Bad Boy 1500G User manual

Ride With An Attitude
MODEL 1500G
OWNER’S & PARTS MANUAL
For additional information, please see us at
www.badboymowers.com
Bad Boy, Inc.
102 Industrial Drive
Batesville, Arkansas 72501
[phone]

UTV OWNER’S MANUAL GAS-POWERED
Table of Contents
General Safety ..................................................................................................................... 3
Specifications..................................................................................................................4–5
Important Identification Numbers ....................................................................................... 5
Starting/Operating Procedure ............................................................................................. 6
Periodical Maintenance Schedule ...................................................................................6–9
Basic Safety Rules..............................................................................................................10
Service Record ...................................................................................................................11
PARTS LIST................................................................................. 13
OWNER’S REGISTRATION & TRAINING CERTIFICATE ................................33
DEAR CUSTOMER:
Our Bad Boy Mower UTV is manufactured under strict quality control systems. The Warranty document sent to dealers
guarantees all written items. Given that you follow the maintenance procedure by using original parts and riding normally, we
will repair or replace any components found to be defective.
This warranty is not valid if the following occurs:
 •UsingunspeciedEngineOil.
 •Impropermaintenanceorrepairs.
 •Usingnon-originalormodiedaccessoriesandparts.
 •ImproperOperationorevidenceofabuse.
 •Normalwearandtearitemsarenotcovered—Seat,SparkPlug,Bulbs,Filters,Brakes,Belt,Chain,
Tires, etc.
This manual is a simple introduction of operation and basic maintenance.
If you have additional questions, contact your dealer for assistance.
OWNER MEMO
Name: ___________________________________________________________
Purchasing Date: ___________________________________________________________
Type: ___________________________________________________________
Pin Number: ___________________________________________________________
Special Note: ___________________________________________________________
IGNITION KEY
Yourkeyisaseriestypekey,ofwhichthereareahighrangeofnumbers.Itishighlyrecommendedthatyouobtainadditional
copiesofyourkey.Ifallkeysarelost,areplacementignitionswitchmustbeinstalled.
PAGE 2

GENERAL SAFETY
Carbon Monoxide
When running your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an
open area, if you have to run your engine in a closed area, be sure to use an exhaust fan.
Caution
Exhaustcontainstoxicgaswhichmaycauseonetoloseconsciousnessandevenresultindeath.
Gasoline
Gasolinehasalowignitionpointandisanexplosivematerial.Workinawell-ventilatedplace,noameorsparkshouldbe
allowedintheworkplaceorwheregasolineisbeingstored.
Used Engine Oil
Prolongedcontactwithusedengineoil(ortransmissionoil)maycauseskincanceralthoughitmaynotbeveried.
We recommend that you wash your hands with soap and water right after coming in contact with used oil. Keep used oil
beyond reach of children.
Hot Components
Componentsoftheengineandexhaustsystemcanbecomeextremelyhotafterenginerunning.Theyremainveryhoteven
aftertheenginehasbeenstoppedforsometime.Whenperformingserviceworkontheseparts,wearinsulatedglovesand
wait until cooling off.
Battery
TheBatteryemitsexplosivegases;ameisstrictlyprohibited.Keepyourworkareawellventilatedwhenchargingthebattery.
TheBatterycontainssulfuricacid(electrolyte)whichcancauseseriousburns,sobecarefulnottomakecontactwithyour
eyesorskin.Ifyougetbatteryacidonyourskin,washitoffimmediatelywithwater.Ifyougetbatteryacidinyoureyes,ush
it out immediately with water and then see a doctor.
Keep electrolyte beyond reach of children.
Brake Dust
Donotuseanairhoseoradrybrushtocleancomponentsofthebrakesystem:useavacuumcleanerorequivalenttoavoid
dustying.Inhalingbrakedusthasbeenknowntocausebreathingdisordersorcancer.
Brake Fluid
Brakeuidishygroscopicwhichmeansitabsorbsmoisture.Moistureinsidebrakecomponentscancausepartdeterioration.
Spillingbrakeuidonpainted,plasticorrubberpartsmaycausedamagetotheparts.PlaceaCleantowelontheabove-
mentionedpartsforprotectionwhenservicingthebrakesystem.Keepbrakeuidbeyondreachofchildren.
OWNER’S REGISTRATION AND
TRAINING CERTIFICATE
PRINTEDONPAGE 33,MUSTBEFILLED
OUTANDSIGNEDBYPURCHASERAND
DEALER.
PAGE 3

BEFORE DRIVING:
Fuel: Check that you have sufficient fuel for your journey.
Brakes: Check the brakes for operation.
Tires: Check for proper inflation. Check tires for physical damage.
Lighting System: Check lights and signaling devices.
Engine Oil: Check oil level.
SPECIFICATIONS
Dimensions OverallLength................................................ 103 inches
Overall Width ................................................. 53 inches
 OverallHeight ................................................ 75 inches
Wheel Base.................................................... 71.5 inches
Weight CurbWeight................................................... 1,125 lbs
Passengers/Weight ....................................... Two / 500 lbs
 CargoWeight................................................. 400 lbs
Total Weight................................................... 2,025 lbs
Type ............................................................... S.O.H.C
Performance Max Speed..................................................... 35 to 50 mph depending upon vehicle
Suspension System Front............................................................... DoubleA-Arm
Rear................................................................ 4-Link
Tire Specifications Front............................................................... 25x8-12
Rear................................................................ 25x10-12
Brake System Front.............................................................. Disk(0200mm)
Rear................................................................ Disk(0220mm)
Transmission Devices Transfer ......................................................... Shaft drive
 ShiftLever...................................................... L,H,N,R
Shift ............................................................... Manual lever
 Clutchtype..................................................... Wetmulti-plate
Transmission ................................................. Continuouslyvariablecentrifugaltype
Engine FuelUsed....................................................... 87 octane or higher having less than an
  E15ethanolrating
 Cycle/cooling................................................ 4-stroke/watercooled
Bore ............................................................... 86 mm
 CylinderStroke .............................................. 69.4 mm
Number/Arrangement .................................... SingleCylinder
Displacement ................................................. 403.1 cc
 CompressionRatio ........................................ 9.2:1
Ignition........................................................... C.D.I.
Starting System ............................................. Electrical/Recoilstarter
 AirFiltration ................................................... Paper
PAGE 4

Lubrication LubricationSystem........................................ PumpForcedCirculation
 EngineOil....................................................... BadBoyMowerUTVEngine
  LubricantSAE10w40
 Lubrication..................................................... SG/CC
 EngineOilcapacity ........................................ 3.5L
Gear Lubrication Differential/FinalReductiondevice.............. Spec.90#,Capacity350c.c.
Exhaust  Concentration ................................................ Solid Particulate
 CO.................................................................. Below7.0g/km
 HC.................................................................. Below1.5g/km
Nox ................................................................ Below0.4g/km
 FuelCapacity................................................. 5.0 gal
 SparkPlug ..................................................... NGKCR7E
Battery............................................................ 12V18AH
Lamps FrontLamps................................................... 12V 55WX2
IMPORTANT IDENTIFICATION NUMBERS
PIN Number
Record PIN number for future reference. The PIN Number is located on passenger side under seat and on driver’s side under
hood.
Warning Labels:
Before driving, read these labels thoroughly.
Do not tear off decals. In case of wear or damage, contact your dealer for replacements.
PAGE 5

STARTING/OPERATING PROCEDURES
Choke
 •ChokeLeverisforuseinlowtemperaturestartingsituations.DonotdrivetheUTVwiththechokeactivated.
 •Thisvehicleisequippedwithasafetyprotectionsystem—tostarttheenginebrakemustbeapplied.
 •TheUTVwillstartinanygearwhenbrakeisapplied.Keepthisinmindwhenstartingtopreventinjuryfrom
movement of the vehicle.
 •TheUTVfuelsystemissensitiveandwillnotallowthevehicletostartifmorethan1/8ththrottleisapplied
 whencranking.
 •Forcoldweatherstarting,itisbesttostartthemachineinneutral,withnothrottleappliedandchokefullyengaged.
Brake Pedal
 •Beforeeachtrip,checkthefunctionofthebrakepedal.Alsocheckforsufcientbrakeuidinthereservoir.
 •Attention:Irregularitiesofthebrakessuchasleaksandpoorperformanceshouldonlybedealtwithbyan
 authorizeddealer.ThebrakeuidlevelmustbeabovetheMINmark.AlwaysuseDOT#4brakeuid.
Shift Lever
 L:Hightorqueuse(advancegear)
 H:Normaluse(drivinggear)
 N:Parkinguse(neutral)
R: Reverse use
Shift Lever Instructions:
 •EngagethebrakeandmovetheshiftleverfromNtoH,LorR(Lshiftisusedforroughsurfaces)
 *WhenShiftingHtoLoranygear/directionthevehiclemustbeatacompletestop.
Notice: Operating the shift lever when vehicle is moving can be hazardous and can cause damage to the vehicles
transmission. This is strictly prohibited. Always wait until the vehicle comes to a complete stop.
Do not operate the UTV at high speed in reverse under any circumstances.
2WD/4WD Select Lever
 •The2WD/4WDselectleverisusedforchangingtheenginepowersuppliedtothewheels.Youcanselect2WDor
4WD for your preference according to different surface conditions.
 •2WD:Engagestheenginepowertotherearwheelsonly.Thisismainlyusedfornormalriding.
 •4WD:Engagestheenginepowertobothfrontandrearwheelswithdifferentialfunction.Thereisalimitedslipgear
assembly inside the front differential that can engage the right and left front wheels at different speeds. This
provides much more traction than 2WD and should be used when riding on wet, slippery, or loose surfaces.
GENERAL MAINTENANCE
Recoil Starter
In case the vehicle does not start with the electric starter, the emergency recoil starter can be used to start the engine. To use
therecoilstartermakesuretheheadlightsareswitchedoff,shifttoneutral(N),settheparkbrakeandgripthestarterrope-
handle, which is on the engine magneto cover. Pull the rope until you feel the starter engage. Pull the rope forcefully to start
the engine. At the moment the engine starts, be sure to return the starter rope to its prior normal position.
Tires
The vehicle is equipped with tubeless tires. Tubeless tires should never be repaired. Damaged tires must be replaced.
Yourauthorizeddealershouldonlyreplacetubelesstires.Sincethetirepressureinuencesthedrivingability,themandatory
tire pressure should always be maintained. You should determine outer damages of tires. The suggested minimum profile
depth is 3mm; replace the tire immediately if below 3mm. Tire pressure: 12 PSI
PAGE 6

Check Coolant Reserve Tank
YourUTVcomeslledwithExtendedLifeAntifreezethatisredincolor.Useonlythistypewhenaddingcoolant.Donotmix
antifreezecolorsortypes.Addcoolanttoproperlevelifbelowthe“LOW”markonthereservetank.
Caution: Thereservecoolanttanklevelshouldnotbeoverlledtoallowthermalexpansion.
Maintenance Schedule
The below maintenance schedule is established by months and hours and are dependent on whichever comes first.
Haveyourvehiclechecked,adjustedandrecordedmaintenancedatabyUTVdealertomaintaintheUTVattheoptimum
condition.
Usethechartbelowfornecessaryserviceworktokeepthevehicleoperatingatpeakperformanceandeconomy.
Periodical Maintenance Schedule
Key to table
L:LubricateC:CleanR:ReplaceT:TightenI:Inspection,cleaningandadjustment
HaveyourUTVservicedandcheckedayanauthorizedUTVdealer.Ensuretheservicebookisstampedandsigned.Failure
todosocouldinvalidateyourwarranty.Themaintenancescheduleisestablishedbytakingthemonthly/hourlyasareference
whichever comes first.
INTERVAL
HOURS 25 100 500 1000
ITEM MONTHS 1 3 6 12
MuferBolts&ExhaustPipeNuts  T T T T
ValveClearance  I  I I
AirCleaner  I R R R
EngineIdleRPM  I I I I
SparkPlug    R R
EngineOil  R R R R
FrontDifferentialSetOil  R R R R
FinalGearOil  R  R R
C.V.T.Belt    I R
FuelTube   I I I
ThrottleCablePlay  I I I I
Brakes  I I I I
BrakeHose    I I
BrakeFluid   I I I
Tires I I I
Suspensions I I
Steering System I I I I
ChassisBolts&Nuts  T T T T
GeneralLubrications   L L L
GreaseNipple(UniversalJointAssembly   L L
PAGE 7

Additional maintenance suggestions:
CleanorreplacetheaircleanerelementmoreoftenwhentheUTVisoperatedindustyconditionsorinaheavilypolluted
environment. Maintenance should be performed more often if the UTV is frequently operated in high speed and after the UTV
has accumulated a higher mileage.
Preventive maintenance:
Ignition system-performmaintenanceandcheckwhencontinuousabnormalmisre,after-burnoroverheatingoccurs.
Carbon deposit removal – remove carbon deposits in cylinder head, piston and exhaust system when power is obviously
lower than normal.
Spark Plug
Recommendedsparkplug:CR7E.
Installation instructions:
 •Removesparkplugcap.
 •Cleandirtaroundthesparkplughole.
 •Removesparkplug.
 •Measuresparkpluggap.Sparkpluggap:0.7-0.8mm.
 •Carefullybendgroundelectrodeoftheplugtoadjustthegapifnecessary.
 •Holdsparkplugwasherandinstallthesparkplug.
 •Tightentheplugbyturning½turnmorewithplugsocketafterinstalled.
Air Cleaner
Installation Instructions:
 •Loosen2hooksfromtheaircleanercoverandthenremovethecoverandthenremovetheaircleaner.
 •Donotclean.Replaceasnecessary.
Carburetor Idle Speed Adjustment
 •Settheparkingbrake.
 •Shiftthetransmissiontoneutral.
 •Warmuptheengine.
 •Turnthethrottlevalvestopperscrewtospeciedidlespeed.(Speciedidlespeed:1500+-100rpm)
Engine Oil
 •PulltheUTVontoaatsurface,turnofftheengineandengagetheparkingbrake.
 •Checktheoillevelwithoildipstick.
 •Donotscrewthedipstickintotheenginewhenchecking.Ifoillevelislow,llwithrecommendedoiltoupperlevel.
Instructions for changing:
 •PlaceanoilpanundertheUTVandremoveoildrainplug.
 •Afterdrained,makesurewashercanbere-used.
 •Installoildrainplug.
PAGE 8

Instructions for changing engine oil filter:
 •Drainengineoilout.
 •Installoillter.
 •Addoiltocrankcase(UTVbyBadBoyEngineLubricantSAE10w40:partnumber785-1030-00)
 •Engineoilcapacity:3500/3860c.cc
 •Installdipstick,runtheengineforseveralminutes.
 •Turnofftheengineandcheckoillevelagain.
 •Checkforanyengineoilleaks.
Differential Oil
Instructions for changing:
 •Removeoilllerbolt.
 •Removedrainpluganddraingearoil.
 •Installthedrainplug.
 •Makesurethatthedrainboltwashercanbereusedorreplaced.
 •Addoiltospeciedquantity.(oilviscositySAE80-90#)
 •GearOilQuantity:300-350ml.
Fuse and Battery
In order to access the battery or to replace the fuse, you first remove the seat. Under the seat on the driver’s side, you will find
the fuses.
Note: Only install the correct fuse for replacement. If the fuse should fail several times, you should immediately consult your
authorized dealer.
Instructions for installation:
 •Lifttheseat.Youcanseethebattery.Thebatteryisasealedtype.Youcantakeittoyoudealertocheckthe
battery’s charge condition periodically. In order to remove the battery, loosen the bolts from the battery clamp then remove the
battery.Whenthebatteryneedstoberecharged,use1.8Acurrentfor5-10hours.Maximumchargingrate:9Ax1hr.
Reversing the battery lead wires can harm your UTV, the battery and\or the charging system.
 •Whenconnectingthebattery,connecttheredwirewiththemark(+)andtheblackwirewiththemark(-)ofthe
battery, Note:connecttheredwire(+)rst,thentheblackwire(-).
Disconnect the battery when not in use for long periods of time.
Attention: The maximum power consumption must not exceed 5a.
PAGE 9

BASIC SAFETY RULES
 •WhoeverridestheUTV,mustcarefullyobservetheinstructionsgivenbelow.
 •Approvedsafetyhelmet,boots,goggles,glovesandprotectiveclothingarehighlyrecommended.
 •Beforegettinginthevehicle,makesuretheparkingbrakeisontoavoidanyinjuryordamagetothevehicle.
 •Afterstartingtheengine,removeparkingbrake,selectagearposition,andgraduallyopenthethrottle.Makesurethat
the throttle opens and closes smoothly and the steering wheel steers smoothly in both directions.
 •Thebrakescouldgetdampwhentheroadiswet.Makesurethebrakesfunctionproperlybeforeriding.
 •Ifyoumustrideyourvehicleinrainyweather,oronloosesurfaces,rememberthattractionisgreatlyreduced.Under
 theseconditions,avoidsuddenbrakingwhichmaycausethevehicletoskid.
 •Whenyourstreceiveyourvehicle,ensureyouhavebasicdrivingskillssuchasgoingforward,makingturnsand
stopping. Do no attempt any high performance operation until you are very comfortable with your vehicle and your
 abilities.Starttheengineandletitidleforseveralminutes,releaseparkingbrake,selectagearposition,andopenthe
 throttle.Alwayslookstraightaheadanddrivewithbothhandsonthesteeringwheel.
 •Whenbackingupuseextremecaution.Besurethepathisclearandapplythethrottleslowly.Donotsteerabruptly
 whenbackingupbecauseitcouldleadtoloseofcontrolorrollover.
Dear UTV Rider:
ByfollowingtheinstructionsoutlinesinthismanualyouwillknowhowtooperateyourUTV.Alsoyouarebeingprovided
instructions on how to maintain your UTV, so you can ride safely. Be aware of the Safety Instructions.
Haveasafeandenjoyableride.
 •ShouldanypartsofcomponentsoftheUTVbechanged,itmaycausethewarrantytobecomeinvalid.Consult
 yourauthorizeddealerbeforemakinganymodication.
 •Damagecausedbyusingnon-genuinepartscouldinvalidatethewarranty.
 •Failuretofollowtheinstructionsoutlinedinthismanualcouldinvalidatewarrantyclaims.
 •GenuineaccessoriesfortheUTVaremadeaccordingtothecontractbetweenthedealerandthemanufacturer.
 •Themanufacturerreservestherighttointroduceanymodicationwithoutpriornotice.
SAFE RIDING TIPS:
 •Beforeembarkingonanyjourney,makesureyourUTVisingoodandsafeworkingorder.
 •Alwayswearanapprovedhelmet.Helmetsareyourbestdefenseagainstseriousheadinjuries.
 •Inadditiontoyourhelmet,weareyeandfaceprotection.Longpants,gloves,bootsandadurablelong-sleeved
 jacketarerecommended.
 •Beseen!Wearbrightlycoloredclothing.
 •NeverdrinkalcoholortakedrugsbeforeoperationofanUTV.
 •Alwaysindicatewhenyouareturningleftorright.
 •Beawareofotherroadusers’intentions.
 •Leaveplentyofroombetweenyouandthevehicleinfront.
 •Slowdownbeforeenteringblindturnsandbewatchfulatjunctionsandintersections.
 •Watchforhazardsontheroadortrailway.
 •Don’tspeed–50percentofdriversinvolvedinseriousaccidentswerespeeding.
PAGE 10

SERVICE RECORD
PDI
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
1st Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
2nd Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
3rd Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
4th Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
5th Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
6th Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
7th Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
8th Service
Date: ________________________________
 HourMeterReading: _____________________
Dealer Stamp:__________________________
PAGE 11

UTV PARTS MANUAL 1500G Gas
Table of Contents
Dump Bed Assembly..........................................................17
Hood, Dash & Bumper Assembly..................................18-19
Roll Cage Assembly .......................................................... 20
Front Gas Tank & Steering Assembly................................ 21
Seat Frame Assembly .................................................. 22-23
Brake Pedal & Battery Compartment Assembly........... 24-25
Front Axle Assembly .................................................... 26-27
Brake Cylinder and Lines................................................... 28
Exhaust Assembly............................................................. 29
Engine .......................................................................... 30-31
Rear Axle Assembly..................................................... 32-33
Engine Assembly............................................................... 34
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