Bad Boy Ambush IS Guide

SERVICE PARTS MANUAL
SERVICE PARTS MANUAL
634510
634510
ISSUED NOVEMBER 2013
ISSUED NOVEMBER 2013
REVISED SEPTEMBER 2014
REVISED SEPTEMBER 2014
iS
iS
AMBUSH
AMBUSH

Page i
634510 Service Parts Manual
SERVICE PARTS MANUAL
4 X 4 HYBRID UTILITY VEHICLE
AMBUSH iS
STARTING MODEL YEAR 2014
CALIFORNIA Proposition 65 Warning
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known
to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids con-
tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability, or increase
the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. Bad Boy
Buggies prohibits and disclaims responsibility for any such modifications or any other alterations which would adversely
affect the safety of the vehicle.
BB Buggies Inc. reserves the right to incorporate engineering and design changes to products in this manual, without
obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by BB Buggies Inc., and therefore is subject to
change without notice.
BB Buggies Inc. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US:
Bad Boy Buggies
1451 Marvin Griffin Rd.
Augusta, GA 30906
PHONE: [phone]
E-mail: [email protected]
For parts and repair, contact your local dealer. To locate a local dealer, please go online to our web site:
www.BADBOYBUGGIES.com

Page ii
NOTES
634510 Service Parts Manual
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. The battery charger and the controller are both sources of
electrical drain. Unplug the battery charger DC plug from the vehicle receptacle.
As with all electric vehicles, the batteries must be checked and recharged as required or at
a minimum of 30 day intervals.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, place residue in acid-resistant
containers with absorbent material, sand or earth and dispose of in accordance with local,
state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.
WARRANTY
Separate inserts supplied in packaging with the vehicle provide information on Product
Warranty and on Emissions Warranty. Failure to follow instructions for emission parts
replacement may violate Federal Law (40 CFR part 1068.105 (b)) and be subject to fines and
other penalties as described in the Clean Air Act.

Page iii
Service Parts Manual
SECTION Page No.
TABLE OF CONTENTS
634510 Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
BODY - FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1
BODY - MID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 3
BODY - REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 5
BODY - ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 9
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F
DIRECTION SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K
ENGINE AND MUFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
FRONT SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
OPERATOR PROTECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U
TRUCK BED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y

Page iv Service Parts Manual
NOTES
634510 Service Parts Manual

Page v
634510 Service Parts Manual
This manual is divided into several sections:
•GENERAL INFORMATION
•ILLUSTRATED PARTS BREAKDOWN
•APPENDIX
The first section, GENERAL INFORMATION, contains the following information:
•WARRANTY INFORMATION
•GENERAL INDEX
•HOW TO USE THE SERVICE PARTS MANUAL
The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your
vehicle.
The third section, APPENDIX, contains a listing of specialty products and accessories.
USE OF THE MANUAL
To use this manual, consult the GENERAL INDEX to locate the information or illustration required.
Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its
model number be supplied to Service Parts when ordering any replacement components.
Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its loca-
tion) and note the complete number shown on the plate.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi 634510 Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the General Index and select the most
appropriate title.
•Turn to the page number indicated and locate the desired part on the illustration.
•From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying
description for specific information regarding the part.
2. IF YOU KNOW THE PART NUMBER
•Locate the part number or description in the appropriate column on the parts list page.
NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on
the illustrated page.
Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted
is not available for purchase.
NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
Title Title
Left hand illustration page
(continued on right hand page
if required) Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74 70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,8684,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 - Includes Items 71 - 74
81 - Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - Includes Items 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

Page vii
634510 Service Parts Manual
3. COLOR CODE FOR BODY COMPONENTS
The last two digits of the part number for the body part will denote the color code. Locate the part number for the cowl,
rear body, seat pod, side panel or seat wrap then locate your color in the list below. Replace the last ** or XX with the
two digit color code.
CODE # DESCRIPTION
39 FLAME RED
55 REALTREE ADVANTAGE MAX 4-DIPPED
72 MATTE BLACK
73 MATTE GREEN
78 REALTREE XTRA DIPPED
HOW TO USE THE SERVICE PARTS MANUAL

Service Parts Manual
ACCELERATOR
Page A-1 634510 Service Parts Manual
ACCELERATOR PEDAL ASSEMBLY includes items 2 - 13
1
1
2
8
5
6
3
9
4
7
16
21
18
17
19
20
10
11
12
13

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Service Parts Manual
ACCELERATOR
Page A-2
Service Parts Manual
634510 Service Parts Manual
1 632681 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 2 - 13)................. 1
2 626140 ACCELERATOR PEDAL BRACKET ........................................................ 1
3 600019 ROTARY POSITION SENSOR................................................................. 1
4 600543 TORX BOLT, M4 - 0.75 X 12MM LG......................................................... 2
5 612889 PEDAL SWITCH....................................................................................... 1
6 620030 SOCKET HEAD CAP SCREW, M5 - 0.8 X 10MM LG.............................. 2
7 600683 PIN, 4MM X 26MM ................................................................................... 1
8 626142 ACCELERATOR PIVOT SHAFT .............................................................. 1
9 613098 TORSION SPRING, 4.5MM DIA............................................................... 1
10 625731 FLANGED BUSHING, 16MM X 12MM..................................................... 2
11 604097 REBOUND BUMPER ............................................................................... 1
12 632679 SUSPENDED ACCELERATOR PEDAL................................................... 1
13 610529 ACCELERATOR PEDAL COVER ............................................................ 1
14
15
16 632759 ACCELERATOR BRACKET ........................................................................... 1
17 635195 ACCELERATOR PEDAL CABLE.................................................................... 1
18 10386G2 CLEVIS PIN .................................................................................................... 1
19 632919 ACCELERATOR PEDAL HELPER SPRING .................................................. 1
20 612920 HEX HEAD BOLT, M6 - 1 X 25MM LG............................................................ 3
21 601476 LOCK NUT, M6 - 1.......................................................................................... 3

Service Parts Manual
ACCELERATOR
Page A-3 634510 Service Parts Manual
8
6
710
9
7
13
11
12
16
GOVERNOR BRACKET ASSEMBLY includes items 6 - 13
5
GOVERNOR ASSEMBLY includes items 2 - 19
1
Front of Vehicle
2
4
3
17
18
22
19

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Service Parts Manual
ACCELERATOR
Page A-4
Service Parts Manual
634510 Service Parts Manual
1 633162 GOVERNOR ASSEMBLY (INCLUDES ITEMS 2 - 19) ................................... 1
2 00734G5 LOCK NUT, #10 - 32................................................................................. 1
3 633425 GOVERNOR LEVER WELDMENT .......................................................... 1
4 15944G1 BALL JOINT ............................................................................................. 1
5 22751G5 GOVERNOR BRACKET ASSEMBLY (INCLUDES ITEMS 6 - 13)........... 1
6 22754G1 BUSHING FLIP LOK, 0.25"................................................................ 1
7 25661G01 CUP WASHER, 0.84"......................................................................... 2
8 25274G1 GOVERNOR ROD............................................................................. 1
9 22752G1 GOVERNOR BRACKET WELDMENT............................................... 1
10 635053 COMPRESSION SPRING ................................................................. 1
11 23859G1 GOVERNOR ADJUSTER.................................................................. 1
12 00734G5 HEX NUT, #10 - 32............................................................................. 1
13 22754G2 BUSHING FLIP LOK, 0.375".............................................................. 1
14
15
16 14390G4 LOCK NUT, 1/4" - 20 ................................................................................ 1
17 635194 GOVERNOR CABLE................................................................................ 1
18 71215G01 SET SCREW WITH PATCH LOCK, 1/4" - 20........................................... 2
19 01076G01 COTTER PIN............................................................................................ 1
20
21
22 635011 GOVERNOR SPRING EXTENSION............................................................... 1

Service Parts Manual
Notes:
ACCELERATOR
Page A-5 634510 Service Parts Manual

Service Parts Manual
Notes:
ACCELERATOR
Page A-6
Service Parts Manual
634510 Service Parts Manual

Service Parts Manual
BATTERY SYSTEM
Page C-1 634510 Service Parts Manual
A
25
3
1
22
13
15
14
16
1
1
17
28
29
29
27
26
2
31
34
35
33
32
4
9
5
6
6
8
6
6
7
7
10
7
8
920
17
17
17
21
B
D
C
A
C
B
D
23

Service Parts Manual
BATTERY SYSTEM
Page C-2
Service Parts Manual
634510 Service Parts Manual
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
1 641828 BATTERY, 8V.................................................................................................. 6
2 635993 STARTER BATTERY, 12V .............................................................................. 1
3 632784 BATTERY RACK WELDMENT ....................................................................... 1
4 632688 SEAT FRAME WELDMENT............................................................................ 1
5 00440G6 HEX HEAD BOLT, 5/16” - 18 X 2.75" LG........................................................ 2
6 00559G8 FLAT WASHER, 5/16”..................................................................................... 10
7 11098G6 LOCK NUT, 5/16” - 18..................................................................................... 6
8 00438G8 HEX HEAD BOLT, 5/16” - 18 X 1" LG............................................................. 4
9 00715G2 FLANGED HEX HEAD BOLT, 5/16” - 18 X .875" LG...................................... 4
10 70200G01 TRUSS HEAD MACHINE SCREW, 3/8 -16 X 1" LG ...................................... 2
11
12
13 633190 BATTERY HOLD DOWN WELDMENT, 3 - 8V................................................ 1
14 633191 INNER BATTERY HOLD DOWN BRACKET, 3 - 8V....................................... 2
15 608513 RUBBER PAD................................................................................................. 4
16 01101G01 TIE DOWN BOLT............................................................................................ 4
17 11027G1 FLANGED LOCK NUT, 5/16” - 18................................................................... 13
18
19
20 629688G01 BATTERY TRAY BRACKET (DRIVER SIDE)................................................. 1
21 616229 BATTERY HOLD DOWN WELDMENT, 1 - 8V................................................ 1
22 70386G01 TIE DOWN BOLT............................................................................................ 2
23 35493G01 BATTERY DISPOSAL DECAL........................................................................ 7
24
25 634672 BATTERY TRAY FRAME BRACKET.............................................................. 1
26 634673 FRONT BATTERY HOLD DOWN................................................................... 1
27 604197 BATTERY HOOK BOLT.................................................................................. 2
28 633636 FRONT BATTERY FILL SYSTEM .................................................................. 1
29 548604 FLANGED HEX HEAD BOLT, 5/16” - 18 X 3/4” LG........................................ 5
30
31 634471 12V STARTER BATTERY TRAY TIEDOWN................................................... 1

Service Parts Manual
BATTERY SYSTEM
Page C-3 634510 Service Parts Manual
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
32 00426G8 HEX HEAD BOLT, 5/16" - 18 X 1" LG.............................................................. 2
33 00560G1 FLAT WASHER, 3/8"....................................................................................... 2
34 12262G1 LOCK NUT, 5/16" - 18 ..................................................................................... 2
35 608513 RUBBER PAD ................................................................................................. 2

Service Parts Manual
Notes:
BATTERY SYSTEM
Page C-4
Service Parts Manual
634510 Service Parts Manual

Service Parts Manual
BATTERY SYSTEM
Page C-5 634510 Service Parts Manual
1
2
2
3
3
6
14
15
To Controller
To Solenoid
16
18
19
17