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2008 Big Dog Mastiff

Component

Structure:Body

Consequence of Defect

on certain motorcycles, the rear fender strut attaching bolts can fail allowing the rear fender to detach from the motorcycle.

Corrective Action

this could occur without prior warning and could result in an injury or a crash.

Recall Notes

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 is expected to begin on or about january 9, 2008. owners may contact big dog at 316-267-9121.

2008 Big Dog Mastiff

Component

Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain motorcycles, the fuel line can potentially contact heated metal parts of the motorcycle and melt.

Corrective Action

this condition could occur without any prior warning and could result in fuel leakage. fuel leakage, in the presence of an ignition source, could result in a fire.

Recall Notes

dealers replaced the fuel line with one that has higher thermal resistance properties. also new fuel lines were rerouted to further reduce exposure to heated metal. all motorcycles have been repaired. no owner notification will be necessary.

2007 Big Dog Mastiff

Component

Structure:Body

Consequence of Defect

on certain motorcycles, the rear fender strut attaching bolts can fail allowing the rear fender to detach from the motorcycle.

Corrective Action

this could occur without prior warning and could result in an injury or a crash.

Recall Notes

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 is expected to begin on or about january 9, 2008. owners may contact big dog at 316-267-9121.

2006 Big Dog Mastiff

Component

Structure:Body

Consequence of Defect

on certain motorcycles, the rear fender strut attaching bolts can fail allowing the rear fender to detach from the motorcycle.

Corrective Action

this could occur without prior warning and could result in an injury or a crash.

Recall Notes

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 is expected to begin on or about january 9, 2008. owners may contact big dog at 316-267-9121.

2006 Big Dog Mastiff

Component

Electrical System:Ignition:Module

Consequence of Defect

on certain motorcycles, the ignition modules are oriented within the battery tray in a way that makes the ignition module susceptible to vibration.

Corrective Action

this susceptibility to vibration may contribute to a stalling condition that could occur without any prior warning and result in a crash.

Recall Notes

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.

2006 Big Dog Mastiff

Component

Electrical System

Consequence of Defect

on certain motorcycles, the electronic harness control (ehc) module can fail resulting in a total shut down of the vehicle's electronic power.

Corrective Action

this condition could occur without any prior warning and could result in a crash.

Recall Notes

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.

2006 Big Dog Mastiff

Component

Electrical System:Alternator/Generator/Regulator

Consequence of Defect

on certain motorcycles, a warped bus bar within the voltage regulator can cause a short circuit.

Corrective Action

this could possibly result in a fire.

Recall Notes

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 is expected to begin on or about october 1, 2007. owners may contact big dog at 1-316-219-9129 or email to customer.service@bigdogmotorcycles.com.

2006 Big Dog Mastiff

Component

Structure

Consequence of Defect

on certain motorcycles, the long pivot bolt may bend or break during normal operation of the motorcycle.

Corrective Action

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.

Recall Notes

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.

2006 Big Dog Mastiff

Component

Structure:Motorcycle Kickstand/Center Stand

Consequence of Defect

on certain motorcycles, the kickstand spring may stretch and detach from the mounting bracket or the kickstand.

Corrective Action

this will allow the kickstand to deploy into the extended position and cause a crash.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Power Train

Consequence of Defect

on certain motorcycles, the primary drive sprocket nut may back off the engine main shaft.

Corrective Action

this could cause the primary drive to lock up and cause a crash. this condition could occur without any prior warning.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Wheels:Lugs/Nuts/Bolts

Consequence of Defect

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.

Corrective Action

this condition could occur without any prior warning and could result in a crash.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Structure:Body

Consequence of Defect

on certain motorcycles, the rear fender strut attaching bolts can fail allowing the rear fender to detach from the motorcycle.

Corrective Action

this could occur without prior warning and could result in an injury or a crash.

Recall Notes

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 is expected to begin on or about january 9, 2008. owners may contact big dog at 316-267-9121.

2005 Big Dog Mastiff

Component

Electrical System:Ignition:Module

Consequence of Defect

on certain motorcycles, the ignition modules are oriented within the battery tray in a way that makes the ignition module susceptible to vibration.

Corrective Action

this susceptibility to vibration may contribute to a stalling condition that could occur without any prior warning and result in a crash.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Electrical System

Consequence of Defect

on certain motorcycles, the electronic harness control (ehc) module can fail resulting in a total shut down of the vehicle's electronic power.

Corrective Action

this condition could occur without any prior warning and could result in a crash.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Electrical System:Alternator/Generator/Regulator

Consequence of Defect

on certain motorcycles, a warped bus bar within the voltage regulator can cause a short circuit.

Corrective Action

this could possibly result in a fire.

Recall Notes

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 is expected to begin on or about october 1, 2007. owners may contact big dog at 1-316-219-9129 or email to customer.service@bigdogmotorcycles.com.

2005 Big Dog Mastiff

Component

Structure

Consequence of Defect

on certain motorcycles, the long pivot bolt may bend or break during normal operation of the motorcycle.

Corrective Action

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.

Recall Notes

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.

2005 Big Dog Mastiff

Component

Structure:Motorcycle Kickstand/Center Stand

Consequence of Defect

on certain motorcycles, the kickstand spring may stretch and detach from the mounting bracket or the kickstand.

Corrective Action

this will allow the kickstand to deploy into the extended position and cause a crash.

Recall Notes

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.

2004 Big Dog Mastiff

Component

Service Brakes, Hydraulic:Foundation Components:Master Cylinder

Consequence of Defect

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.

Corrective Action

this could result in a crash.

Recall Notes

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.

2004 Big Dog Mastiff

Component

Structure:Motorcycle Kickstand/Center Stand

Consequence of Defect

on certain motorcycles, the kickstand spring attaching stud may break off allowing the kickstand to deploy into the extended position.

Corrective Action

if the kickstand deploys, it could cause a crash without prior warning.

Recall Notes

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.

2004 Big Dog Mastiff

Component

Steering:Wheel And Handle Bar

Consequence of Defect

on certain motorcycles, a screw may become loose in the handlebar control due to the lack of a lock washer and loctite.

Corrective Action

this could cause the throttle or front brake control to bind, which could result in a crash.

Recall Notes

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.

2004 Big Dog Mastiff

Component

Structure:Motorcycle Kickstand/Center Stand

Consequence of Defect

on certain motorcycles, the kickstand spring may stretch and detach from the mounting bracket or the kickstand.

Corrective Action

this will allow the kickstand to deploy into the extended position and cause a crash.

Recall Notes

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.

2003 Big Dog Mastiff

Component

Structure:Motorcycle Kickstand/Center Stand

Consequence of Defect

on certain motorcycles, the kickstand spring attaching stud may break off allowing the kickstand to deploy into the extended position.

Corrective Action

if the kickstand deploys, it could cause a crash without prior warning.

Recall Notes

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.