NHTSA vehicle safety data

2004 Bigdog Chopper Recalls & Complaints

The 2004 Bigdog Chopper has 5 NHTSA recall campaigns and 7 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Bigdog dealer.

NHTSA recall and complaint data for the 2004 Bigdog Chopper. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Bigdog Chopper owner complaints

Owners have filed 7 complaints with NHTSA about the 2004 Bigdog Chopper, describing incidents dated August 6, 2004 to June 1, 2008.

Most-cited components

Electrical System 3 complaints
Power Train 2 complaints
Equipment 1 complaint
Exterior Lighting 1 complaint
Service Brakes 1 complaint

Newest complaints

ODI #10229998 · Filed June 5, 2008
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…
ODI #10208969 · Filed November 14, 2007
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…
ODI #10206475 · Filed October 21, 2007
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…

Read all 7 complaints

KICKSTAND SPRING

NHTSA #06V019000 · Structure — Motorcycle — Kickstand/Center Stand · NHTSA notice

Reported January 25, 2006 · BIG DOG MOTORCYCLES, LLC

Potentially affected: 9,726 vehicles

Owners notified February 17, 2006 · Vehicles built August 8, 2003 – January 13, 2006 (per NHTSA)

Defect description

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

Safety consequence

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

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

BIG DOG/KICKSTAND SPRING STUD FRACTURE

NHTSA #04V523000 · Structure — Motorcycle — Kickstand/Center Stand · NHTSA notice

Reported November 2, 2004 · BIG DOG MOTORCYCLES, LLC

Potentially affected: 4,457 vehicles

Owners notified December 20, 2004 · Vehicles built August 8, 2003 – September 23, 2004 (per NHTSA)

Defect description

ON CERTAIN MOTORCYCLES, THE KICKSTAND SPRING ATTACHING STUD MAY BREAK OFF ALLOWING THE KICKSTAND TO DEPLOY INTO THE EXTENDED POSITION.

Safety consequence

IF THE KICKSTAND DEPLOYS, IT COULD CAUSE A CRASH WITHOUT PRIOR WARNING.

Manufacturer 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.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

BIG DOG/HANDLEBAR

NHTSA #04V164000 · Steering — Steering Wheel/Handle Bar · NHTSA notice

Reported April 6, 2004 · BIG DOG MOTORCYCLES, LLC

Potentially affected: 2,098 vehicles

Owners notified April 12, 2004 · Vehicles built August 8, 2003 – March 26, 2004 (per NHTSA)

Defect description

ON CERTAIN MOTORCYCLES, A SCREW MAY BECOME LOOSE IN THE HANDLEBAR CONTROL DUE TO THE LACK OF A LOCK WASHER AND LOCTITE.

Safety consequence

THIS COULD CAUSE THE THROTTLE OR FRONT BRAKE CONTROL TO BIND, WHICH COULD RESULT IN A CRASH.

Manufacturer 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.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

BIG DOG/REAR MASTER CYLINDER PISTON

NHTSA #04V137000 · Service Brakes, Hydraulic — Foundation Components — Master Cylinder · NHTSA notice

Reported March 23, 2004 · BIG DOG MOTORCYCLES, LLC

Potentially affected: 1,906 vehicles

Owners notified April 12, 2004 · Vehicles built September 19, 2003 – March 16, 2004 (per NHTSA)

Defect description

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.

Safety consequence

THIS COULD RESULT IN A CRASH.

Manufacturer 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.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

BIG DOG/FRAME CRACKS

NHTSA #03V535000 · Structure — Frame and Members · NHTSA notice

Reported December 18, 2003 · BIG DOG MOTORCYCLES, LLC

Potentially affected: 1,446 vehicles

Owners notified January 15, 2004

Defect description

ON CERTAIN MOTORCYCLES ASSEMBLED WITH AN EARLY VERSION ROLLING THUNDER FRAME, A STRESS CRACK COULD EMERGE IN THE FRAME.

Safety consequence

THIS CONDITION COULD OCCUR WITHOUT ANY PRIOR WARNING, INCREASING THE RISK OF A CRASH.

Manufacturer remedy

DEALERS WILL REPAIR THE FRAME. OWNER NOTIFICATION BEGAN JANUARY 15, 2004. OWNERS SHOULD CONTACT BIG DOG AT 1-316-267-9121.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

try.vin has no NCAP crash-test rating on file for the 2004 Bigdog Chopper. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

7 owner complaints have been filed with NHTSA for the 2004 Bigdog Chopper.

Electrical System

ODI #10229998

Incident: June 1, 2008 · Filed: June 5, 2008

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

ODI #10208969

Incident: December 10, 2006 · Filed: November 14, 2007

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

ODI #10206475

Incident: June 8, 2007 · Filed: October 21, 2007

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; Equipment

ODI #10198224

Incident: April 29, 2007 · Filed: August 1, 2007

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

ODI #10111604

Incident: November 21, 2004 · Filed: February 16, 2005

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

ODI #10109462

Incident: August 6, 2004 · Filed: January 13, 2005

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

ODI #10107039

Incident: November 2, 2004 · Filed: January 7, 2005

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

Other Bigdog Chopper model years

Check your 2004 Bigdog Chopper VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Bigdog Chopper at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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