Bad Boy MZ MAGNUM Owner'S, Service & Parts Manual Download Page 1

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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

MZ MAGNUM

MODELS

Summary of Contents for MZ MAGNUM

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 5 MZ MAGNUMMODELS ...

Page 2: ... Section 5 page 12 Troubleshooting and FAQ Section 6 pages 13 Controls Section 7 page 14 Moving Inoperable Mower Section 8 page 15 Instrumentation Section 9 page 15 Mower Blade Maintenance Section 10 page 16 Greasing Bearings Section 11 page 16 How to choose the right blade Page 17 Mowing Tips Page 18 PAGE 2 Service Section Page 19 Parts Section Page 38 Limited Warranty Page 58 ...

Page 3: ...e Hi Lift Fusion 038 0005 00 Gator Blade 038 0003 00 Wave Blade 038 5220 00 48 MZ Deck 041 6027 00 54 MZ Deck 041 4022 00 MZ Pump Belt 041 6400 00 Oil Filter Kohler Engine Kawasaki Engine 063 5004 00 063 8017 00 Air Filter Kohler Engine Kawasaki Engine 063 5002 00 063 5003 00 063 2097 00 Pre Cleaner Element Fuel Filter Kohler Engine Kawasaki Engine 063 5001 00 063 6000 00 Spark Plug Kohler Engine ...

Page 4: ...Replacement parts are available through your local Bad Boy Mower Dealer Remember to always provide the following information when ordering parts 1 Correct part number 2 Correct serial number All warranty repair and service must be handled through your authorized Bad Boy Mowers dealer To locate the nearest dealer go to our website and click on Locate a Dealer EVAPORATIVE EMISSION CONTROL WARRANTY S...

Page 5: ...and 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 the blades when crossing gravel surfaces 2 10 Never operate the machine without the discharge chute grass catcher or other safety devices correctly in place and functioning properly 2 11 Slow down befo...

Page 6: ...pes 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 activity NEVER assume that children will remain where you last saw them 2 33 Keep children out of the mowing area and in the watchful care of a responsible adult other that the operator 2 34 Maintain ...

Page 7: ...SERVICE 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 operate a poorly maintained machine 2 58 Do not touch hot areas of the machine 2 59 Never interfere with the intended function of a safety device or reduce the protection provided by a safety device Chec...

Page 8: ...portant safety precautions Note the operator must be seated properly on the machine during these tests and the engine should have been previously allowed to warm to operating temperature 2 71 With the parking brake engaged bring lever arms to their inward position then attempt to start the machine the blade actuator should be in off position the engine should not start 2 72 On a level surface dise...

Page 9: ...d recently 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 fast position toward the rabbit 3 10 Owners must become familiar with the controls before operating a zero turn radius vehicle 3 11 Start slowly and build your skill level Have ample practice befo...

Page 10: ...for fuel and oil leakage Section 3 Initial oil change Section 3 Change engine oil and filter Section 3 Tighten nuts and screws Grease mower Section 5 Replace air element and pre cleaner Section 3 Replace fuel filter Section 3 Clean or replace spark plugs and set gap Section 3 Clean combustion chamber Dealer Check and adjust valve clearance Dealer Clean and lap valve seating surface Dealer Maintena...

Page 11: ...formed 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 Hours Maintenance Log Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours ...

Page 12: ...red 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 Parking Brake is in up position 5 8 In wet conditions tires may spin while loading unloading If necessary wait for dry conditions before loading unloading 5 9 Make sure mode of transportation is suitable...

Page 13: ...ed and make sure air filter is clean a dirty filter makes it more difficult for the engine to draw air Check the integrity of the 25 amp main fuse also check 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 engager to ensure the plug is secure at switch Al...

Page 14: ...ngine rpm 7 3 Choke Control Not Shown The choke control located to the right of the operator s right calf is a push pull type When the choke knob is pushed in the choke is in the off run position When the choke is pulled out it is in the on start position Do not operate the machine in the on start position 7 4 Control Levers Not Shown These levers control the mower s speed direction and neutral lo...

Page 15: ...n Return the arms to the forward position for normal operation Your Bad Boy Mower Weighs MZ MAGNUM SERIES 585 620 lbs Weights fluctuate with the addition of accessories 8 5 As you can see by the weights of the machines you shouldn t ever try to push or pull a Bad Boy Mower by hand This could cause serious bodily injury 8 6 Hopefully you ll never need to use this section of the manual However if yo...

Page 16: ...hick 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 NEVER CHECK BLADES WHILE BLADES ARE ENGAGED SECTION 11 GREASING THE BEARINGS 11 1 Park the machine on a level surface and disengage the blade control switch 11 2 Move the motion control levers outward...

Page 17: ...ific 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 mulch clippings you should see about the availability of mulching blades or a mulching kit The type of blade installed on a new mower is a decision the retailer makes for each model of mower based o...

Page 18: ...season 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 your mower s oil at least once during the mowing season For brand new mowers change the oil after about 5 hours of operation during the initial break in period At the end of the mowing season use a ...

Page 19: ...image These bypass levers serve as a neutral for moving the mower while the engine is not running Pull the levers out and lock them into place to activate the bypass 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 the overall length of the rod slows the pump down Lengthening the rod will in...

Page 20: ...lt tensioner Tightening the two 3 4 jamnutsontheright sidewill increase the belt tension The tension should be adjusted so that there is between 50 to 55 lbs of tension on the belt This can be checked with a belt tension gauge as shown to the right PAGE 20 ...

Page 21: ...stick and open oil drain Allow oil to completely drain Make sure to have an oil pan ready to capture old oil and properly dispose old oil 2 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 shallow pan with open end up Fill with new oil until oil reache...

Page 22: ...r is located in the fuel line about 12 from the carburetor on the side of the engine Replace the filter yearly Prior to the removal of the old filter note the direction of fuel flow as indicated on the filter Have towels readily available n order to quickly remove any fuel leakage always use new hose clamps and ensure the security of the new filter by lightly pulling on each hose Always preform ma...

Page 23: ... into place and remove clamps The air cleaner is the engine s only defense against damaging foreign particles Itisveryimportantthattheair cleaner elementisinspected priortoeachuse Removetheelementandtapitssidesinorderto removedebris Do notblow the filteroutusingcompressedair Doing sowillgreatlyreducetheaircleaner s effectiveness Replace yearly more often in dusty environments Adhering to these pra...

Page 24: ...e spark plugs you will need to remove the rear engine cover This can be accomplished by removing the two carriage bolts using a 7 16 ratcheting wrench in the back as well as the two connecting the rear engine cover to the plastic shrouds Then loosen the two carriage bolts on the side and the rear engine cover will swing down for easy access to the spark plugs 2 Remove the wire on the spark plug an...

Page 25: ...the threads Allow 2 minutes for oil to be absorbed by filter material 4 Apply a thin film of clean oil to rubber gasket on new filter 5 Refer to instructions on oil filter for proper installation 6 Fill crankcase with approximately 2 quarts of new oil Level should top of indicator on dipstick 7 Reinstall oil fill dipstick and tighten securely 8 Start engine check for oil leaks Stop Engine correct ...

Page 26: ...lypullingoneach 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 Locate your fuel filter and mark the direction it is facing 2 Clamp each side of the fuel filter to minimize and gas spills 3 Remove the clips from each side of the fuel filter and remove the fuel f...

Page 27: ...atlyreducetheair cleaners effectiveness Replace yearly more often in dusty environments Adhering to these practices will help prevent loss of power and premature engine failure 3 3 Changing the air cleaner 1 Locate the air filter and lift up the cover 2 Loosen the tensioner on the right side of the air filter 3 Clean or replace paper element 4 Place the paper element back into place and tighten th...

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 Install the plug into cylinder head and torque to 16 ft lbs Be careful not to overtighten the spark plug Page 28 ...

Page 29: ... electricalcomponents If been pushed out of the relay block afuseis repeatedlyblowing contactyourBad Boydealer PAGE 29 This mower is equipped with two protective fuses a 25 amp main fuse pictured to the right and a 10 amp clutch blade engagement The main fuse is located on the left side of the unit towards the front of the engine The Clutch fuse is located just underneath the control panel In orde...

Page 30: ... wire with engine at full throttle Check the condition and connection of the relays located under the control panel Ensure that they are clean and connected Make sure that wire terminal ends have not been pushed out of the relay block If you are having issues starting your mower ensure the signal wire is connected to your starter solenoid ...

Page 31: ...PAGE 31 ...

Page 32: ...d has a grease fitting at its pivot point Grease at every engine oil change The deck belt tensioner is located at the rear of the deck and has a grease fitting on its pivot point Grease at every engine oil change top of each block Grease one time a year Grease fittings on MZ model total 8 SECTION 6 CUTTING DECK The control arm blocks have grease fittings located on the top of each block Grease one...

Page 33: ...e pulley covers 4 Remove the belt on the left side blade pulley as facing the mower Roll the belt off of the pulley Exercise caution while performing this step as fingers can easily becomecaught between the belt and pulley Deck belt installation 1 Follow steps 1 3 from the deck belt removal section 2 Run the new belt from the clutch through to the deck 3 Route the belt according to the belt routin...

Page 34: ... as fingers can easily become caught between the belt and PAGE 34 4 Ensure the belt is on every pulley and then place the belt on the bolt of the pulley on the left side and place pressure on it and roll the pulley to allow the belt to fall into place 5 Check to make sure the belt is on all the pulleys and matches the belt routing sticker 6 Place the pulley covers back onto the deck ...

Page 35: ...vel from left to right and front to back All decks should be level from left to right and have a 1 8 pitch down in the front 5 Adjust deck to ensure deck is level from left to right and has a 1 8 downward pitch from the back of the deck to the front If deck adjustments are necessary the deck hanger bolts have adjustable slots These adjusters affect the overall heightofthedeckandthelevel fromleftto...

Page 36: ...ltsinreduced cut quality andearlybeltfailure Spring tensionadjustments canbe madebyslidingtheboltshownabove forward or backwardin theslotofthedeck Belttensionshouldbe set between 60 65 lbs withthedeckatits lowestsetting Use a belt tension gauge to ensure the proper tension Your dealer or service center will have a belt tension gauge or you can buy one Part Number 041 9999 00 Blade Sharpening Thebl...

Page 37: ...rill or a wrench 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 Bolts usedhaveright handedthreads Re torquetheblade bolts to 90 110lbs The blade spindles contain a sealed ballbearing insidethetopandbottomofthespindle The bearings arereplaceable fora morecost effective repair ...

Page 38: ...Fine Thread 1 2 Nylock Nut 013 9004 00 1 4 1 14 x 5 Hex Bolt Grade 8 Zinc Yellow 018 0005 00 1 5 Caster Bearing 2009 Up 010 2000 00 2 6 Rubber Bearing Cap 014 2050 00 1 7 MZ Caster Bearing Spacer 025 0005 00 1 8 1 2 Nylock Nut 1 2 Jam 018 4010 00 1 9 1 3 8 Wheel Bearing 022 7009 00 2 10 11 x6 5 Front Tire Wheel Assembly 022 8049 00 1 11 1 3 9 2 4 8 6 5 7 Front Tire Assembly 10 10 11 ...

Page 39: ...PAGE 39 1 14 9 4 11 8 10 7 13 15 6 5 Steering Arm Assembly 17 18 Welded to Frame Items Per Side 2 3 5 5 6 5 19 20 16 12 14 9 23 22 22 21 24 ...

Page 40: ... 10 Safety Switch 077 8073 00 1 11 1 4 Press in Grease Fitting 024 6034 00 1 12 12 24x 1 2 HWH Bolt 018 1080 00 2 13 5 16 18 1 2 HWH Bolt Steering 018 2020 00 2 14 1 2 13 Mechanical Lock Nut Grade F 013 0010 00 1 15 505 Nylon Spacer 019 8054 00 1 16 Black Steering Arm Elbow Right 031 9025 70 1 17 Black Steering Arm Elbow Left 031 9020 70 1 18 Left Drive Arm Lever Housing 027 9000 00 1 19 Right Dri...

Page 41: ...PAGE 41 17 22 30 21 12 14 10 11 9 8 32 7 5 1 2 29 30 12 20 19 18 14 12 21 30 14 22 22 14 15 4 30 29 22 3 23 12 30 MZ Magnum Shroud Assembly 13 16 24 6 25 26 28 27 12 31 25 33 ...

Page 42: ...r head type F screw 030 7045 00 8 14 1 4 x 1 Hex Head Tek screw 030 7040 00 2 15 2013 Magnum Left Fender Shroud 074 4000 00 1 16 2013 Magnum Right Fender Shroud 074 4001 00 1 17 Fuel Cap 2013 Magnum 080165AE 066 0050 00 1 18 2 5 Gal EPA Tank Assy 071145AE 067 0050 00 1 19 MZ Magnum Tank Clamp 63164 072 0075 00 2 20 360 ID Plastic Washer 019 6042 00 2 21 Ratchet Fastener 040 6080 00 5 22 10 24 U Nu...

Page 43: ... 5 16 18 x 1 Carriage Bolts Zinc 018 8065 00 2 6 360 ID Plastic Washer 019 6042 00 2 7 5 16 Nylock Flange Nut 013 8049 00 2 8 3 8 x 1 1 4 Hex Bolt 018 5040 00 2 9 3 8 Lock Washer 019 5037 00 2 10 3 8 Hex Nut 013 6014 00 2 11 5 16 x 3 4 Hex Bolt 018 8063 00 4 12 5 16 Lock Washer 019 8051 00 4 13 3 8 Flat Washer 019 5029 00 2 14 1 4 Flat Washer 019 7040 00 4 15 11 10 3 9 4 13 12 6 7 8 5 1 2 14 15 12...

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

Page 45: ...050 00 1 24 5 8 x 4 Hex Bolt 018 5311 00 1 25 630 ID Plastic Washer 019 6017 00 3 26 5 8 Std NC Nylock Nut 013 7021 00 1 27 1 2 Hex Nut 013 7018 00 2 28 All Thread Pump Idler Tensioner 018 2004 00 1 29 Deck spring big diameter 034 9050 00 1 30 3 8 16 x 1 1 2 short neck bolt 018 0001 00 4 31 3 8 Flat Washer 019 5029 00 4 32 3 8 Hex Nut 013 6014 00 4 33 Brake cable for MZ 064 8057 75 1 34 10 24 X 5 ...

Page 46: ...er 019 2073 00 10 4 Deck Spacer MZ 025 0010 00 2 5 3 8 Flange Nut 013 5201 00 4 6 3 8 x 1 1 2 Hex Bolt 018 6012 00 4 7 MZ Deck Linkage Rod 028 0050 00 1 8 Deck Spacer MZ Front 025 0020 00 2 9 3 8 x 1 1 4 Hex Bolt 018 5040 00 10 10 2x2 Square Plug 014 9000 00 2 11 A Magnum Deck Lift Assembly 1 9 6 5 10 8 10 10 9 3 6 10 2 4 3 10 10 7 10 7 10 7 4 4 10 7 4 5 6 3 3 11 3 6 3 3 4 4 3 3 4 4 4 10 ...

Page 47: ...PAGE 47 DETAIL A A 23 29 24 28 30 31 25 11 26 10 17 16 18 19 11 22 21 14 13 5 1 6 9 7 2 8 20 Axle Assembly 27 11 15 12 12 3 26 12 26 11 26 4 3 2 32 33 34 35 36 37 ...

Page 48: ...uick Release Ball Joint 099 2009 00 2 17 3 8 Lock Washer 019 5037 00 4 18 3 8 Fine Threaded Jam Nut 013 6051 00 4 19 MZ Magnum Push Rod 2014 035 9000 00 2 20 EZT Left MZ Models 050 4031 00 1 21 EZT Right MZ Models 050 4030 00 1 22 Rear rim for a 48 54 022 8026 00 2 23 18 x 9 50 8 Tire Only MZ 48 54 Deck only 022 8025 00 2 24 Acorn Lug Nut 013 3000 00 8 25 5 16 Nylon Flange Nut 013 8049 00 12 26 MZ...

Page 49: ...00 1 12 Universal Inline Fuel Filter 063 6000 00 1 13 726cc Kawasaki Engine FR651V 015 0022 00 1 14 Exhaust for FR Kawasaki MZ 015 0038 00 1 15 1 2 Clear Braded Hose Priced Foot 051 8064 00 1 16 Kawasaki Oil Filter 063 8017 00 1 17 Clutch 2015 Magnum MZ 070 0050 00 1 18 3 8 Set Screw 030 6029 00 1 19 1 2 Belleville Washer 019 6020 00 1 20 7 16 20 x 4 Hex Bolt Gr 8 018 0029 00 1 21 O Ring 015 5403 ...

Page 50: ...ose 051 5401 00 1 12 Clutch 2015 Magnum MZ 070 0050 00 1 13 1 4 20 Hex Flange Nuts Zinc w Serrations 013 9001 00 1 14 3 8 Set Screw 030 6029 00 1 15 1 2 Belleville Washer 019 6020 00 1 16 7 16 x 4 Fine Thread Bolt 018 0029 00 1 17 Exhaust Gasket 015 2751 00 2 18 5 16 Lock Washer 019 8051 00 4 19 Universal Fuel Filter 063 6000 00 1 20 KT 725 KT 740 Precleaner 063 5002 00 1 21 KT 725 KT 740 Air Elem...

Page 51: ...Z Upper 039 4891 00 1 2 Rubber Discharge Chute MZ Component 210 6015 00 1 3 5 16 Nylon Flange Nut 013 8049 00 9 4 5 16 18x3 4 carriage bolt 018 8062 00 9 5 360 ID Plastic Washer 019 6042 00 2 6 Discharge Chute Bracket MZ Lower 039 4890 00 1 7 Parts 2 3 5 7 8 Make s up the Mz discharge Assembly 210 6015 98 1 8 3 2 7 1 4 8 4 4 5 5 5 6 ...

Page 52: ...Page 52 DETAIL A A 7 9 8 1 23 MZ 48 Deck Assembly 22 10 5 37 15 3 2 17 36 11 12 14 19 18 20 21 5 4 16 17 5 5 27 34 25 32 28 31 35 33 30 24 6 26 12 13 29 38 2 ...

Page 53: ...2 16 Deck Idler Bracket 039 6945 00 1 17 5 8 x 4 Hex Bolt 018 5311 00 1 18 635 ID Plastic Washer 019 6017 00 2 19 5 8 11 Nylon Insert Jam Half Nut 013 5301 00 1 20 1 2 x 2 3 4 Hex Bolt 018 6036 00 1 21 Deck Wheel 022 1000 00 2 22 Deck Wheel Bolt 018 0010 00 2 23 Spindle Assembly 037 2000 00 3 24 MZ Deck Pulley 033 4820 00 3 25 3 16 x 1 Square Key 042 0010 00 3 26 1 2 20 x 1 1 2 Grade 5 Hex Bolt Zi...

Page 54: ...PAGE 54 DETAIL A A 23 24 10 11 10 9 42 25 5 7 8 13 13 27 28 18 15 14 20 13 6 7 16 43 17 1 31 34 30 29 12 12 39 35 36 33 32 4 3 2 4 MZ Magnum 54 Deck Assembly 37 19 21 22 38 40 40 41 13 26 ...

Page 55: ... 4 Flat Washer 019 7040 00 4 19 2014 54 MZ Mag Pulley Cover 014 4855 00 2 20 Deck Idler Arm 039 6945 00 1 21 Deck Idler Assembly 039 6945 98 1 22 5 8 x 4 Hex Bolt 018 5311 00 1 23 635 ID Plastic Washer 019 6017 00 2 24 5 8 11 Nylon Insert Jam Half Nut 013 5301 00 1 25 1 4 Press in Grease Fitting 024 6034 00 1 26 Deck Wheel 022 1000 00 2 27 Deck Wheel Bolt 018 0010 00 2 28 MZ Deck Pulley 033 4890 0...

Page 56: ...s List DESCRIPTION PART NUMBER QTY ITEM Spindle Housing 037 6027 00 1 1 Spindle Spacer Component 037 6028 00 1 2 Spindle Shaft 037 6025 00 1 3 Spindle Bearing 037 6024 00 2 4 037 2000 00 Spindle Assembly 4 2 1 4 3 ...

Page 57: ...PAGE 57 ...

Page 58: ...R EXPRESS WARRANTY ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you B BAD BOY INC W...

Page 59: ...ISTRATION 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 Serial _______________________________________________________ Date of Purchase ________________________________________________ Dealer Information _______________________________________________ PAGE ...

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

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