2006 RIDGEBACK OWNERS MANUAL THANKS FROM BIG DOG MOTORCYCLES for your purchase. With that purchase comes a commitment to provide you support for your handcrafted motorcycle. This Owners Manual has been prepared to acquaint you with the care and maintenance of your motorcycle while providing important safety information. Follow these instructions for maximum motorcycle performance, personal motorcycling safety and pleasure.
TABLE OF CONTENTS SECTION PAGE 1. GENERAL INFORMATION ....................................................................4 Quick Start Guide | Specifications | Vehicle Identification | Tires | Cargo and Passenger Weight | General Information 2. MAJOR COMPONENTS .....................................................................22 Battery | Controls | Gear Shifter | Power Train System | Clutch | Electrical System | Ignition Switch | Display | Brake System | Fuel System | Fuel Valve 3.
HOW TO USE THIS MANUAL Many people read their Owners Manual from beginning to end when they first receive their new motorcycle. If you do, it will help you learn about the features and controls for the motorcycle. Every warning and caution has been carefully placed to keep you and those around you safe when operating the motorcycle. ! WARNING Emphasize areas or improper procedures that could result in mechanical damage or jeopardize your personal safety.
QUICK START GUIDE ! WARNING PROLONGED IDLING WITH INADEQUATE AIRFLOW OVER THE ENGINE WILL CAUSE OVERHEATING AND PERMANENT DAMAGE TO THE ENGINE. HEAVY STOP AND GO TRAFFIC AND EXTENDED IDLING SHOULD BE AVOIDED ESPECIALLY DURING THE BREAK-IN PERIOD. IT IS THE OWNERS RESPONSIBILITY NOT TO EXCEED THE MAXIMUM RPMs DURING THE BREAK-IN PERIOD. OVER-REVVING THE MOTORCYCLE CAN CAUSE PERMANENT DAMAGE TO THE ENGINE AND WILL VOID THE POWER TRAIN WARRANTY.
QUICK START GUIDE RPM TO MPH CONVERSION The below chart converts RPM to MPH. It is a guideline only. For more information contact a Big Dog Motorcycles Dealer or Authorized Service Center.
QUICK START GUIDE COLD STARTING PROCEDURE This motorcycle comes equipped with electronic compression releases to aid in the starting of the engine. Make certain the motorcycle is in neutral. Turn fuel valve to the ON position. Turn ignition switch to the ON position. Depress handlebar ENGINE STOP switch to the RUN position. Note: The handlebar ENGINE STOP switch defaults to OFF every time the ignition switch is turned on. Prime the motor with two twists of the throttle.
QUICK START GUIDE NOTE: A BATTERY DISCHARGES UP TO 2% PER DAY WHEN IDLE. IF THE MOTORCYCLE IS NOT RIDDEN FOR A MONTH, THE BATTERY MAY NOT HAVE SUFFICIENT CHARGE TO START THE MOTORCYCLE. FOR THE OCCASIONAL RIDER, BIG DOG MOTORCYCLES RECOMMENDS USING A TRICKLE CHARGER (BDM250-00004). BIG DOG MOTORCYCLES DOES NOT RECOMMEND USING A STANDARD AUTOMOTIVE BATTERY CHARGER AS EARLY BATTERY FAILURE NOT COVERED UNDER WARRANTY MAY RESULT. HOT ENGINE START Use the same procedure as cold start.
QUICK START GUIDE SHUTTING DOWN Use the ENGINE STOP SWITCH on the right handlebar to shut off the engine. Turn the ignition key switch to the OFF position. Turn the fuel valve to the OFF position. SHIFTING INTO NEUTRAL This motorcycle is equipped with the Baker six-speed transmission with a positive neutral engagement. This will make shifting to neutral easier from first gear. TURN SIGNALS The motorcycles turn signal system is designed to self-cancel.
QUICK START GUIDE to speed shift or shift without using the clutch. Become acquainted with the brake and shifting characteristics of your new motorcycle at a low speed and in a familiar environment. NOTE: BIG DOG MOTORCYCLES ARE EQUIPPED WITH A BAKER SIX-SPEED DIRECT DRIVE TRANSMISSION. WHEN SHIFTING GEARS EITHER UP OR DOWN, THE THROTTLE SHOULD BE CLOSED AND THE CLUTCH DISENGAGED.
SPECIFICATIONS Dry Weight Front ...........254 Lbs Dry Weight Rear............400 Lbs Dry Weight Total............654 Lbs GVWR ............................1,085 Lbs GAWR Front ...................390 Lbs GAWR Rear ....................695 Lbs Fuel Capacity - Total......4.4 Gal Fuel Capacity - Main......4.0 Gal Fuel Capacity - Reserve 0.4 Gal Oil Capacity...................3.5 Qts Frame Specs .................4'' OS BB, 8'' OS DT Frame Rake ...................39 Degrees Front Suspension ..........
VEHICLE IDENTIFICATION VEHICLE ID NUMBER ENGINE ID NUMBER TRANSMISSION ID NUMBER The full 17-digit Vehicle Identification Number (VIN) is stamped on the steering head. Always give the full 17digit number when ordering parts or making any inquiries about the motorcycle. The engine identification number can be located on the upper left of the engine case. The transmission identification number is found on the right underside of the case.
TIRES ! WARNING REPLACE TIRES WITH BIG DOG MOTORCYCLES APPROVED TIRES ONLY. SERVICING TIRES AND WHEELS REQUIRES SPECIAL TOOLS AND SKILLS. WE RECOMMEND YOU SEE A BIG DOG MOTORCYCLES DEALER OR AUTHORIZED SERVICE CENTER FOR THESE SERVICES. TIRES, RIMS AND AIR VALVES MUST BE CORRECTLY MATCHED IN ORDER TO INSURE YOUR PERSONAL SAFETY. MISMATCHING TIRES, RIMS AND AIR VALVES MAY RESULT IN DAMAGE TO THE TIRE BEAD DURING MOUNTING OR MAY ALLOW THE TIRE TO SLIP ON THE RIM, POSSIBLY CAUSING TIRE FAILURE.
TIRES CUTS AND ABRASIONS A part of your pre-ride inspection should be to inspect the tires each time before you ride. You should look for cuts, abrasions or abnormalities. Cuts on the tire, nails or glass fragments embedded in the tire can all be very dangerous. If you find these conditions, you should have the tire replaced. TIRE INTEGRITY Maintaining tire integrity cannot be stressed enough.
CARGO AND PASSENGER WEIGHT ! WARNING KEEP CARGO WEIGHT CONCENTRATED CLOSE TO THE MOTORCYCLE AND AS LOW AS POSSIBLE TO MINIMIZE ANY CHANGE TO CENTER OF GRAVITY (BALANCE POINT). DISTRIBUTE WEIGHT EVENLY ON BOTH SIDES OF THE MOTORCYCLE AND DO NOT LOAD BULKY ITEMS OR ADD WEIGHT TO THE HANDLEBARS OR FRONT FORKS. DO NOT EXCEED 15 POUNDS MAXIMUM LOAD IN EACH SADDLEBAG. IMPROPER LOADING CAN CAUSE VEHICLE HANDLING PROBLEMS AND RESULT IN PERSONAL INJURY.
CARGO AND PASSENGER WEIGHT 1. Our motorcycles are carefully engineered to be ridden in their original configuration or only with authorized Big Dog Motorcycles accessories. 2. Unauthorized accessories that change the operators riding position may reduce reaction time and alter handling characteristics. 3. Overloading the motorcycle by exceeding Gross Vehicle Weight Rating (GVWR) may alter handling characteristics and reduce braking efficiency. 4.
GENERAL INFORMATION ! WARNING SHOULD ANY ABNORMALITY OCCUR IN THE OPERATION OF YOUR MOTORCYCLE, IMMEDIATELY CONTACT A BIG DOG MOTORCYCLES DEALER OR SERVICE CENTER FOR CORRECTION OF THE PROBLEM. BE SURE ALL EQUIPMENT REQUIRED BY FEDERAL, STATE AND LOCAL LAW IS INSTALLED AND IN GOOD OPERATING CONDITION. REGULARLY INSPECT SHOCK ABSORBERS AND FRONT FORKS, CHECKING FOR LEAKS. WORN PARTS CAN AFFECT STABILITY. USE ONLY AUTHORIZED REPLACEMENT FASTENERS TIGHTENED TO THE PROPER TORQUE.
GENERAL INFORMATION HEAT The engine, drive train, exhaust pipes and muffler on the motorcycle become very hot when the engine is running and remain too hot to touch for some time after the engine is turned off. Make sure that you, as well as any passenger you carry, wear clothing that will completely cover legs when riding. Avoid contact with the exhaust system. EXHAUST HAZARDS Motorcycle exhaust contains carbon monoxide gas.
GENERAL INFORMATION ROAD CONDITIONS Pay strict attention to your surroundings. Avoid riding when the weather is a serious factor such as high wind, heavy fog, rain, snow, ice or other factors that would make the ride less safe. Know your limitations and do not ride when the weather is beyond your skills or comfort zone. The first 15 minutes of a rainstorm brings all oil and contaminants to the road surface causing a slippery condition.
GENERAL INFORMATION GOOD JUDGMENT Safe motorcycle operation requires mental awareness and good judgment, combined with a defensive driving attitude. SAFE SPEED Operate your motorcycle only at moderate speed in and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions. If you are an inexperienced rider, we recommend that you take a certified course on motorcycle riding. RIDING TIP MAKE SURE YOU ARE WEARING A D.O.T.
GENERAL INFORMATION FRAME CONSTRUCTION The frame is made from high-strength seamless steel tubing and utilizes a high tensile strength welding process held to extremely tight tolerances. Any attempt to modify the frame of the motorcycle is extremely dangerous and will void the manufacturers warranty. Altering the frame in any way takes the motorcycle out of its original configuration and may expose it to stresses that it was never intended to withstand.
GENERAL INFORMATION Riding your motorcycle can be an enormous source of enjoyment. However, there are risks associated with riding any motorcycle. To minimize these risks, you should: 1. Review and follow the operating and maintenance instructions in this manual. 2. Take notice of every warning in this manual. 3. Recognize and respect the rules of the road. To ensure your personal safety, obtain a copy of your states Motorcycle Handbook and understand the contents. 4.
SECTION 2 MAJOR COMPONENTS Battery | Controls | Gear Shifter | Power Train System | Clutch | Electrical System | Ignition Switch | Display | Brake System | Fuel System | Fuel Valve 22 2006 RIDGEBACK MAJOR COMPONENTS
BATTERY BATTERY The battery and electrical components are located under the seat. This motorcycle has a maintenance-free battery. Any attempt to open the battery is extremely dangerous and will void the warranty. You cannot check the battery electrolyte level or add distilled water as you would with a conventional type battery. If the battery seems weak, causing slow starting or other electrical problems contact a Big Dog Motorcycles Dealer or Authorized Service Center.
CONTROLS A C D ! 24 B 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. HEAD LAMP HIGH/LOW SWITCH The head lamp switch controls the head lamp high and low beams. C. HORN SWITCH The horn is operated by depressing the horn switch. D. LEFT TURN SIGNAL The left turn signal is operated by the TURN-L switch.
CONTROLS E F J G H I E. ELECTRIC STARTER SWITCH After the ignition key is turned to the ON position, press RUN on the ENGINE STOP SWITCH before pressing the START SWITCH. F. ENGINE STOP SWITCH The engine stop switch turns the ignition on or off and should be used every time to stop the engine. G. FRONT BRAKE HAND LEVER The front brake hand lever is operated with the right hand. Pull the lever in towards the handlebar grip to engage the front brake. H.
GEAR SHIFTER ! WARNING DO NOT FORCE THE TRANSMISSION TO SHIFT UNDER ANY CIRCUMSTANCES. FORCING A SHIFT MAY DAMAGE THE SHIFT LEVER OR THE PRIMARY DRIVE TRAIN. DO NOT RIDE WITH YOUR FOOT ON THE GEAR SHIFTER. WHEN UP-SHIFTING OR DOWNSHIFTING, THE THROTTLE SHOULD BE CLOSED AND THE CLUTCH FULLY DISENGAGED.
GEAR SHIFTER The gear shifter is located on the left forward foot control. There are six forward gears and no reverse. Pushing the lever down shifts the transmission into the next lower gear, lifting the shift lever up shifts the transmission into the next higher gear. This motorcycle comes equipped with a Baker six-speed transmission. The top three gears are helical cut to reduce noise, improve gear engagement and ease shifting effort.
POWER TRAIN SYSTEM A B D 28 C 2006 RIDGEBACK MAJOR COMPONENTS
POWER TRAIN SYSTEM SYSTEM COMPONENTS The power train of this motorcycle is composed of: A. V-TWIN, 117 CUBIC-INCH, FOUR-STROKE ENGINE B. CHAIN DRIVEN PRIMARY DRIVE The primary drive delivers power from the engine to the transmission. The primary drive of this motorcycle is composed of a double row drive chain running from the crankshaft sprocket inside the primary drive case to the clutch. C.
CLUTCH MANUAL, MULTI-PLATE CLUTCH The purpose of the clutch is to engage and disengage the flow of power from the engine to the transmission. A multi-plate clutch assembly is attached to the transmission input shaft. The transmission drive sprocket is attached to this clutch basket and is driven by the engine via a double row primary chain. A starter ring gear, also attached to this clutch assembly, engages with the starter motors pinion gear to start the engine.
CLUTCH CLUTCH ADJUSTMENTS Maintaining the proper tension on the clutch cable is critical to the longevity of the motorcycles clutch. If the clutch cable is too tight, the clutch plates will not fully engage. This causes the clutch to slip. If the clutch cable has too much slack, the clutch will not completely release. This may cause hard shifting, vehicle creep, overheating and warping of the clutch plates and may make finding neutral difficult.
ELECTRICAL SYSTEM D I K C H F G 32 2006 RIDGEBACK MAJOR COMPONENTS J K A E B
ELECTRICAL SYSTEM The electrical system supplies electrical power to all the various components of the motorcycle. The electrical system of this motorcycle can be broken down into four major systems and are composed of the following: 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. HEADLIGHT; J. TAIL LIGHT; K.
ELECTRICAL SYSTEM 2006 ELECTRONIC DEVICES AND THEIR DEFAULTS Incorporated in the 2006 electrical system are: 1. 2. 3. 4. 5. Electronic controlled compression releases. Self-canceling turn signals after a 10-second interval. Self-diagnosing EHC (Electronic Harness Control). LED tail light, turn signals, tag light and front and rear running lights. Ignition switch off, returns the headlight to low beam for the next time ignition switch is turned on. 6.
ELECTRICAL SYSTEM If your motorcycle exhibits any of the following symptoms the ignition system may need diagnostic analysis by a Big Dog Motorcycles Dealer or Authorized Service Center: 1. 2. 3. 4. 5. Engine does not start or difficulty in starting. Starter kickback. Poor running at low speeds. Poor running or low power at high speeds. Knocking or abnormal engine noise. For any electrical problems, it is best to take your motorcycle to a Big Dog Motorcycles Dealer or Authorized Service Center.
IGNITION SWITCH The ignition switch activates the EHC which controls the electrical functions of the motorcycle. COIL COVER & IGNITION SWITCH IGNITION KEY OFF IGNITION KEY ON SWITCH POSITIONS There are only two ignition key positions. Vertical, or up, is ignition OFF and the key is removable in this position. Horizontal, or sideways, is ignition ON and the key should not be able to be removed. In the horizontal or ON position, the following will occur: A.
IGNITION SWITCH After shutting down the engine, always turn the switch to the OFF position. If you leave the ignition ON, the lights will run down the battery. To prevent theft, always lock the ignition and remove the key when the motorcycle is left unattended. ! WARNING DO NOT ATTACH LARGE, HEAVY KEY RINGS OR OTHER OBJECTS TO THE IGNITION KEY AS THIS CAN DAMAGE THE COIL COVER AND THE IGNITION SWITCH.
DISPLAY ! WARNING NEVER ATTEMPT TO TAMPER WITH OR ALTER THE VEHICLE ODOMETER. THIS IS ILLEGAL. A. LEFT TURN INDICATOR LIGHT The yellow turn indicator will flash when the left turn indicator is activated. B. OIL INDICATOR LIGHT The red oil pressure indicator light signals low oil pressure when lit. This light will come on when the ignition is on, and off F when minimum engine oil pressure is reached. C.
DISPLAY F. SPEEDOMETER/ODOMETER The speedometer registers speed in statute miles per hour. The odometer registers the total number of statute miles the vehicle has traveled. The trip odometer registers the total statute miles the motorcycle traveled since it was last reset. To reset the trip odometer, depress and hold the black button under the odometer when the total miles ridden are displayed. This will zero out and reset the trip odometer. G.
BRAKE SYSTEM D C A H B 40 2006 RIDGEBACK MAJOR COMPONENTS G F E
BRAKE SYSTEM FRONT BRAKE COMPONENTS The front brake is a hydraulic disc type, which is operated by the hand lever on the right handle bar. It is composed of: A. FRONT DISC ROTOR B. FOUR-PISTON CALIPER C. BRAIDED STAINLESS STEEL LINE D. 5/8 BORE MASTER CYLINDER & RESERVOIR REAR BRAKE COMPONENTS The rear brake is a hydraulic disc type, which is operated by the pedal on the right foot rest. It is composed of: E. REAR DISC ROTOR F. FOUR-PISTON CALIPER G. BRAIDED STAINLESS STEEL LINE H.
BRAKE SYSTEM ! FOR NORMAL BRAKING Apply both front and rear brakes. The brake system supplies best stopping when applied simultaneously. Pull in the clutch lever to prevent the engine from stalling. ONLY APPLYING THE REAR BRAKE CAN REDUCE YOUR BRAKING ABILITY BY UP TO 70%. WARNING HARD BRAKING MAY CAUSE WHEEL LOCK AND CAN RESULT IN LOSS OF CONTROL OF THE MOTORCYCLE.
BRAKE SYSTEM ! WARNING RIDING THE BRAKES CAN CAUSE OVERHEATING, REDUCING THEIR EFFECTIVENESS. NEVER RIDE WITH YOUR FOOT RESTING ON THE BRAKE PEDAL OR YOUR HAND PUTTING PRESSURE ON THE FRONT BRAKE LEVER EXCEPT WHEN STOPPING. AVOID PROLONGED BRAKE APPLICATION. THIS CAN OVERHEAT THE BRAKES AND REDUCE THEIR EFFECTIVENESS. If you experience trouble with the brake system, have it inspected by a Big Dog Motorcycles Dealer or Authorized Service Center.
FUEL SYSTEM F D E C A TANK CAPACITY Main Capacity 4.0 gal Reserve Capacity 0.4 gal Total Capacity 4.
FUEL SYSTEM The fuel system of this motorcycle is composed of: A. FUEL TANK One-piece tank design incorporating gas-cap vents. To open the gas cap turn counterclockwise. B. FUEL VALVE (See illustration on next page) C. CARBURETOR The carburetor is the central part as well as the most complex part of the fuel system. For information on maintenance of the air filter see Section 3. D. FUEL LINE E. ENRICHENER Facilitates cold starting by creating a richer than normal fuel condition.
FUEL VALVE IN THE FUEL ON POSITION, FUEL ENTERS THE VALVE FROM APPROXIMATELY ONE INCH ABOVE THE BOTTOM OF THE TANK. THE RESERVE POSITION ALLOWS THE FUEL THAT IS LEFT IN THE BOTTOM OF THE TANK TO ENTER THE VALVE IF YOU USE THE FUEL RESERVE, REMEMBER TO TURN THE VALVE FROM THE RESERVE TO THE ON POSITION AFTER REFUELING. FUEL VALVE This motorcycle comes equipped with a high performance, high flow fuel valve. The fuel valve is located under the fuel tank on the left side of the motorcycle.
SECTION 3 MAINTENANCE & STORAGE Maintenance | Maintenance Log | Service | Cleaning | Storage | Trouble-Shooting 2006 RIDGEBACK MAINTENANCE & STORAGE 47
MAINTENANCE ! To achieve the greatest safety, reliability and performance from this motorcycle regular maintenance procedures must be followed. These include inspection, lubrication and adjustment. A Big Dog Motorcycles Dealer or Authorized Service Center will service your motorcycle, using factory approved methods, equipment and products, assuring you competent service. WARNING MAINTENANCE AT REGULAR INTERVALS IS REQUIRED TO KEEP YOUR NEW MOTORCYCLES WARRANTY IN EFFECT.
MAINTENANCE GENERAL INSPECTION Good maintenance means a safe machine. A careful check of certain equipment must be made after periods of storage and frequently between the regular service intervals to determine if additional maintenance is necessary. The following items should be checked regularly: 1. 2. 3. 4. 5. 6. 7. 8. 9. Tires - for correct pressure, abrasions or cuts. Brakes, steering and throttle - for responsiveness. Drive belt - for condition. Brake fluid - for level and condition.
MAINTENANCE By using the following recommended maintenance schedule, you will be assured longevity, reliability and performance of your motorcycle. The mileage intervals shown in the maintenance schedule are intended as a guide for regular maintenance and lubrication periods for this motorcycle. With sustained adverse conditions (temperature extremes, dusty climate operation, poor road conditions, high-speed operation, through deep water, etc) more frequent servicing may be required.
MAINTENANCE LOG 51 Engine Oil and Filter Air Cleaner Filter Primary Drive Lubricant and Magnetic Plug Primary Drive Chain Clutch Transmission Lubricant and Magnetic Plug Lubricate Clutch Pushrod Drive Belt (with rider on bike) Brake Pads and Rotor (front and rear) Master Cylinder Reservoir Fluid Level and Condition (front & rear) Fluid Lines (oil, brake & fuel) Brake and Clutch Levers and Cables (including throttle cables) Throttle and Enrichener Controls Fuel Valve and Fuel Filter Screen Tires Steering H
R = Replace; I = Inspect, clean, lubricate, adjust, repair or replace if necessary 500 MILE 2,500 MILE 5,000 MILE 7,500 MILE 500 MILE MAINTENANCE R R R R DATE: MILES: I I I I DEALER: R R COMMENTS: I I I I I I R R R R 2,500 MILE MAINTENANCE I I DATE: MILES: I I DEALER: I I I I COMMENTS: I I I I I I I I I I I I 5,000 MILE MAINTENANCE I I I I DATE: MILES: I I I I DEALER: I I I I COMMENTS: I I I I I I I I 7,500 MILE MAINTENANCE I I I I I I DATE: MILES: I I DEALER: I I COMMENTS: I I I I DOWNLOAD DOWNLOAD DOWNLOA
10,000 MILE 12,500 MILE 15,000 MILE 17,500 MILE R R R R I I I I R R R R I I I I I I I I R R R R I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I DOWNLOAD DOWNLOAD DOWNLOAD DOWNLOAD 10,000 MILE MAINTENANCE DATE: MILES: DEALER: COMMENTS: 12,500 MILE MAINTENANCE DATE: MILES: DEALER: COMMENTS: 15,000 MILE MAINTENANCE DATE: MILES: DEALER: COMMENTS: 17,500 MILE MAINTENANCE DATE: MILES: DEALER: COMMENTS:
SERVICE If you decide to perform the scheduled maintenance, it is essential you have the proper tools, knowledge and skills required. Improper maintenance will cause permanent damage to your motorcycle. In performing any service or maintenance Big Dog Motorcycles recommends the following safety precautions: 1. Wear safety glasses, goggles, or face shield when attempting any maintenance or service operations. 2. The motorcycle must be firmly supported in an upright position. 3.
SERVICE AIR FILTER This motorcycle is equipped with a dry paper air filter. In order to function properly, the air cleaner must provide an airtight seal between the air cleaner cover and backing plate. Without this complete seal, dirt contaminated air may enter the engine causing rapid wear and possible engine failure. The air filter must be serviced or replaced at 500 miles and every 2,500 miles thereafter. A drypaper filter cannot be cleaned with any type of solvent or water.
SERVICE ! FUEL TANK STRAINER A screen-type fuel strainer is located on top of the supply valve inside the fuel tank. The screen should be inspected and cleaned every service interval. With the gas tank empty (drained through the fuel valve line with the valve set to reserve), carefully unscrew the fuel supply valve from the tank. Inspect and clean the fuel strainer, then reinstall the valve in the fuel tank.
SERVICE ENGINE OIL Use only premium 20W50 V-Twin, detergent motorcycle oil. The quality and cleanliness of your engine oil, as well as maintaining the proper oil level helps prevent wear inside your engine. CHANGING ENGINE OIL The oil tank should be drained only after the engine has reached normal operating temperature and proceed as follows: 1. Position the motorcycle upright and level. The oil drain is located at the rear of the oil tank. 2.
SERVICE ENGINE OIL FILTER The oil filter is located at the base in the front of the engine. The oil filter should be replaced every time the oil is changed. Use only factory recommended filters. TAPPET OIL FILTER SCREEN The tappet lifter oil filter screen is located in the crankcase above the oil pump. The removal and cleaning of the oil filter screen should take place every service interval or if there is abnormal lifter noise. Use caution when cleaning so not to damage the filter screen when removing.
SERVICE TRANSMISSION LUBRICANT The transmission lubricant level should be checked monthly. Big Dog Motorcycles recommends premium V-Twin motorcycle transmission lubricant whereas synthetic lubricants are NOT recommended. CHECKING TRANSMISSION LUBRICANT LEVEL The transmission lubricant level should be checked only when the drive train is at normal operating temperature. 1. Turn the engine off and position the motorcycle upright and level.
SERVICE CHANGING TRANSMISSION LUBRICANT The transmission lubricant should be changed at all service intervals and every 2,500 miles thereafter. The drain plug is located on the left side trap door bottom center under the transmission case. 1. Unscrew the threaded drain plug to allow fluid to drain. 2. Remove speed sensor and clean any material on it. 3. Replace and secure the drain plug. 4. Fill the transmission case with 20 oz. of lubricant.
SERVICE 6. Note sealant placement on inspection cover. Remove old sealant from primary opening and inspection cover. 7. Install new inspection cover O-rings. Apply new sealant, part number 270-000005-00, to O-rings and inspection cover. CHANGING PRIMARY DRIVE LUBRICANT Primary lubricant should be changed initially at 500 miles and every 5,000 miles thereafter. The drain plug is located under the clutch, on the underside of the primary. The filler access is the tensioner inspection cover.
SERVICE to drain. Inspect and clean the magnetic drain plug. Install the drain plug and tighten to 10 ftlbs torque. Do not over tighten. Fill with 32 oz. of lubricant. For routine maintenance purposes, with bike upright and level, the proper fluid level can be visually checked by looking for partial oil coverage of the internal inner primary casting web as shown. 2. When draining or refilling with lubricant, do not allow dirt or debris to enter the primary.
SERVICE FRONT FORK OIL Drain and refill the front forks every 5,000 miles or annually. All 2006 models use 10 oz. of 30W synthetic fork oil. Improper fluid level or leaking seals will cause the front forks to malfunction. If the fork does not appear to be working properly or evidence of oil leakage should develop, see a Big Dog Motorcycles Dealer or Authorized Service Center. LUBRICATION 1. Lubricate throttle control cables with graphite every 2,500 miles. 2.
SERVICE DRIVE BELT INSPECTION The rear drive belt tension is set at the factory and should be checked along with pulley wear at the 500-mile service and each 2,500 miles thereafter. Inspect the belt for signs of excessive wear, tears, cracks and missing or broken teeth. Replace the belt if any of these conditions are found. The inner tooth surface area of a new belt is coated with a thin layer of polyethylene. This coating will wear off as the motorcycle is ridden and its appearance will change.
SERVICE FRONT AND REAR BRAKE INSPECTION Initially, check your front and rear brakes at 500 miles then every 2,500 miles thereafter. If you ride under adverse conditions like steep hills or heavy traffic, more frequent inspection may be necessary. Visual inspection of brake pads can be made without removing the caliper by viewing the lower area of each caliper with the aid of a flashlight. If brake pad material is 1/16" in thickness (the thickness of a nickel) the pad must be replaced immediately.
SERVICE BRAKE LINE AND MASTER CYLINDER INSPECTION AND SERVICING Whenever you inspect the brake pads and discs, also inspect the brake lines, connections, master cylinders and calipers for leakage. To service the front brake master cylinder: 1. Stand the motorcycle on its side stand. 2. Turn the handlebars until the front brake master cylinder lid is close to level (you may need assistance to keep the front handlebars in this position). 3.
SERVICE CLUTCH CABLE INSPECTION AND ADJUSTMENT The clutch cable should be checked, lubricated and adjusted at all service intervals and every 2,500 miles thereafter. If you experience slippage with the clutch engaged (clutch lever released) or dragging with the clutch disengaged (clutch lever pulled in) see a Big Dog Motorcycles Dealer or Authorized Service Center. ALTERNATOR CHARGING RATE AND VOLTAGE REGULATOR The alternator output is controlled by the voltage regulator.
SERVICE ! Batteries can lose some of their charge even with the ignition turned off. Discharge rate depends on the storage temperature and the condition of the battery. After 30 days of non-use, the battery may not have sufficient cranking power to start the motorcycle. Big Dog Motorcycles recommends using the BDM250-00004 trickle charger in order to maintain sufficient cranking power. No other charger is recommended by Big Dog Motorcycles. DO NOT use an automotive battery charger.
SERVICE The spark plug gap should be 0.040 inches. Make sure that the new spark plugs are the same type as the ones being replaced: Champion® RA8HC. Spark plugs should be torqued to 14 ftlbs. If the engine seems to be running on only one cylinder, check the spark plug wire connection at both ends. HEADLIGHT REPLACEMENT The headlight has a replaceable quartz halogen bulb. When replacing a halogen bulb never touch the glass portion with your bare fingers. Oil contamination will reduce bulb life.
CLEANING ! WARNING OBSERVE WARNINGS AND CAUTIONS GIVEN ON LABELS OF CLEANING PRODUCTS TO PREVENT DAMAGE TO YOUR MOTORCYCLE. DO NOT WASH YOUR BRAKE DISCS WITH ANY CLEANERS THAT CONTAIN EITHER CHLORINE OR SILICONE. WHEN WASHING YOUR MOTORCYCLE, BE CAUTIOUS NOT TO EXPOSE THE BRAKES, ENGINE, MUFFLER, INSTRUMENTS, AIR CLEANER, WHEEL BEARING OR PAINTED AREAS TO HIGHPRESSURE SPRAY. USE OF A HIGH-PRESSURE SPRAY OR PRESSURE WASHER IS NOT RECOMMENDED.
CLEANING CHROME Use a chrome polish to shine your chrome. Multipurpose cleaners are not recommended. LEATHER Many accessories and seats are either made of leather or have a leather insert. Natural materials require different care than man made materials. Leather must be periodically cleaned and treated to maintain its appearance and extend its life. Use only products that are specifically made for leather on your leather accessories. PAINT is one of the distinguishing characteristics of your motorcycle.
CLEANING ! surfaces and use a clean applicator with a non-abrasive polish to avoid scratching your paint. 5. Wipe off gasoline immediately. The chemicals and additives in gasoline can dull or fog your paint if allowed to remain on the paint. 6. Use only approved cleaners on your paint. Harsh cleaners may work great for removing road tar but also may damage your paint. 7. Avoid constant contact (rubbing) with any clothing or travel gear on your paint.
STORAGE PREPARING YOUR MOTORCYCLE FOR STORAGE There are things to do if your motorcycle will not be operated for several months. To protect parts against corrosion, preserve the battery and prevent the build up of deposits in the carburetor the following steps are recommended to prepare your motorcycle for storage: 1. Change the oil and filter. 2. Fill the fuel tank and add a gasoline stabilizer. 3.
STORAGE REMOVING YOUR MOTORCYCLE FROM STORAGE When removing your motorcycle from storage, here is a checklist of things you will need to do prior to riding: 1. Remove and inspect the spark plugs. Replace if necessary. 2. Check and clean or replace the air filter. 3. Reinstall battery. 4. Start the engine and run until it reaches normal operating temperature. Then turn off the engine. 5. Check the oil level. 6. Check the transmission lubricant level. 7. Check controls for proper operation. 8.
TROUBLE-SHOOTING TROUBLE-SHOOTING GUIDE The trouble-shooting guide provides only the most common problem/solutions. ENGINE STARTER DOES NOT OPERATE OR DOES NOT TURN ENGINE OVER: 1. Engine run switch in OFF position. 2. Ignition switch not on. 3. Discharged battery, loose, corroded or broken connections (solenoid chatters). ENGINE TURNS OVER BUT DOES NOT START: 1. Fuel valve turned off (low fuel requires the fuel valve to be turned to reserve). 2. Fuel tank empty. 3. Engine flooded with fuel. 4.
TROUBLE-SHOOTING 4. 5. 6. 7. 8. 9. Loose wire or cable connection(s) at one of the battery terminals or at coil. Spark plug cables in bad condition. Battery nearly discharged. Carburetor not adjusted correctly. Water or dirt in fuel system and/or carburetor. Engine oil too viscous (winter operation). STARTS, BUT RUNS IRREGULARLY OR MISSES: 1. Spark plugs in bad condition or partially fouled. 2. Spark plug cables in bad condition or have become detached (check both ends of each spark plug cable). 3.
TROUBLE-SHOOTING 3. Incorrect spark plug or plug gap. 4. Air filter clogged. 5. Excessive pumping of the throttle grip. PREIGNITION OR DETONATION (KNOCKS OR PINGS): 1. Incorrect fuel. 2. Incorrect spark plug. 3. Incorrect ignition timing. 4. Insufficient oil supply or oil circulation. 5. Heavy carbon deposit from lugging engine. 6. Carburetor set too lean. 7. No air flow over engine (i.e. stopped in traffic). EXCESSIVE VIBRATION: 1. Front or rear engine mounting bolts loose. 2.
TROUBLE-SHOOTING LUBRICATION SYSTEM OIL DOES NOT RETURN TO OIL TANK: 1. Oil tank empty. 2. Restricted oil lines or fittings. 3. Restricted oil filter. 4. Internal motor damage. ENGINE LEAKS OIL FROM CASE, PUSH RODS, HOSES: 1. Loose parts. 2. Imperfect seal at gasket, push rod cover, washers, etc. 3. Restricted oil return line to tank. ELECTRICAL SYSTEM ALTERNATOR DOES NOT CHARGE: 1. Regulator not grounded or defective. 2. Engine ground wire loose or broken. 3. Malfunction in charging system.
TROUBLE-SHOOTING CLUTCH SYSTEM DRAGS OR DOES NOT RELEASE: 1. Clutch controls improperly adjusted. 2. Clutch steel discs warped. CLUTCH SLIPS: 1. Clutch controls improperly adjusted. 2. Worn friction discs. 3. Insufficient clutch spring attitude. CLUTCH CHATTERS: 1. Friction disc or steel discs worn or warped. TRANSMISSION HARD TO SHIFT: 1. Transmission shifting mechanism needs adjustment. 2. Bent shifter fork. 3. Clutch out of adjustment. TRANSMISSION JUMPS OUT OF GEAR: 1. Shifter rod improperly adjusted.
TROUBLE-SHOOTING BRAKES POOR BRAKE PERFORMANCE: 1. Front and/or rear master cylinder low on fluid. 2. Air bubbles in the hydraulic system. 3. Contaminated brake pad/disc. 4. Brake pads badly worn (1/16 in. minimum lining thickness). 5. Brake discs badly worn or warped. 6. Brake fades because of heat build up due to: a. Excessive braking (riding the brakes). b. Brake pads dragging. c. Insufficient hand lever or rear pedal free play. 7. Master or caliper pistons worn.
SECTION 4 WARRANTY Warranty | Warranty Transfer 2006 RIDGEBACK WARRANTY 79
WARRANTY This Manufacturers Limited Warranty is between BIG DOG MOTORCYCLES, L.L.C. , and you, the owner (OWNER). Your motorcycle is warranted against defects in materials and workmanship for a period of two (2) years, with the exception of defects in paint and chrome, which are warranted for a period of six (6) months. BIG DOG MOTORCYCLES will be the sole arbitrator of defective paint.
WARRANTY TRANSFER OF WARRANTY This Manufacturers Limited Warranty is, in most instances, transferable to a subsequent owner. However, BIG DOG MOTORCYCLES reserves the right to decline the transfer of the remainder of the warranty to subsequent owners under certain circumstances. It is the duty of subsequent purchasers to determine, prior to purchase, if the warranty is transferable.
WARRANTY 4.
WARRANTY 7. Any vehicle that does not have a valid manufacturers VIN or title branded as salvage, junk, rebuilt, totaled, or flood damaged. Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined is not covered. 8. Damage to paint from any cause other than factory defects. Specifically, fading caused by over exposure to direct sunlight, rock chips, abuse, road debris abrasion or overfilling of the fuel tank(s). 9.
WARRANTY 1. Repair or replacement of defective components. PICK-UP/TOWING - In the event of a mechanical breakdown caused by a defect in a Covered Component, BIG DOG MOTORCYCLES will reimburse the OWNER for reasonable pick-up and towing charges to transport the motorcycle to a BIG DOG MOTORCYCLES Dealer or Authorized Service Center. Maximum allowance per occurrence is $100 and is subject to the terms and conditions of the current towing policy.
WARRANTY 2. Authorized Dealers are independently owned and operated and BIG DOG MOTORCYCLES is not responsible in any way for any parts, labor, alterations or modifications made to said motorcycle. Dealers are not an agent and cannot provide a warranty. LEGAL RIGHTS THIS MANUFACTURES LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER ORAL, WRITTEN, EXPRESSED, OR IMPLIED. BIG DOG MOTORCYCLES OBLIGATIONS AND OWNERS REMEDIES, HEREUNDER, ARE SOLELY AND EXCLUSIVELY AS STATED.
WARRANTY In addition to this Limited Warranty, the motorcycle is covered by the Emissions System Warranty that follows: YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the emission control system warranty on your 2006 BIG DOG MOTOTCYCLES motorcycle. In California, new motor vehicles must be designed, built and equipped to meet the States stringent anti-smog standards.
WARRANTY to applicable regulations of the United States Environmental Protection Agency and, if applicable, the California Air Resources Board within 5 years or 18,641 miles (30,000 kilometers) whichever occurs first. Warranty defects shall be remedied during customary business hours at any Authorized Dealer in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and, if applicable, the California Air Resources Board.
WARRANTY suggested retail price for all warranted parts replaced and labor charges based on BIG DOG MOTORCYCLES recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The OWNER will be required to provide receipts and return the failed parts to BIG DOG MOTORCYCLES in order to receive compensation.
WARRANTY prior to sale at retail, on the date it is first placed in service. The liability of BIG DOG MOTORCYCLES is limited solely to the remedying of defects in material or workmanship by an Authorized Dealer at their place of business during customary business hours. These warranties do not cover inconvenience or loss of use of the motorcycle.
WARRANTY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
WARRANTY or BIG DOG MOTORCYCLES. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 or (202) 366-0123 in the Washington D.C. area) or write to: NHTSA, U.S. Department of Transportation, 400 7th Street S.W., (NASS-11) Washington, DC. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
WARRANTY decision, BIG DOG MOTORCYCLES will be bound to abide by the decision and comply with its terms (subject to any limited right of review that may be provided by state or federal law); the OWNER must comply with the terms of the decision; and OWNER gives up the right to sue BIG DOG MOTORCYCLES in court on any claim that has been resolved at the arbitration hearing unless BIG DOG MOTORCYCLES fails to perform according to the arbitrators decision (or unless otherwise provided by state or federal law).
WARRANTY by BIG DOG MOTORCYCLES. For more information about the BBB arbitration process, or to file a claim with this mechanism, OWNER may write to: Better Business Bureau of Wichita 328 S. Laura Wichita, KS 67211 or call toll-free 1-800-856-2417. This Arbitration process affects important legal rights, and OWNER should check with an attorney with any QUESTIONS ABOUT THOSE rights.
WARRANTY owners to obtain a replacement vehicle or a refund under certain circumstances. In some states, the law requires that you first notify the manufacturer in writing of a problem so that the manufacturer has an opportunity to make any needed repairs, before you are eligible for remedies these laws provide. Your written notification should be sent to: BIG DOG MOTORCYCLES Attn: Warranty Dept. 1520 E.
WARRANTY TRANSFER OWNERS NAME: ADDRESS: City/State/Zip: PHONE: EMAIL: VIN: o CHOPPER o K-9 o MASTIFF o PITBULL o RIDGEBACK DEALERSHIP: DATE OF PURCHASE: MILES AT PURCHASE: PURCHASE PRICE: IGNITION KEY #: MAIL TO: Big Dog Motorcycles, 1520 E. Douglas, Wichita, KS 67214 California residents only: failure to complete and return this form does not diminish your warranty rights.
Please mail this Warranty Transfer to: Big Dog Motorcycles, 1520 E.
WARRANTY TRANSFER OWNERS NAME: ADDRESS: City/State/Zip: PHONE: EMAIL: VIN: o CHOPPER o K-9 o MASTIFF o PITBULL o RIDGEBACK DEALERSHIP: DATE OF PURCHASE: MILES AT PURCHASE: PURCHASE PRICE: IGNITION KEY #: MAIL TO: Big Dog Motorcycles, 1520 E. Douglas, Wichita, KS 67214 California residents only: failure to complete and return this form does not diminish your warranty rights.
Please mail this Warranty Transfer to: Big Dog Motorcycles, 1520 E.
