Chop- pers, Inc. reserves the right to make changes to their motorcycles without notice or obligation. As...
  • Page 5 V e h i c l e I d e n t i f i c a t i o n The engine and transmission identification numbers are assigned to the bike when it gets built. These assigned numbers become a permanent part of the motorcycle’s identification. The en- gine identification number can be located on the upper left of the engine case and the transmis- sion identification number is found on the top righthand side of the case.
  • Page 6 1 . 0 W a r r a n t y R e g i s t r a t i o n 2009 OWNER’S MANUAL [WARRANTY REGISTRATION] TO REGISTER YOUR WARRANTY, PLEASE COMPLETE THIS WARRANTY DOCUMENT, PHOTOCOPY AND MAIL TO BIG BEAR CHOPPERS ONLY IF YOU YOUR DEALER HAS NOT DONE THIS. BIG BEAR CHOPPERS...
  • Page 7 NOTE: A battery discharges up to 2% per day when idle. If your motorcycle is not ridden for ap- proximately for a month, the battery may not have sufficient charge to start your motorcycle. Big Bear Choppers does not recommend using a standard automotive battery charger as battery failure is not covered under warranty.
  • Page 8 NOTE: A battery discharges up to 2% per day when idle. If your motorcycle is not ridden for ap- proximately for a month, the battery may not have sufficient charge to start your motorcycle. Big Bear Choppers does not recommend using a standard automotive battery charger as battery failure is not covered under warranty.
  • Page 9 OFF position. If you leave the ignition ON, the lights will run down the battery. Always lock the ignition and remove the key from the bike when you leave. Don’t make it easy for somebody to steel your bike. Because believe us, everyone wants your Big Bear Chopper! ENGINE RPM CONTROL During the break in period of your new motorcycle, figure out the relationship of the clutch and the throttle.
  • Page 10 1 . 2 I n i t i a l B r e a k - i n P r o c e d u r e If you leave your engine idling with inadequate airflow over the engine, it may cause overheating and permanent damage to the engine.
  • Page 11 1 . 4 G e n e r a l S a f e t y T i p s Attention: Failure to read and follow the cautions below may cause serious HEAT Injury or death. Read carefully. The engine, drive train, exhaust pipes, etc. on your Big Bear Chopper become very hot when the engine is running and will remain way too hot to touch for some time after the engine is turned off.
  • Page 12 1 . 4 G e n e r a l S a f e t y T i p s RIDING YOUR MOTORCYCLE Make sure the kickstand is fully retracted before riding. If the kickstand is not in the fully locked position against the frame rail, it could hit the road surface causing loss of control of the bike.
  • Page 13 Those and other alterations to the bike will have dangerous handling characteristics. The addition of unauthorized accessories and additional weight to your Big Bear Chopper can affect handling characteristics that can make for unsafe riding. Since we cannot test and make...
  • Page 14 Riding your Big Bear Chopper is the coolest thing in the world. Guess what? Riding your bike is risking your safety. To minimize any risk, consider these points...
  • Page 15 2 . 0 H a n d l e b a r C o n t r o l s A. CLUTCH HAND LEVER: The clutch hand lever is operated with the left hand. Pull the lever against the handlebar grip to disengage clutch; release the lever smoothly outward to engage clutch. B.
  • Page 16 Pushing the lever down shifts the transmission into the next lower gear while lifting the shift lever shifts the transmission into the next higher gear. Most Big Bear Choppers come equipped with a 6-speed transmission and a few come with 5-speeds. The rider must release the gearshift foot lever after each gear change and allow the lever to return to its central position before another gear change can be made.
  • Page 17 An improperly adjusted clutch cable can cause clutch plates to overheat and/or warp. Clutch repairs and adjustments are a serious mat- ter and is recommended to be fixed by an authorized Big Bear Choppers Dealer. CLUTCH ADJUSTMENTS Maintaining the proper tension on the clutch cable is very important to the life of your bike’s...

  • Page 18: Brake Pedal

    Big Bear Choppers Dealer. FOR BIG BEAR CHOPPERS SPRINGER FRONTENDS Be advised with a Big Bear Chopper Springer on your bike, your braking power may be reduced by up to 50% compared to a telescopic style hydraulic frontend.

  • Page 19: Turn Signals

    2. Ignition 3. Charging 4. Lighting It is best to take your bike to an authorized Big Bear Choppers Dealer if you have any electrical problems. IGNITION Adjusting the ignition timing on your Big Bear Chopper without proper knowledge could lead to engine damage and void your warranty.

  • Page 20: Fuel System

    Pay close attention when fueling up your tank at a public gas station, no matter how many people want to talk to you about your Big Bear Chopper.
  • Page 21 This filter picks up any fine particles that was not caught by the petcock strainer. This fuel filter is between the fuel tank and the carburetor. Big Bear Choppers recommends changing this filter between the miles of 100-300 as it picks up particles left from the fuel tank construction. By us- ing a clear filter housing, you will be able to see the flow of the fuel going through to determine when to change it or not.

  • Page 22: Safety Precautions

    All of the listed maintenance recommendations should be performed at the recommended millage in- tervals by an authorized Big Bear Choppers Dealer in order to ensure the safe operation of your bike. Remember that an authorized Big Bear Choppers Dealer is equipped to maintain and service your bike.

  • Page 23: Transmission Lubricant

    Oil must be changed after the first 500 miles and thereafter at 2500-mile intervals in normal service conditions. Oil change intervals should be shorter in cold weather. Big Bear Choppers recommends 20W50 V-Twin oil. 2.5 - 4.5 quarts of oil is needed, depending on model.
  • Page 24 10 oz. of 5W fork oil. Improper fluid level or leaking seals will cause the front forks to not work properly. If the fork does not appear to be working properly or evidence of oil leakage should develop, have it checked out by an authorized Big Bear Choppers Dealer.
  • Page 25 A damaged tire can fail and cause major injury or death. Striking objects, such as curbs, may result in internal tire damage not visible from the outside. If you are uncertain of the tire integrity, have your tires inspected by an authorized Big Bear Chop- pers Dealer.

  • Page 26: Ignition Timing

    If you experience trouble and think it might be the timing, give your bike to an authorized Big Bear Choppers Dealer to be inspected. If you are assembling a kit with an S&S engine, you will have to install the supplied ignition system and time the engine.
  • Page 27 2,500 miles. If your clutch is slipping with the clutch engaged (clutch lever released) or dragging with the clutch disengaged (clutch lever pulled in) have an authorized Big Bear Choppers Dealer check it out if you do not have the proper knowledge and tools.
  • Page 28 Do not attempt to remove bulb while it is still hot. Do not replace or use any noncompliant or unauthorized Big Bear Choppers electrical components. This could lead to one or more electrical faults or system failures. This will void the electrical warranty.

  • Page 29: Final Drive

    “seat” or mate to one another. These factors will determine engine longevity. PRIMARY DRIVE The primary drive delivers power from the engine to the transmission. The standard primary drive on your Big Bear Chopper is our proprietary enclosed drive system. BDL® open belt drive is an option. TRANSMISSION The transmission delivers the power it receives from the primary drive to the rear wheel by the final drive belt or chain.
  • Page 30 3 . 5 T r o u b l e S h o o t i n g G u i d e TROUBLE SHOOTING GUIDE This trouble-shooting guide covers only the most common potential problems. ENGINE STARTER DOES NOT OPERATE OR DOES NOT TURN ENGINE OVER: 1.
  • Page 31 3 . 5 T r o u b l e S h o o t i n g G u i d e SPARK PLUG KEEPS FOULING: 1. Excessive enrichener use. 2. Fuel mixture too rich. 3. Incorrect spark plug or plug gap. 4.
  • Page 32 3 . 5 T r o u b l e S h o o t i n g G u i d e LUBRICATION SYSTEM OIL DOES NOT RETURN TO OIL TANK: 1. Oil tank empty. 2. Restricted oil lines or fittings. 3.
  • Page 33 3 . 5 T r o u b l e S h o o t i n g G u i d e TRANSMISSION JUMPS OUT OF GEAR: 1. Shifter rod improperly adjusted. 2. Shifter fork bent (inside transmission.) 3. Worn shifter clutch gears in transmission. BRAKES POOR BRAKE PERFORMANCE: 1.
  • Page 34 An authorized Big Bear Choppers Dealer knows how to service your motorcycle, using appropriate methods, equipment and products assuring you competent service. However, Big Bear Choppers is not liable for any actions or claims any shop or dealership may make.
  • Page 35 3 . 7 M a i n t e n a n c e S c h e d u l e SCHEDULED MAINTENANCE LOG 500 Mile 2500 Mile 5000 Mile 7500 Mile 10000 Mile 1. Change engine oil and filter 2.
  • Page 36 3 . 8 M a i n t e n a n c e R e c o r d 500 MILE MAINTENANCE: 1. Change engine oil and filter 2. Change transmission lubricant and clean magnetic drain plug 3. Change primary drive lubricant and clean magnetic drain plug for enclosed primary 4.
  • Page 37 3 . 8 M a i n t e n a n c e R e c o r d 2,500 MILE MAINTENANCE: 1. Change engine oil and filter 2. Change transmission lubricant and clean magnetic drain plug 3. Change primary drive lubricant and clean magnetic drain plug for enclosed primary 4.
  • Page 38 3 . 8 M a i n t e n a n c e R e c o r d 5,000 MILE MAINTENANCE: 1. Change engine oil and filter 2. Change transmission lubricant and clean magnetic drain plug 3. Change primary drive lubricant and clean magnetic drain plug for enclosed primary 4.
  • Page 39 3 . 8 M a i n t e n a n c e R e c o r d 7,500 MILE MAINTENANCE: 1. Change engine oil and filter 2. Change transmission lubricant and clean magnetic drain plug 3. Change primary drive lubricant and clean magnetic drain plug for enclosed primary 4.
  • Page 40 3 . 8 M a i n t e n a n c e R e c o r d 10,000 MILE MAINTENANCE: 1. Change engine oil and filter 2. Change transmission lubricant and clean magnetic drain plug 3. Change primary drive lubricant and clean magnetic drain plug for enclosed primary 4.
  • Page 41 3 . 9 S t o r a g e PREPARING YOUR BIKE FOR STORAGE There are things to do if your bike will not be ridden for several months. To protect parts against corrosion, preserve the battery, and prevent the build up of deposits in the carburetor, the follow- ing steps are recommended to prepare your bike for storage: 1.

  • Page 42: General Cleaning

    3 . 1 0 G e n e r a l C l e a n i n g GENERAL CLEANING Care should be taken to keep your new Big Bear Chopper clean to help prevent rust and corro- sion. Chrome and aluminum parts must be maintained regularly to ensure that they retain their original shine.
  • Page 43 8. Big Bear Choppers brand of wheels and pulleys are warranted for the duration of 1 year and is transferable. 9. If your motorcycle was contracted to Big Bear Choppers to build upon spec, Big Bear Choppers will be the sole arbitrator of defective parts.
  • Page 44 PICK-UP/TOWING In the event of a mechanical breakdown caused by a defect in a Covered Component, BIG BEAR CHOPPERS will reimburse the OWNER for reasonable pick-up and towing charges to transport the motorcycle to BIG BEAR CHOPPERS or an authorized BIG BEAR CHOPPER Dealer.
  • Page 45 BIG BEAR CHOPPERS authorized Dealer or by any individual. This Big Bear Chopper motorcycle is equipped with a carbon air filter, which is an evaporative emission control devise. At no cost to you, an authorized Big Bear Choppers Dealer will replace this carbon air filter at each required maintenance point, or at any...
  • Page 46 For five years or 30,000 kilometers (18,641 miles), whichever first occurs, if an emission-related part on your motorcycle is defec- tive, the part will be repaired or replaced by BIG BEAR CHOPPERS. This is your emission control system defects warranty. As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your OWNER’S MANUAL.
  • Page 47 (subject to any limited right of review that may be provided by state or federal relaw); the OWNER must comply with the terms of the decision; and OWNER gives up the right to sue BIG BEAR CHOPPERS in court on any claim that has been resolved at the arbitration hearing unless BIG BEAR CHOPPERS fails to perform according to the arbitrator’s decision (or unless otherwise provided by state or federal law).
  • Page 48 Big Bear Lake, CA 92315 NOTE: When writing to BIG BEAR CHOPPERS, you will need to provide your name, address, phone number, ve- hicle model, vehicle identification number, date of purchase, current odometer reading, the name of your BIG BEAR CHOPPERS authorized Dealer with their contact information and a description of the problem.
  • Page 49 • Class III motorcycles (280 cc and larger): for a period of use of five (5) years or 30,000 kilometers (18,641 miles), whichever first occurs. If an emission-related part on your motorcycle is defective, the part will be repaired or replaced by Big Bear. This is your emission control system DEFECTS WARRANTY.
  • Page 50 Administrative Code, may be performed by other than an authorized Big Bear dealer. An emergency situa- tion occurs when an authorized Big Bear dealer is not reasonably available, a part is not available within 30 days or a repair is not complete within 30 days. Any replacement part can be used in an emergency repair.
  • Page 51 VII. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, Big Bear is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual.
  • Page 53 5 . 0 W a r n i n g s WARNING Potential hazard Grinding frame welds. What can happen Catastrophic frame failure when operating the motorcycle, resulting in potential serious injury or death. How to avoid the hazard Do not, under any circumstance, modify your frame or grind frame welds. WARNING Potential hazard Starting or running the engine in a closed area.
  • Page 54 5 . 0 W a r n i n g s WARNING Potential hazard Improper handling of gasoline. What can happen Gasoline can catch fire and you could be burned. Also, gasoline is highly toxic. How to avoid the hazard Always turn off the engine when refueling.
  • Page 55 5 . 0 W a r n i n g s WARNING Potential hazard Loose articles causing loss of control. What can happen Loose clothing, long hair, or articles worn by the rider or passenger, or articles improperly stowed on the motorcycle, can impair the motorcycle’s handling.
  • Page 56 5 . 0 W a r n i n g s WARNING Potential hazard Riding your motorcycle with improper oil level. What can happen Motor may seize, causing loss of control and a subsequent serious accident. How to avoid the hazard Make sure that you have followed exactly the above instructions.
  • Page 57 5 . 0 W a r n i n g s WARNING Potential hazard Malfunction of the throttle. What can happen The throttle can become stuck, thus making it difficult to speed up or slow down when it is necessary to do so.
  • Page 58 5 . 0 W a r n i n g s WARNING Potential hazard Riding with wet brakes. What can happen The effectiveness of your brakes are greatly reduced if they are wet. This can lead to a serious accident with serious injury or even death.
  • Page 59 5 . 0 W a r n i n g s WARNING Potential hazard Motorcycle runaway when starting. What can happen If the motorcycle is started without appropriate brake application, the motorcycle can move forward under its own power inadvertently, causing an accident, subsequent serious injury or even death. How to avoid the hazard Always apply the rear brake when starting the motorcycle.
  • Page 60 5 . 0 W a r n i n g s WARNING Potential hazard Improper parking. What can happen You can injure yourself, or others, if the motorcycle is improperly parked and falls over. How to avoid the hazard Park the motorcycle only on hard, level ground. Carefully follow the instructions above when parking the motorcycle.
  • Page 61 5 . 0 W a r n i n g s WARNING Potential hazard Riding with inoperative turn signals. What can happen Drivers of other vehicle may not see that you are about to make a turn and may run into you, causing a serious accident with subsequent injury or even death.
  • Page 62 5 . 0 W a r n i n g s WARNING Potential hazard Improper handling of brake and clutch fluid. What can happen Brake and clutch fluid is highly toxic and corrosive. If spilled on painted or plastic parts, it will quickly destroy them.
  • Page 63 5 . 0 W a r n i n g s WARNING Potential hazard Unbalanced tires. What can happen An unbalanced tire can grossly upset the handling of your motorcycle to the point where control may be lost, resulting in an accident and serious injury or even death. How to avoid the hazard Always have replacement tires balanced by your authorized motorcycle dealer.
  • Page 64 5 . 0 W a r n i n g s WARNING Potential hazard Losing control while adjusting mirrors. What can happen If you try to adjust the mirrors while riding, you could lose control of your motorcycle. How to avoid the hazard Always stop and park before attempting to adjust the mirrors.

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