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Big Dog · Pushrod four-stroke twin, dry sump, separate gearbox oil, belt drive

Pitbull

Library entry covers 2004-2011

24 factory 33 guideline

Published source

Big Dog 2006 Pitbull Owner's Manual, Maintenance Log printed pp.51-52

Factory owner's handbook. Covers Big Dog 2006 Pitbull, Mastiff and Ridgeback owner's manuals (ManualsLib 824819, 966294, 865454); the maintenance log pages are byte-identical in all three; 2006 manuals, the catalog Mastiff and Ridgeback rows are 2008-2011 and later years are not checked; chart ends at 7,500 miles.

57 items for a 2005 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)
Engine cycle
Four-stroke
Engine lubrication
Dry sump (separate oil tank)
Oil filtration
Replaceable cartridge or spin-on filter
Valve gear
Overhead valve, pushrods, adjustable tappets
Ignition
Electronic (CDI / transistor / ECU)
Charging
Alternator / stator with rectifier
Battery
Wet cell (flooded lead-acid, needs topping up)
Fuel system
Two or more carburetors
Cooling
Air / oil cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Separate gearbox oil
Clutch control
Hand lever, cable
Final drive
Toothed belt
Front suspension
Telescopic fork
Rear suspension
Swingarm, twin shocks
Front brake
Disc, hydraulic
Rear brake
Disc, hydraulic
Wheels
Cast / alloy, tubeless
Sidecar
No sidecar
Maintenance schedule

2005 Big Dog Pitbull

On the road: every 300 km

1 item
  • Check engine oil level
    Pre-ride / on the road
    Guideline

    Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline

Every 4,000 km

14 items
  • Change engine oil
    Engine
    Factory

    Manual: Engine oil and filter (replace). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): R marked at 500, 2,500, 5,000 and 7,500 miles

  • Clean oil strainers / mesh screens
    Engine
    Factory

    Manual: Tappet screen (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles; text p.56: removal and cleaning of the tappet oil filter screen every service interval or if there is abnormal lifter noise

  • Electrical components and switches (inspect)
    Engine
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Inspect, clean and gap spark plugs
    Engine
    Factory

    Manual: Spark plugs (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Master cylinder reservoir fluid level and condition, front and rear (inspect)
    Engine
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Check throttle cable(s) free play and return
    Fuel and air
    Factory

    Manual: Brake and clutch levers and cables, including throttle cables (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Clean / inspect air filter
    Fuel and air
    Factory

    Manual: Air cleaner filter (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles; air filter text p.53: serviced or replaced at 500 miles and every 2,500 miles thereafter

  • Replace fuel filter
    Fuel and air
    Factory

    Manual: Fuel valve and fuel filter screen (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles; fuel strainer text p.54: inspect and clean every service interval

  • Download ignition module to customer service (AWS)
    Ignition and electrics
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): DOWNLOAD marked at 500, 2,500, 5,000 and 7,500 miles

  • Adjust clutch free play, lubricate cable and lever pivot
    Primary and gearbox
    Factory

    Manual: Clutch (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Transmission lubricant and magnetic plug (replace)
    Primary and gearbox
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): R marked at 500, 2,500, 5,000 and 7,500 miles

  • Grease swingarm pivot
    Rear suspension and frame
    Factory

    Manual: Rear swingarm, pivot arm, pivot shaft nut and shocks (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Inspect brake hoses; replace old rubber
    Brakes
    Factory

    Manual: Fluid lines, oil, brake and fuel (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

  • Throttle and enrichener controls (inspect)
    Controls and cables
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 2,500, 5,000 and 7,500 miles

Every 5,000 km or 12 months

4 items
  • Clean fuel tap filter / sediment bowl
    Fuel and air
    Guideline
  • Inspect fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Grease and check center / side stand and springs
    Rear suspension and frame
    Guideline

Every 8,000 km or 12 months

1 item
  • Replace oil filter
    Engine
    Guideline

Every 8,000 km

7 items
  • Engine idle speed (inspect)
    Engine
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles

  • Inspect torque of all fasteners excluding engine head bolts
    Engine
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles

  • Lubricate clutch pushrod
    Primary and gearbox
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles

  • Primary drive lubricant and magnetic plug (replace)
    Primary and gearbox
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): R marked at 500 and 5,000 miles

  • Inspect drive belt, pulleys and tension
    Final drive
    Factory

    Manual: Drive belt (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles; the rest of this row's label is unreadable under the ManualsLib watermark in all three copies checked

  • Primary drive chain (inspect)
    Final drive
    Factory

    Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles

  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Factory

    Manual: Tires (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 5,000 miles

Every 9,500 km or 12 months

7 items
  • Clean carburetor float bowl(s), check float level and jets
    Fuel and air
    Guideline

    Ethanol fuel varnishes old carbs quickly in storage.

  • Synchronize carburetors
    Fuel and air
    Guideline
  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check swingarm bushes for play
    Rear suspension and frame
    Guideline
  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Guideline
  • Lubricate control cables and lever pivots
    Controls and cables
    Guideline
  • Lubricate speedometer / tachometer cables, check drive
    Controls and cables
    Guideline

    A dry speedo cable whips the needle and eventually kills the instrument.

Every 12,000 km

2 items
  • Check steering head bearing adjustment
    Front end
    Factory

    Manual: Steering head bearings, fork stem and upper fork bracket (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 7,500 miles

  • Check wheel bearings for play
    Wheels and tires
    Factory

    Manual: Wheel bearings for spin (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500 and 7,500 miles

Every 13,000 km or 2 years

1 item
  • Check and adjust valve clearances
    Engine
    Guideline

Every 16,000 km or 2 years

2 items
  • Compression test (or leak-down)
    Engine
    Guideline
  • Change gearbox oil
    Primary and gearbox
    Guideline

Every 19,500 km or 2 years

1 item
  • Replace air filter element
    Fuel and air
    Guideline

Every 24,000 km or 3 years

1 item
  • Change fork oil
    Front end
    Guideline

    Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 25,500 km or 4 years

1 item
  • Replace spark plugs
    Engine
    Guideline

Every 32,000 km or 4 years

2 items
  • Repack / replace steering head bearings
    Front end
    Guideline

    Many old machines use loose balls in cups and cones. Taper roller conversions are common.

  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

    Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 48,500 km or 6 years

1 item
  • Rebuild forks: seals, bushes, springs
    Front end
    Guideline

Every 80,500 km

1 item
  • Replace drive belt (wear or damage based)
    Final drive
    Guideline

Every 6 months

1 item
  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Guideline

Every 2 years

3 items
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline
  • Replace brake fluid
    Brakes
    Guideline

Every 4 years

2 items
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

  • Rebuild calipers and master cylinders (seals)
    Brakes
    Guideline

Every 6 years

1 item
  • Replace tires on age (regardless of tread)
    Wheels and tires
    Guideline

No interval set

1 item
  • Check brake pads and discs
    Brakes
    Factory

    Manual: Brake pads and rotors, front and rear (inspect). Factory: Maintenance log pp.51-52 (columns 500, 2,500, 5,000, 7,500 mile; R = replace; I = inspect, clean, lubricate, adjust, repair or replace if necessary): I marked at 500, 5,000 and 7,500 miles, not at 2,500 miles (label partly covered by the ManualsLib watermark)

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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