Big Dog Bulldog / K-9 / Chopper / Mastiff / Pitbull 2007 Service Manual (P/N BDM260-00033)

• Model coverage: 2007 Big Dog Bulldog, Chopper, K-9, Mastiff, and Pitbull, all with the 117 ci OHV 45-degree V-Twin and Baker 6-speed Balance-Drive transmission.
• Chassis and running gear: model-specific swingarm and rigid-frame layouts, fuel and oil tanks, handlebars and forward controls, wheels, rotors, drive pulley, brake repair, standard and inverted fork service, rear shocks, and ride-height adjustment.
• Engine repair: engine removal and installation; rocker-box, pushrod, cylinder-head, valve, piston, lifter, cam and pinion work; oil-pump overhaul and priming; plus inspection limits and torque data.
• Fuel-system configurations: closed-loop Alpha-N EFI sensor diagnosis and throttle-body service, in-tank pump/filter/regulator repair, and separate carburetor disassembly, inspection, float, accelerator-pump, and initial adjustment coverage.
• Primary drive and transmission: clutch adjustment and clutch-pack inspection, primary-chain tension, inner and outer primary service, gearset removal, shift-drum and fork work, bearing and seal replacement, gear-cluster installation, and shifter-pawl adjustment.
• Electrical diagnosis: single-board and Smart EHC operation, fault-LED interpretation, PC-based EHC and ignition-module diagnostics, connector pinouts, charging and starting-system tests, and wiring diagrams.

Workshop Data and Specifications

This 244-page Rev. B PDF is the factory service manual for the five listed 2007 models. Big Dog states that this edition was published for motorcycle mechanical technicians already familiar with its service procedures, so it is suited to trained technicians and highly experienced mechanics with the specified shop and diagnostic equipment—not beginners.

The opening specifications distinguish each model's frame geometry, suspension, fuel capacity, wheels and tires, brake layout, ignition, battery, and charging system. Throughout the manual, component-specific tables provide fastener torques and threadlocker requirements, fluid types and capacities, bearing and running clearances, wear limits, electrical test values, and adjustment data. Exploded assembly views and illustrated parts lists support identification, although the manual identifies those lists as typical and directs the technician to AWS for model-specific parts ordering.

Repair Depth and Configuration Differences

Engine coverage extends well beyond routine maintenance. It includes rocker-arm bushing replacement, adjustable-pushrod setup, cylinder-head and valve service, piston and cylinder inspection, lifter-guide alignment, cam/pinion gear measurement and matching, reed-valve work, and oil-pump disassembly, installation, binding checks, and priming. The engine chapter does not provide a crankcase-splitting or flywheel/connecting-rod overhaul procedure, an important limit if a complete bottom-end rebuild is planned.

The chassis chapters separate the Pitbull rigid frame from the swingarm models and provide different rear-axle alignment methods for each. They cover brake-system bleeding, caliper rebuilding, master-cylinder rebuilding, wheel-bearing and hub work, rotor and wheel runout checks, steering-head fall-away, conventional and Bulldog inverted-fork service, and hidden-shock ride-height adjustment. Model-specific fuel-tank procedures include the late-Mastiff welded tank mount that replaced the earlier removable mounting boss.

Powertrain alignment is treated as more than a rear-wheel adjustment. The manual covers angular, vertical, and lateral engine/transmission alignment, final-drive pulley alignment, shimming, and belt tension using the factory alignment and measuring tools. The required-tool lists identify equipment such as the BDM260-00069 belt-tension tool, 263-000005-00 rear-axle alignment tool, BDM260-00070 brake-bleed kit, 260-000062-00 EFI sensor tester, and the power- and backbone-harness breakout boxes.

Electrical and Diagnostic Coverage

The electrical section distinguishes the single-board EHC used on most carbureted models from the Smart EHC used on EFI models and the carbureted K-9. It explains solid-state circuit protection, fault storage, ProFET status, sensor and input data, system and RPM logs, memory checks, and system-override capability. The period PC-link procedures require the specified interfaces, diagnostic software, and a Windows XP laptop.

Named reference drawings include the EFI and non-EFI Connector A power-harness pin charts, matching Connector B backbone-harness pin charts, the Ignition Wiring Diagram (Non-EFI), the Starter Wiring Diagram, the Oil Pump Assembly exploded view, and the Balance-Drive transmission gearset and power-flow views.

Two cautions show why the factory procedure matters. The oil-pump chapter warns that an incorrect pump-body gasket or misplaced drive-gear keys can eliminate oil pressure and cause engine failure. The oil-tank section also distinguishes the Pitbull pipe-thread drain plug from the non-pipe-thread plug used on the other covered models, avoiding a damaging sealing or thread mistake.

Fuel, brake, spring-loaded fork, electrical, and heavy powertrain work can create fire, loss-of-braking, stored-energy, or crush hazards. Use the specified support equipment and test tools, isolate the battery where directed, and have safety-critical repair work performed or verified by a qualified motorcycle technician.