2005 Bigdog MASTIFF: complaints, problems and recalls

SEVERAL EVENTS HAVE BEEN LISTED AND SUBMITTED TO THE DEALER. THE DEALER HAS ATTEMPTED MANY TIMES TO FIX THE PROBLEM, WITH NO SUCCESS. THE DEALER SENT THE MOTORCYCLE TO THE HEADQUARTERS IN ANOTHER CITY, STILL UNABLE TO KEEP THE BIKE FROM POURING OIL OUT AT HIGH SPEEDS. THIS IS GETTING OIL ON THE REAR TIRE, REAR WHEEL AND REAR BRAKE. IT HAS SINCE BEEN DISCOVERED THAT THE DEALER THAT SOLD THE MOTORCYCLE WAS NOT AN AUTHORIZED LOCATION, NOR WAS THEIR MECHANIC. BUT THEIR MAIN STORE IS AUTHORIZED. I HAVE BEEN FORCED TO ASK FOR LEGAL HELP. BIG DOG HA…

Owner-reported narrative. Look up ODI 10141119 at NHTSA ↗

Reported: 2005-04-14 (April 14, 2005)

ON CERTAIN MOTORCYCLES, THE PRIMARY DRIVE SPROCKET NUT MAY BACK OFF THE ENGINE MAIN SHAFT.

Consequence: THIS COULD CAUSE THE PRIMARY DRIVE TO LOCK UP AND CAUSE A CRASH. THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING.

Remedy: DEALERS WILL INSPECT AND REPLACE THE DRIVE SPROCKET NUT FREE OF CHARGE. THE RECALL BEGAN ON MAY 13, 2005. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2005-09-28 (September 28, 2005)

ON CERTAIN MOTORCYCLES, THE REAR WHEEL HUB BOLTS COULD LOOSEN AND BACK OUT ALLOWING THE HUB AND BRAKE ROTOR TO DETACH FROM THE WHEEL WITH AN ASSOCIATED LOSS OF STOPPING POWER.

Consequence: THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING AND COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REMOVE, CLEAN AND REATTACH THE REAR HUB BOLTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 14, 2005. OWNERS MAY CONTACT BIG DOG AT 1-312-267-9121.

Reported: 2006-01-25 (January 25, 2006)

ON CERTAIN MOTORCYCLES, THE KICKSTAND SPRING MAY STRETCH AND DETACH FROM THE MOUNTING BRACKET OR THE KICKSTAND.

Consequence: THIS WILL ALLOW THE KICKSTAND TO DEPLOY INTO THE EXTENDED POSITION AND CAUSE A CRASH.

Remedy: DEALERS WILL INSTALL A NEW KICKSTAND SPRING FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 17, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2006-08-09 (August 9, 2006)

ON CERTAIN MOTORCYCLES, THE IGNITION MODULES ARE ORIENTED WITHIN THE BATTERY TRAY IN A WAY THAT MAKES THE IGNITION MODULE SUSCEPTIBLE TO VIBRATION.

Consequence: THIS SUSCEPTIBILITY TO VIBRATION MAY CONTRIBUTE TO A STALLING CONDITION THAT COULD OCCUR WITHOUT ANY PRIOR WARNING AND RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A NEW IGNITION MODULE MOUNTING SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 25, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2006-08-11 (August 11, 2006)

ON CERTAIN MOTORCYCLES, THE ELECTRONIC HARNESS CONTROL (EHC) MODULE CAN FAIL RESULTING IN A TOTAL SHUT DOWN OF THE VEHICLE'S ELECTRONIC POWER.

Consequence: THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING AND COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE EHC MODULES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 19, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2006-10-12 (October 12, 2006)

ON CERTAIN MOTORCYCLES, THE LONG PIVOT BOLT MAY BEND OR BREAK DURING NORMAL OPERATION OF THE MOTORCYCLE.

Consequence: THIS COULD POTENTIALLY CAUSE THE REAR FENDER TO ABRADE AGAINST THE REAR TIRE WHILE THE MOTORCYCLE IS BEING DRIVEN. THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING AND COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE LONG PIVOT BOLT AND, IF NECESSARY, STRAIGHTEN THE REAR FRAME SIDE PANEL. THE SHORT LEFT SIDE PIVOT BOLT AND PIVOT SHAFT MAY ALSO BE REPLACED FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 1, 2006. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.

Reported: 2007-08-08 (August 8, 2007)

ON CERTAIN MOTORCYCLES, A WARPED BUS BAR WITHIN THE VOLTAGE REGULATOR CAN CAUSE A SHORT CIRCUIT.

Consequence: THIS COULD POSSIBLY RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE EXISTING CIRCUIT BREAKER LOCATED BETWEEN THE VOLTAGE REGULATOR POSITIVE BATTERY LEAD (B+ LEAD) AND THE POSITIVE BATTERY TERMINAL WITH AN ALTERNATIVE CIRCUIT PROTECTION DEVICE THAT WILL PREVENT A THERMAL EVENT IF THERE IS A SHORT TO GROUND. THE RECALL BEGAN ON OCTOBER 1, 2007. OWNERS MAY CONTACT BIG DOG AT 1-316-219-9129 OR EMAIL TO [email protected].

Reported: 2007-12-18 (December 18, 2007)

ON CERTAIN MOTORCYCLES, THE REAR FENDER STRUT ATTACHING BOLTS CAN FAIL ALLOWING THE REAR FENDER TO DETACH FROM THE MOTORCYCLE.

Consequence: THIS COULD OCCUR WITHOUT PRIOR WARNING AND COULD RESULT IN AN INJURY OR A CRASH.

Remedy: DEALERS WILL REMOVE EXISTING STRUT BOLTS AND REPLACE WITH HIGHER TENSILE STRENGTH ATTACHING BOLTS AND UPDATED WASHERS. HIGHER TORQUE VALUES WILL BE OBSERVED WHEN INSTALLING THE REPLACEMENT FASTENERS. THE RECALL BEGAN ON JANUARY 21, 2008. OWNERS MAY CONTACT BIG DOG AT 316-267-9121.