Bad Boy OFF ROAD AMBUSH iS Guide

640770-AB
REVISED JULY 2017ISSUED OCTOBER 2014
SERVICE PARTS MANUAL

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. Textron Specialized Vehicles prohibits
and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
TSV 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 TSV, and therefore is subject to change without notice.
TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
These are the original instructions as defined by 2006/42/EC.
TO CONTACT US:
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
NORTH AMERICA:
Technical Assistance & Warranty PHONE: [phone], FAX: [phone]
Service Parts PHONE: [phone], FAX: [phone]
International: PHONE: [phone], FAX: [phone]
For parts and repair, contact local dealer. Dealers can be located at www.BADBOYOFFROAD.com
i
640770 Service Parts Manual
SERVICE PARTS MANUAL
4 X 4 HYBRID UTILITY VEHICLE
AMBUSH iS
STARTING MODEL YEAR 2015 THROUGH MODEL YEAR 2017
CALIFORNIA Proposition 65 Warning
WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which
contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth
defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new
and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates,
all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.

ii
NOTES
640770 Service Parts Manual
This vehicle has been designed and manufactured in the United States of America (USA).
The Standards and Specifications listed in the following text originate in the USA unless
otherwise indicated.
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.
The use of non-Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Failure to properly maintain batteries may void the warranty. Refer to the battery manual for
instructions on the proper maintenance and care of the batteries.
BATTERY PROLONGED STORAGE
Batteries self-discharge over time. The rate of self-discharge varies depending on the
ambient temperature, the age and condition of the batteries.
Fully charged batteries 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 may be left connected to the vehicle to maintain a full charge on the
batteries, provided the charger is plugged into an active electrical source. If power to the
electrical source is disconnected or interrupted, the battery charger will continue to check
the charge on the battery pack. This will draw power from the battery pack and eventually
drain the batteries if power is not restored in a timely manner.
The batteries must be checked and recharged as required or at a minimum of 30 day inter-
vals.
Check and maintain the proper fluid level in all battery cells during the storage period.
Proper fluid level is required for maximum battery performance.
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 envi-
ronmental 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.

SECTION Page No.
TABLE OF CONTENTS
Page iii
640770 Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL......................................................................................................v
ACCELERATOR ..................................................................................................................................................A - 1
BATTERY SYSTEM.............................................................................................................................................B - 1
BODY...................................................................................................................................................................C - 1
BRAKES ..............................................................................................................................................................D - 1
CLUTCH ..............................................................................................................................................................E - 1
DIRECTION SELECTOR.....................................................................................................................................F - 1
DIFFERENTIAL LOCK........................................................................................................................................ G - 1
ELECTRICAL SYSTEM .......................................................................................................................................H - 1
ENGINE ............................................................................................................................................................... J - 1
ENGINE MUFFLER .............................................................................................................................................K - 1
FRONT AXLE ...................................................................................................................................................... L - 1
FRONT SUSPENSION AND STEERING ........................................................................................................... M - 1
FUEL SYSTEM....................................................................................................................................................N - 1
MOTOR................................................................................................................................................................P - 1
OPERATOR PROTECTION SYSTEM (OPS)..................................................................................................... Q - 1
REAR AXLE.........................................................................................................................................................R - 1
REAR SUSPENSION ..........................................................................................................................................S - 1
SEATING .............................................................................................................................................................T - 1
TRUCK BED ........................................................................................................................................................U - 1
WEATHER PROTECTION .................................................................................................................................V - 1
WHEELS AND TIRES.........................................................................................................................................W - 1

NOTES
Notes:
Page iv 640770 Service Parts Manual

Page v
640770 Service Parts Manual
HOW TO USE THE 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.

Page vi 640770 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 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
81,86
84,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 -Incl
udes 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
640770 Service Parts Manual
HOW TO USE THE 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
38 BRIGHT WHITE
39 FLAME RED
72 MATTE BLACK
78 REALTREE XTRA DIPPED
80 REALTREE MAX 5 DIPPED

Service Parts Manual
ACCELERATOR
Page A-1 640770 Service Parts Manual
1
6
5
98
7
16
21
23
23
18
17
19
14
20
10
2
3
4
11
12
13
ACCELERATOR PEDAL ASSEMBLY includes items 2 - 14
1

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
640770 Service Parts Manual
1 653676 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 2 - 14) ................. 1
2 626140 ACCELERATOR PEDAL BRACKET ........................................................ 1
3 600019 ROTARY POSITION SENSOR................................................................. 1
4 600543 TORX BOLT, M4 - .75 X 12MM LG........................................................... 2
5 612889 PEDAL SWITCH....................................................................................... 1
6 620030 SOCKET HEAD CAP SCREW, M5 - .8 X 10MM LG................................ 2
7 600683 COILED SPRING PIN, 4MM X 26MM...................................................... 1
8 638177 ACCELERATOR PIVOT SHAFT............................................................... 1
9 653205 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 12064G3 PUSH NUT, 3/16" ..................................................................................... 2
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 00415G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG......................................................... 3
21 14390G4 LOCK NUT, 1/4" - 20....................................................................................... 3
22 31539G1 NYLON CLAMP, 15.5" LG (NOT ILLUSTRATED)........................................... 1
23 00559G7 FLAT WASHER, 1/4"....................................................................................... 6

Service Parts Manual
ACCELERATOR
Page A-3 640770 Service Parts Manual
2
4
3
15
17
18
24
Front of Vehicle
GOVERNOR BRACKET ASSEMBLY
includes items 6 - 13
5
GOVERNOR ASSEMBLY includes
items 2 - 21
1
12
10
11
13
16
9
7
7
6
8
Front of Vehicle
Engine Shown For Reference
15
17
20
21
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
640770 Service Parts Manual
1 638641 GOVERNOR ASSEMBLY (INCLUDES ITEMS 2 - 21) ................................... 1
2 00734G5 LOCK NUT, #10 - 32................................................................................. 1
3 638954 GOVERNOR LEVER WELDMENT .......................................................... 1
4 72732G01 BALL JOINT.............................................................................................. 1
5 22751G2 GOVERNOR BRACKET ASSEMBLY (INCLUDES ITEMS 6 - 13)........... 1
6 22754G1 BUSHING FLIP-LOCK, .25"............................................................... 1
7 25661G01 CUP WASHER, .84"........................................................................... 2
8 25274G1 GOVERNOR ROD ............................................................................. 1
9 22752G1 GOVERNOR BRACKET WELDMENT............................................... 1
10 23578G1 COMPRESSION SPRING ................................................................. 1
11 23859G1 GOVERNOR ADJUSTER .................................................................. 1
12 00526G4 HEX NUT, #10 - 32............................................................................. 1
13 22754G2 BUSHING FLIP-LOCK, .375"............................................................. 1
14
15 635313 GOVERNOR CABLE................................................................................ 1
16 14390G4 LOCK NUT, 1/4" - 20 ................................................................................ 1
17 646094 GOVERNOR CABLE................................................................................ 1
18 71215G01 SET SCREW WITH PATCH LOCK, 1/4" - 20 ........................................... 2
19 646070 GOVERNOR CABLE MOUNTING BRACKET ......................................... 1
20 23726G7 SPACER, .315" X .4" X .55" LG................................................................ 2
21 643471 FLANGED HEX HEAD BOLT, M6 - 1 X 35MM LG ................................... 2
22
23
24 635011 GOVERNOR SPRING EXTENSION............................................................... 1

Service Parts Manual
Notes:
ACCELERATOR
Page A-5 640770 Service Parts Manual

Service Parts Manual
Notes:
ACCELERATOR
Page A-6
Service Parts Manual
640770 Service Parts Manual

Service Parts Manual
BATTERY SYSTEM
Page B-1 640770 Service Parts Manual
B
A
25
3
1
22
13
15
14
1
24
17
28
29 29
27
26
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
D
23
31
2
36
38
16
37

Service Parts Manual
BATTERY SYSTEM
Page B-2
Service Parts Manual
640770 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 612626 BATTERY, 8V.................................................................................................. 4
2 639553 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 652443G103 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 614382 BATTERY, 8V (HYDROLINK).......................................................................... 2
25 634672 BATTERY TRAY FRAME BRACKET.............................................................. 1
26 634673 FRONT BATTERY HOLD DOWN ................................................................... 1
27 604197 BATTERY HOOK BOLT.................................................................................. 2
28 623299 FRONT BATTERY FILL SYSTEM................................................................... 1
29 548604 FLANGED HEX HEAD BOLT, 5/16" - 18 X 3/4" LG........................................ 5
30
31 626723 12V STARTER BATTERY TRAY HOLD DOWN ............................................. 1

Service Parts Manual
BATTERY SYSTEM
Page B-3 640770 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 FLANGED LOCK NUT, 5/16" - 18 ................................................................... 2
35 608513 RUBBER PAD ................................................................................................. 2
36 640359 TERMINALADAPTER, POSITIVE.................................................................. 1
37 640360 TERMINALADAPTER, NEGATIVE................................................................. 1
38 640428 BOLT EXTENDER........................................................................................... 2

Service Parts Manual
Notes:
BATTERY SYSTEM
Page B-4
Service Parts Manual
640770 Service Parts Manual

Service Parts Manual
BATTERY SYSTEM
Page B-5 640770 Service Parts Manual
1
2
2
3
3
9
14
10
11
12
To Controller
To Solenoid
15 6