2004 Bigdog Chopper
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Have the VIN?
Vehicles › Bigdog › Chopper › 2004
These records cover every 2004 Bigdog Chopper. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 2004 Bigdog Chopper. Newest first.
Big dog IS recalling certain 2004 chopper, bulldog, ridgeback, mastiff, boxer, and pitbull motorcycles. there IS a possible loose connection between the harness connector and the electronic harness controller.
Risk and remedy
Risk
This condition may cause the motorcycle to experience intermittent loss of electrical power to various components, which can lead to, among other things, a loss of headlamp function or a vehicle stall, increasing the risk of a crash.
Remedy
Big dog will notify owners and dealers will repair the motorcycles free of charge. the safety recall began on may 24, 2010. owners may contact big dog at 1-316-219-9121.
On certain motorcycles, the kickstand spring may stretch and detach from the mounting bracket or the kickstand.
Risk and remedy
Risk
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.
On certain motorcycles, the kickstand spring attaching stud may break off allowing the kickstand to deploy into the extended position.
Risk and remedy
Risk
If the kickstand deploys, it could cause a crash without prior warning.
Remedy
Dealers will inspect and install a new kickstand unit. the recall began on december 20, 2004. owners should contact big dog at 316-267-9121.
On certain motorcycles, a screw may become loose in the handlebar control due to the lack of a lock washer and loctite.
Risk and remedy
Risk
This could cause the throttle or front brake control to bind, which could result in a crash.
Remedy
Dealers will install a lock washer and loctite. Owner notification began on april 12, 2004. owners should contact big dog at 1-316-219-7006.
On certain motorcycles, the piston in the rear master cylinder may have been improperly sized, which could cause the rear brakes to drag or lockup.
Risk and remedy
Risk
This could result in a crash.
Remedy
Dealers will remove the piston from the rear master cylinder and replace it with a new piston. Owner notification began on april 12, 2004. owners should contact big dog at 1-316-267-9121.
On certain motorcycles assembled with an early version rolling thunder frame, a stress crack could emerge in the frame.
Risk and remedy
Risk
This condition could occur without any prior warning, increasing the risk of a crash.
Remedy
Dealers will repair the frame. owner notification began january 15, 2004. owners should contact big dog at 1-316-267-9121.
Owner complaints
10 complaints
What owners report most
Latest complaints
- Service brakes
Where do I get a 2004 master cylinder for my bike??? Everything that's on recall IS on my bike!! And even more to be pissed about IS they sold this to me a few months after there recall when they new about it, everything that was fixed because of multiple problems I had to pay out of pocket. But yet they new about this recall. What do I do??? *tr
- Electrical system · Electronic stability control (esc) · Exterior lighting
Head light turn signals stopped working. They went out while driving at night. Had to have my bike towed. *tr
- Electrical system
TL* the contact owns a 2004 big dog motorcycle chopper. The vehicle was taken to the dealer for repairs under nhtsa recall campaign ID number: 10v180000 (electrical system) in 2006, but the repair did not correct the failure. The contact stated that the motorcycle continued to stall while…
TL* the contact owns a 2004 big dog motorcycle chopper. The vehicle was taken to the dealer for repairs under nhtsa recall campaign ID number: 10v180000 (electrical system) in 2006, but the repair did not correct the failure. The contact stated that the motorcycle continued to stall while traveling at any speed. The dealer and the manufacturer were contacted and both advised that the recall was performed on the motorcycle therefore they will not assist with additional repairs. The vehicle was not further repaired. The failure mileage was 5,000 and the current mileage was 5,500. updated 11/16/10*bf updated 11/23/10*jb
- Electrical system
The 2004 big dog chopper I was operating electrically shut down while I was traveling on the interstate at 70 mph nearly causing me to crash in traffic. I called the manufacturer and was told the electronic harness control module needed dieletric grease in the connector to keep water from shorting…
The 2004 big dog chopper I was operating electrically shut down while I was traveling on the interstate at 70 mph nearly causing me to crash in traffic. I called the manufacturer and was told the electronic harness control module needed dieletric grease in the connector to keep water from shorting it out. I applied their fix and the unit still does not function. I had to purchase the 2007 unit for 641.99 dollars. After researching the matter, I discovered there was a recall on the 2005 and 2006 models but not the 2004. The 2004 model IS experiencing the same malfunction that the 2005 and 2006 models are experiencing. I researched further and found numerous complaints on the internet of owners with the 2004 model experiencing the same exact problem. The part IS defective and IS a major safety hazard to anyone who rides this motorcycle with the old ehc module, a recall needs to be made on the 2004 models of big dog motorcycles. *tr
- Power train › Driveline
Recurring squeaks from drive belt. 4 trips to the 1ST dealer for adjustment until rear pulley was replaced by 2ND dealer due to incompatibility with belt. Squeak continued after 3 additional trips to 2ND dealer. Mfg felt that belt should be replaced but would not cover under warranty because belt…
Recurring squeaks from drive belt. 4 trips to the 1ST dealer for adjustment until rear pulley was replaced by 2ND dealer due to incompatibility with belt. Squeak continued after 3 additional trips to 2ND dealer. Mfg felt that belt should be replaced but would not cover under warranty because belt was considered a wear item. With less than 3000 original miles mfg finally agreed that belt wear was premature due to incompatibility with pulley and replaced belt with a different type to finally resolve problem. *tr
- Electrical system › Ignition › Module
1) signal lights quit working,then headlight blew out, then speedometer quit working, then all electrical went out and bike will not start and all electrical IS out. 3) called bigdog motorcycle dealer. was told the 2004 ehc module has been discontinued and must up grade to an 07 with harness. cost difference $202.00 for 2004 and 650.00 for an 2007 module. *tr
- Electrical system
2004 big dog motorcycle. Motorcycle keeps losing all electrical power when riding on the interstate due to an inherently defective electronic harness controller. This same ehc had been recalled in 2005 and 2006 for the same problem. There was no crash but I hit construction cones and almost crashed trying to get off the highway and out of the way of traffic. *jb
- Exterior lighting › Turn signal › Switch
While driving in rainy weather the motorcycle's turn signal engaged without warning. Dealer was fully aware of the problem, and stated that the turn signal shorted out because water ran down the coil wire. *Ak
- Power train
While riding, the consumer noticed a retching sound coming from the transmission area which took place of the power being transferred to rear wheel during acceleration. *bf the dealer tightened the belt on several occasions in the first month of ownership, but this did not correct the problem. *sc
- Service brakes, hydraulic › Foundation components › Master cylinder
Consumer received nhtsa recall 04v137000 concerning rear master cylinder pistol. after having the rear master cylinder pistol replaced the rear brakes failed. while applying the brake pedal consumer heard a loud knocking noise and the vehicle failed to stop completely. vehicle was taken back to the dealer for inspection, but mechanic mechanic could not duplicate the problem. *ak
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Motorcycle Stalling
This RQ was opened based on seemingly related owner complaints involving motorcycles outside the scope of 06V-301.During the course of subsequent discussions with the company, we learned that the earlier model year Big Dogs had a problem with the electronic harness control module connector that they'd previously…
This RQ was opened based on seemingly related owner complaints involving motorcycles outside the scope of 06V-301.During the course of subsequent discussions with the company, we learned that the earlier model year Big Dogs had a problem with the electronic harness control module connector that they'd previously addressed with a TSB.Since the TSB addressed a safety-related issue (stalling), Big Dog agreed to recall the motorcycles subject to the TSB (10V-180).With that decision, ODI agreed to waive requiring a response to its information request and is now closing this RQ.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10026832Bigdog motorcycle: fuel tank vent may become flooded with fuel, causing the motorcycle to run poorly due to a fuel mixture that IS too rich.
- 10020152Horn harness wires may break.
- 10020065Headlamp connector may melt, making bulb replacement difficult.
- 10020045Ehc contact improvement procedure (revised). Current seal does not allow connector pins to seat properly and moisture may be present in connector.
- 10019984Tachometer board replacement - inaccurate tachometer readings or fluctuation in readings due to moisture.
- 10019909Dielectric grease addition to connectors.
- 10016838Fork dust cover o-ring nonconformance. O-ring IS displaced from o-ring groove.
- 10010470Ehc replacement. Incorrect electrical component installation resulting in a damaged ehc.
- 10010405Belt and chassis issues. Drive belt noise,drive belt ratcheting, swing arm to frame contact. Bigdog service bulletin w/t attachments a-h. Various models including 2003 big dog pitbull, ridgeback and daytec chopper.
- 10009565Kickstand spring stud fracture. All bigdog 2004 models.
Every Bigdog Chopper model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.