Bad Boy 2011 User manual

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2011 BAD BOY MOWERS SERVICE MANUAL
This Manual contains general maintenance and service procedures
that may not be specific to your model.
Section 1- Hydrostatic System …………………………. Pg. 02
Section 2- Drive Belt ……………………………………….. Pg. 09
Section 3- Engine ……………………………………………. Pg. 11
Section 4- Electrical System ……………………………. Pg. 19
Section 5- Frame Maintenance ……………………….... Pg. 24
Section 6- Cutting Deck …………………………………… Pg. 36
Section 7- Mowing Tips ……….…………………………… Pg. 45

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SECTION 1: HYDROSTATIC SYSTEM
To change hydro oil on Pup, Lightning, AOS, and Diesel models,
remove oil return lines from top of hydro tank and place them in a
disposable oil container. Start and run mower until oil level is
reduced down to about 2” of oil remaining in the tank. Do not allow
air to enter the oil lines in the bottom of the tank. Keep in mind that
only about 75% of the hydro oil can be changed at a time. Use only
20w50 motor oil in the hydro system.
(conventional or synthetic oil may be used)
Bad Boy recommends that the hydro oil and filters be changed within
the first 50 hours of usage and every 500 hours thereafter or once a
year.

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(Pup, Lightning, AOS, and Diesel Models)
Change hydro oil filters by unscrewing them from the filter head. Fill
new filters with 20w50 motor oil before installing. Use only bad boy
replacement filters. Using any other filter will result in damage to the
hydro system and void the warranty.

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(Pup, Lightning, AOS, and Diesel Models)
Once the system is refilled with oil, lift rear of mower until tires are
off the ground. Start engine, release parking brake, stay clear of
moving rear tires, loosen bypass bolt ½ to ¾ turns, move drive arms
forward and backward 4 to 6 times slowly. This will purge the air
from the system.
(the bypass bolt has a hole drilled through the side of the bolt head).
This valve also serves as a neutral for moving the mower without the
engine running.

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(ZT and Outlaw Models)
The hydro overflow tank on a zt or outlaw model is located behind the
seat. Notice the “full cold” line at the bottom of the tank. Use only
20w50 motor oil in this tank. Conventional or synthetic oil may be
used.

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(ZT and Outlaw models)
When servicing a mower with a sealed transaxle unit, start by
removing the filter skid plate on the bottom of each unit. The skid is
held on by three 10mm bolts. Next, remove the filter (Outlaws have
one large nut on the filter cover). The filter also serves as the oil
drain. Each transaxle holds about 2 quarts of hydro oil. (Outlaw holds
4 quarts in each transaxle) reinstall new filters and skid plates. Use
only hydro-gear filters. Use of any other type of filter will result in
damage to the hydro system and void the warranty. Transaxle
service recommended within the first 50 hours of usage and every
250 hours thereafter or once a year.

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(ZT and Outlaw Models)
The check plug is located at the top center of the inside case of each
transaxle (outlaw transaxles have this plug on the top). The
transaxle can be filled with oil by removing these check plugs from
both transaxles and pouring the oil in the hydro overflow tank, located
behind the seat. Oil will begin to run out of the check plug holes
when the transaxles are full. Use only 20w50 motor oil in the hydro
system.

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(ZT model shown)
Once the system is filled with oil, lift rear of mower until rear tires are
off the ground. Start engine, release parking brake, stay clear of
moving rear tires. Next, pull the neutral bypass levers (located at the
rear of the frame, on either side of the muffler), move the drive arms
forward and backward 4 to 6 times slowly. This relieves any air that
may be trapped in the system. It may be necessary to add more oil to
the hydro overflow tank after 10-15 minutes of running. These bypass
levers also serve as a neutral for moving the mower without the
engine running.

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SECTION 2: DRIVE BELT
Shown above is the AOS/Diesel pump belt tensioner. Tightening the two ¾”jam
nuts on the left side will increase the belt tension on all models. Factory setting
is about .030” (about the thickness of a credit card) between coils as shown.

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Shown above is a typical pump belt tesioner for ZT, Pup, Lightning,
and Outlaw models.
Shown above is a typical pump belt layout for most models.

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SECTION 3: ENGINE
Shown above is a Kawasaki engine with the “quick drain” oil drain
located on the left side of the engine. Use a flat screw driver as
shown to loosen the drain. (Not available on all models)

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Most models have a drain hose installed on the engine, for easier oil
changes. All gas engines used by Bad Boy use 10w30 and have an oil
capacity of 2 quarts. Bad Boy recommends that the oil and filter be
changed every 50 hours of usage.

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The fuel filter is located in the fuel line about 12” from the carburator
on the side of the engine. Note the direction of flow on the side of
the filter. Replace once a year.

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Most all models have a vacuum operated fuel pump bolted to the side
or top of the engine. The pump has a “fuel in”, a “fuel out”, and a
vacuum line coming from the engine block. Fuel flow can be checked
here if the pump is suspected to be defective.

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When servicing the fuel system on the CAT Diesel, it is necessary to
purge the air from the system by loosening the 9/16” bolt on top of the
fuel filter and pumping the fuel bulb (located underneath the radiator)
until air bubbles are no longer visible.

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Remove and inspect air cleaner weekly. (more often in dusty
conditions). Do not blow filter out with air pressure, this will cause
the filter to be filled with tiny holes that will allow dirt to enter.
Instead, tap filter on side to remove any debris. Replace at least once
a year, more often in dusty conditions.

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Torque the clutch bolt to 50 ft. Lbs. On all models. Retorque at every
oil change.
(All Models)

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Keep radiator screen clean and free of debris on liquid cooled models.
Check screen hourly during dry conditions. Slide radiator screen up
to remove.

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SECTION 4: ELECTRICAL SYSTEM
On most larger commercial engines (27 hp and up). The 25 amp main
fuse is located about 3” from the starter on the engine.

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On smaller commercial and light duty commercial mowers, the 25
amp main fuse is located just behind the battery connected to the
starter solinoid.