Bad Boy COMPACT OUTLAW Owner'S, Service & Parts Manual Download Page 3

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This manual applies to the following equipment:

PAGE 3

Bad Boy Compact Outlaw Series

Compact Outlaw 4200 42” 726cc Kawasaki FX691V
Compact Outlaw 4800 48” 726cc Kawasaki FX691V
Compact Outlaw 4200 42” 810cc Vanguard
Compact Outlaw 4800 48” 810cc Vanguard

COMMONLY USED ITEMS AND PART NUMBERS

Hydraulic Filter

Pump Belt

Fuel Filter

Motor Oil

48" Blade

42" Blade

Hi-Lift Fusion

038-5350-00

Gator Blade

038-5000-00

Wave Blade

038-4825-00

Gator Blade

038-4227-00

Hi-Lift Fusion

038-4226-00

Wave Blade

038-4228-00

063-1050-00

Deck Belt

48"

041-1470-00

42"

041-4022-00

Spark Plug

041-6400-00
063-6000-00

Vanguard 810cc

063-8018-00

Kawasaki FX 691v

063-8017-00

Vanguard 810cc

015-8000-00

Kawasaki FX 691v

015-8001-00

Outer Element

063-8019-00

Inner Element

063-8020-00

Hydro Oil

20W-50 Motor Oil -

Bad Boy Hydrostatic Oil Reccommended;

Approximately 2 quarts per side

Oil Filter

Air Filter

10W-30 Motor Oil -

Bad Boy Synthetic Blend Motor Oil Recommended

Summary of Contents for COMPACT OUTLAW

Page 1: ...ZERO TURN MOWER OWNER S SERVICE PARTS MANUAL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 2015 12 11 COMPACT OUTLAWMODEL...

Page 2: ...on Section 5 page 12 Troubleshooting and FAQ Section6 page 13 Controls Section 7 page 14 Moving In operable Mower Section 8 page15 Instrumentation Section 9 page 15 Mower Blade Maintenance Section10 p...

Page 3: ...n 038 5350 00 Gator Blade 038 5000 00 Wave Blade 038 4825 00 Gator Blade 038 4227 00 Hi Lift Fusion 038 4226 00 Wave Blade 038 4228 00 063 1050 00 Deck Belt 48 041 1470 00 42 041 4022 00 Spark Plug 04...

Page 4: ...nly Bad Boy replacement parts are to be used on your mower Replacement parts are available through your local Bad Boy Mower Dealer Remember to always provide the following information when ordering pa...

Page 5: ...nd behind before and while backing 2 9 Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction as material may ricochet back toward the operator Stop th...

Page 6: ...es For example rocks water cliffs and roadways CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing a...

Page 7: ...ERVICE 2 56 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect 2 57 Keep all nuts and bolts tight to be sure the equipment is in safe working condition Never oper...

Page 8: ...ator should be in off position the engine should not start 2 73 Engage parking brake and leave lever arms in outward position put blade actuator in the on position then attempt to start the machine th...

Page 9: ...ecently engage the choke 3 6 Make sure nothing is under or around machine 3 7 Place key in ignition and turn 3 8 Once machine is started disengage the choke 3 9 Increase RPM by sliding the throttle to...

Page 10: ...ge hudraulic oil and filter Section 1 Clean combustion chamber Dealer Maintenance by hour or annually which ever comes first Check air and fuel filter more often in dusty conditions Dealer Get mainten...

Page 11: ...ormed Performed Performed Performed Performed Performed Performed Performed Performed Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date...

Page 12: ...ed for more than 30 days 5 4 Always secure machine properly when transporting machine 5 5 Do not load machine on trailer with blades engaged 5 6 Do not use ramps to load the machine 5 7 Make sure Park...

Page 13: ...ck for any bare wires and or bad connections 6 3 Q What should I do if the blades won t engage 6 3 A Make sure the safety switch is plugged in on the bottom of seat Check the underside of the PTO enga...

Page 14: ...ever backward to decrease engine rpm 7 3 Choke Control Not pictured When the lever is in the down position the choke is in the off run position When the lever is pulled up the choke is in the on start...

Page 15: ...osition Return the arms to the forward position for normal operation 8 4 Your Bad Boy Mower Weighs 862 925 lbs Weights fluctuate with the addition of accessories 8 5 As you can see by the weights of t...

Page 16: ...ick gloves when handling blades 10 7 ALWAYS check for blade damage if mower strikes rock branch or other objects that could potentially damage the blade REMEMBER NEVER CHECK BLADE WHILE ENGINE IS ON N...

Page 17: ...fic purpose If you re experiencing less than desired cutting or discharging performance with a 3 1 blade you may want to check into using a 2 1 blade Conversely if you re using a 2 1 blade and want to...

Page 18: ...eason Keep several blades around so you ll always have a sharp one on hand Sharp blades cut the grass cleanly and help mulch clippings into small pieces which break down quickly Don t forget to change...

Page 19: ...saxles 2 Remove the three filter guard screws and filter guard from the ZT 3400 Transaxle Clean any loose debris from around the perimeter of the filter 3 Place the oil drain pan under the oil filter...

Page 20: ...draulic fluid reservoirs 13 Re install the caps on the hydraulic fluid reservoirs 14 Now we need to purge the air from the transaxle With your mowers tires off the ground disengage the brake and start...

Page 21: ...out the engine running SECTION 2 DRIVE BELT When adjusting the tracking on the mower the length of the pushrods can be changed by screwing the swivel joint in or out on the ends of the rods Shortening...

Page 22: ...ine Clean area around oil filter Place a container under the oil filter to capture any oil and remove filter Wipe off mounting surface and reinstall drain plug Torque to 10 ft lb 3 Place new filter in...

Page 23: ...llingoneach hose Always perform maintenance outdoors or in a well ventilated area Do not smoke or allow any open flames in the vicinity of any maintenance activities 3 2 Changing your fuel filter 1 Lo...

Page 24: ...environments Adhering to these practices will help prevent loss of power and premature engine failure 3 3 Changing the air cleaner 1 Unlock the air cleaner cover and remove to access the air cleaner...

Page 25: ...ocket to remove the spark plug 2 Check the gap on the spark plug to verify that it is 0 03 in using a feeler gauge 3 If the spark plug is worn overheated wet or carbon fouled replace the spark plug 4...

Page 26: ...e right side of the engine Clean area around oil filter Place a container under the oil filter to capture any oil and remove filter Wipe off mounting surface and reinstall drain plug Torque to 10 ft l...

Page 27: ...each side of the fuel filter and remove the fuel filter 4 Place the new fuel filter in the same direction as the old and place clips back into place and remove clamps The air cleaner is the engine s...

Page 28: ...socket to remove the spark plug 2 Check the gap on the spark plug to verify that it is 0 03 in using a feeler gauge 3 If the spark plug is worn overheated wet or carbon fouled replace the spark plug 4...

Page 29: ...nals are tightly fastened Never replaceafuse withoneofa higheramperageratingor bypass afuseinanyway Doingsocreates asignificant firehazard and cancauseseveredamage tothe mower s electricalcomponents I...

Page 30: ...PAGE 30...

Page 31: ...que turntheforkitselftoensurenodamage isdonetothebearing Thisoperationisonlynecessaryifa repair requires it Torquerearwheellugsto65 75ft lbs Re torqueateveryoil change and check at every mowing There...

Page 32: ...otpoint Greaseatevery engineoil change The deck belt tensioner is located at the rear of the deck and has a grease fitting on its pivot point Grease at everyengine oil change The control arm blocks ha...

Page 33: ...gerscaneasilybecomecaughtbetween thebeltand pulley Deck belt installation 1 Follow steps 1 and 2 from the deck removal section 2 Take off both pulley covers and route the belt by following the belt ro...

Page 34: ...actuator bar using two wrenches 5 Now ensure that the deck is level left to right and has a pitch down of from the back to the front This can be done by adjusting the tabs on the deck 6 Loosen the bo...

Page 35: ...k Belt tension should be 70 75 lbs for a 54 deck and 75 80 lbs for a 61 and 72 deck with the deck at its lowest setting Use a belt tension gauge to ensure the proper tension Your dealer or service cen...

Page 36: ...rench and an extension to gain more leverage You might need to put a wrench on top of the pulley bolt to keep the blade from spinning Boltsusedhave right handedthreads Re torque theblade bolts to 90 1...

Page 37: ...ng 022 7009 00 2 3 1 2 x 9 GR 5 Hex Bolt 018 7010 00 1 4 1 2 13 Nylon Flange Nut 013 8050 00 1 5 Caster Bearing Spacer 025 0004 00 1 6 1 Fine Thread 1 2 Nylock Nut 013 9004 00 1 7 Rubber Bearing Cap 0...

Page 38: ...38 Adjustable Drive Arm Assemblies 32 31 28 28 27 29 26 30 28 28 8 7 22 23 18 17 16 19 33 11 12 13 14 16 6 5 4 2 1 3 21 24 25 25 20 17 34 16 35 35 Welded to Frame 9 10 9 10 37 15 36 15 38 36 10 10 39...

Page 39: ...019 5037 00 2 17 3 8 24 Quick Release Ball Joint 099 2009 00 1 18 Push Rod Left 035 5451 00 1 19 Spherical Rod End Outlaw 048 3000 00 1 20 3 8 x 1 1 4 Hex Bolt 018 5040 00 1 21 5 16 x 3 4 Hex Bolt 01...

Page 40: ...PAGE 40 DETAIL A DETAIL B A B 8 7 6 4 5 28 27 26 28 28 12 5 15 16 3 9 6 7 10 2 24 24 26 24 25 41 23 22 21 18 17 20 19 30 29 30 1 14 13 31 36 37 40 11 38 35 11 39 32 33 34 43 42...

Page 41: ...4 x 3 4 Carriage Bolt 019 8040 00 4 18 350ml Expansion Tank 067 8090 00 2 19 Hydraulic Tank Cap 066 5050 00 2 20 3 16 Vinyl Tubing 051 8073 00 1 21 3 16 Vinyl Hose Clamp 072 8073 00 2 22 M6 1 0 X 16MM...

Page 42: ...8 1 41 21 43 22 41 21 42 24 23 62 14 45 15 44 14 15 12 14 17 26 33 32 35 34 37 39 40 38 36 35 27 31 30 5 29 34 4 2 5 3 6 20 21 18 19 11 12 13 13 12 11 49 47 48 46 37 28 14 12 12 15 45 53 52 54 61 61...

Page 43: ...015 Brake Lever Spacer 025 0001 00 1 31 Safety Switch 077 8073 00 1 32 12 24x 1 2 HWH Bolt 018 1080 00 2 33 5 16 x 1 Carriage Bolt 018 8065 00 2 34 5 16 Flange Nut w Serrations 013 9002 00 2 35 Brake...

Page 44: ...PAGE 44 19 DETAIL A DETAIL B A B 2 3 8 7 5 17 20 18 11 16 26 31 27 30 28 29 5 24 22 22 25 6 4 10 35 34 9 15 14 13 33 12 32 23 21 36 37 11 17 4 5 1 18...

Page 45: ...w Height Indicator Plate Outer 026 2100 00 1 16 3 8 x 1 3 4 Carriage Bolt 018 0009 00 4 17 3 4 OD x 1 2 ID x 3 4 Length 025 5203 00 3 18 390 x 750 x 062 Nylon Washer 019 2003 00 5 19 Outlaw Deck Lever...

Page 46: ...PAGE 46 18 DETAIL A A 26 23 24 15 12 16 5 9 8 28 9 7 8 10 25 2 1 20 17 13 19 17 18 19 6 3 4 22 21 11 27 Transaxle Assembly 14 8 9...

Page 47: ...Brake Cable 064 3000 00 2 12 Brake Spring 034 1025 00 2 13 5 16 x 2 1 2 Bolt 018 5344 00 2 14 1 4 20 Nylon Insert flange Nut 013 2050 00 2 15 1 4 x 3 4 Hex Bolt 018 8052 00 2 16 3 8 x 2 1 2 Hex Tap Bo...

Page 48: ...75 00 4 13 Universal Inline Fuel Filter 063 6000 00 1 14 5 16 Set Screw 030 0050 00 1 15 Black Boot For Ground Cable 103 5400 00 1 16 Ground Cable 064 8061_00 1 17 M8x1 20x20MM Hex head bolt 018 5321...

Page 49: ...ter 063 8019 00 1 11 Canister Air Filter Inner 063 8020 00 1 12 Spark Plug 015 8000 00 1 13 Clutch Assembly 070 1000 00 1 14 Clutch Pigtail 070 2000 00 1 15 7 16 Lock Washer 019 8053 00 1 16 7 16 x 2...

Page 50: ...A DETAIL B A B 36 35 6 5 7 8 23 49 48 30 29 50 31 4 20 28 25 52 26 32 33 2 4 4 37 13 11 10 34 51 4 38 39 4 12 32 21 22 19 4 21 24 53 4 47 45 46 17 12 16 15 9 42 41 43 41 40 44 1 3 14 18 27 42 Deck Ass...

Page 51: ...0 1 25 1 2 13 x GR 5 Hex Bolt Zinc 018 7016 00 1 26 1 4 Press in Grease Fitting 024 6034 00 5 27 Spacer 3 4 OD x 1 2 ID x 3 4 Length 025 5203 00 1 28 1 2 20 x 1 1 2 Grade 5 Fine Thread Bolt 018 6019 0...

Page 52: ...DETAIL B A B 46 12 8 10 9 11 40 41 4 35 4 36 49 48 47 20 20 21 18 4 22 19 4 7 6 52 38 4 53 29 32 33 28 26 50 27 33 4 39 4 2 3 17 16 11 15 14 13 45 43 42 1 34 48 Deck Assembly 24 25 23 31 37 30 51 5 4...

Page 53: ...0 3 25 Deck Idler 039 6945 00 1 26 1 2 13 x GR 5 Hex Bolt Zinc 018 7016 00 1 27 1 4 Press in Grease Fitting 024 6034 00 5 28 Spacer 3 4 OD x 1 2 ID x 3 4 Length 025 5203 00 1 29 1 2 20 x 1 1 2 Grade 5...

Page 54: ...M Spindle Housing 037 6017 50 1 1 Locking Collar w 1 4 20 Set Screw 037 9050 00 1 2 Spindle Dust Cap 037 8002 00 1 3 Spindle Shaft 037 6026 00 1 4 Spindle Spacer 037 8050 00 1 5 Bearing 6206 037 6023...

Page 55: ...02 00 Left Steering Control Decal 091 1103 00 Right Steering Control Decal 091 3309 00 Deck Belt Route Decal 091 3017 00 Pump Belt Route Decal 091 1110 00 810cc Decal 091 1105 00 Outlaw Deck Height De...

Page 56: ...__________________________________________________________ _________________________________________________________________________ ___________________________________________________________________...

Page 57: ...__________________________________________________________ _________________________________________________________________________ ___________________________________________________________________...

Page 58: ...d upon return of parts to Bad Boy for inspection D All warranty issues must be handled through an authorized service center or dealership 4 WARRANTY LIMITATION A THERE IS NO OTHER EXPRESS WARRANTY ANY...

Page 59: ...STRATION Ensure selling dealership has registered mower within 30 days of purchase to validate warranty Please record your serial number date of purchase and dealership information for your records Se...

Page 60: ...For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501...

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