Bad Boy Outlaw 6100 Owner'S, Service & Parts Manual Download Page 64

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PAGE

Parts List

DESCRIPTION

PART NUMBER

QTY

ITEM

Outlaw Transaxle Cross Brace

203-0100-00

1/2" x 1 1/2" Hex Bolt

018-5006-00

ZT - 5400 - Left (Extreme Only)

050-7000-00

1/2" x 1" Hex Bolt

018-2030-00

ZT - 5400 - Right (Extreme Only)

050-7001-00

Acorn Lug Nut

013-3000-00

24 x 12 - 12 Tire Pro Maxxis

022-5349-00

12x12" Black Wheel For 2015 Outlaw

022-4070-00

2015 Outlaw Brake Adapter (4400 Transaxles Only)

039-2135-00

5/16 x 1 1/4 Hex Bolt (4400 Transaxles Only)

018-2006-00

5/16" Flange Nut Zinc W/Serrations (4400 Transaxles Only)

013-8049-00

1/2" Lock Washer

019-5007-00

4400 Transaxle - Left (Base Outlaw)

050-1000-00

4400 Transaxle - Right (Base Outlaw)

050-1050-00

24 x 12 - 12 Tire and Black Wheel Assembly

022-4050-00

Hydro Filter for Outlaw Extreme

063-1060-00

4400 Hydro Filter for Outlaw

063-1070-00

Fan/Pulley Kit for Outlaw

050-2073-00

Summary of Contents for Outlaw 6100

Page 1: ...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 OUTLAW OUTLAW EXTREMEMOD...

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 0001 00 Gator Blade 038 0003 00 Wave Blade 038 5220 00 72 041 0202 00 61 041 0178 00 54 041 1650 00 041 8411 00 Pre Cleaner 063 5006 00 063 5005 00 Spark Plug Vanguard 993cc Vangaurd 810cc Kawas...

Page 4: ...ce Only 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 orderin...

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: ...actuator 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 machin...

Page 9: ...as not been started 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 sl...

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: ...gine 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...

Page 14: ...manually operate the engine choke 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 position Do not operate the mach...

Page 15: ...ach require a quarter turn to allow for proper bypass 8 4 Your Bad Boy Mower Weighs OUTLAW SERIES 1180 1310 lbs Weights fluctuate with the addition of accessories 8 5 As you can see by the weights of...

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: ...ulch 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 oper...

Page 19: ...Outlaw 4400 1 Place an oil drain pan 12 or more in diameter and 8 qt capacity is optimal beneath the oil filter Remove the oil filter cover from the transaxle to drain the oil Remove the O ring from t...

Page 20: ...directions 5 to 6 times as air is purged from the unit the oil level will drop 3 With the bypass valve closed and the engine running slowly move the directional drive arms in the forward and reverse...

Page 21: ...e containers and deliver to an approved recycling collection facility 7 Proceed to the purge procedure below Purging Procedure Due to the effects air has on the efficiency in hydrostatic drive applica...

Page 22: ...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 pivot join...

Page 23: ...on the belt Use a wrench to loosen the jam nuts and either tighten for more belt tension or loosen for less belt tension The belt tension should be set to 60 65 lbs for the Outlaw Use a belt tension...

Page 24: ...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 25: ...r 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 filter 4 Place the new fu...

Page 26: ...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 27: ...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 sh...

Page 28: ...the new filter by lightly pulling on each 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...

Page 29: ...ty 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 cleane...

Page 30: ...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 31: ...ight 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 lb 3...

Page 32: ...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 engines on...

Page 33: ...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 34: ...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 Place new filter in shall...

Page 35: ...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 36: ...greatlyreducetheair cleaner s 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 ai...

Page 37: ...k 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 The Kohler Command Pro EFI ECV870 has a different spark plug...

Page 38: ...the 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...

Page 39: ...ch 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 onl...

Page 40: ...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 41: ...round 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 wit...

Page 42: ...the new filter by lightly pulling on each 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...

Page 43: ...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 2...

Page 44: ...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 45: ...d and can cause severedamage to the mowers electrical components Ifafuseis repeatedlyblowing contact yourBad Boy dealer Onmostmodels thered wirecomingoutofthe engineis thechargingwirefromthealternator...

Page 46: ...PAGE 46...

Page 47: ...que turntheforkitselftoensurenodamage isdonetothebearing Thisoperationisonlynecessaryifa repair requires it Torquerearwheellugsto65 75ft lbs Re torqueateveryoil change and check at every mowing There...

Page 48: ...ivotpoint Greaseateveryengineoil change The deck belt tensioner is located at the rear of the deck and has a grease fitting on its pivot point Greaseateveryengine oil change The control arm blocks hav...

Page 49: ...gerscaneasily become caught betweenthebeltand 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...

Page 50: ...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 bolts on th...

Page 51: ...sion shouldbe70 75lbs for a 54 deck and 75 80 lbs for a 61 and 72 deck withthedeckatits lowest setting Use a belt tension gauge to ensure the proper tension Your dealer or service center will have a b...

Page 52: ...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 Bolts usedhaveright handedthreads Re torquetheblade bolts to 90 11...

Page 53: ...5 Bearing 010 7001 00 2 6 Front Wheel Spanner 025 5202 00 1 7 1 3 8 Wheel Bearing 022 7009 00 2 8 1 Fine Thread 1 2 Nylock Nut 013 9004 00 1 9 1 Lock Washer 019 3000 00 1 10 Spring Cap Cover 014 8047...

Page 54: ...PAGE 54 10 13 11 23 15 15 26 4 7 6 19 3 1 3 5 8 9 33 8 35 8 28 16 9 22 17 18 21 18 17 27 20 34 14 12 26 24 25 Outlaw Drive Arms Welded to Frame 30 31 2 29 32 2 3 1 3 31...

Page 55: ...8 15 3 8 x 1 1 4 Hex Bolt 018 5040 00 2 16 5 16 Flange Nut 013 9002 00 4 17 10mm Damper Ball Stud Steering 018 2050 00 4 18 1 2 13 Mechanical Lock Nut Grade F 013 0010 00 2 19 2013 Drive Lever Housing...

Page 56: ...PAGE 56 DETAIL A DETAIL B A B 29 35 18 33 7 8 9 6 3 2 12 1 19 34 20 10 23 24 22 21 4 5 27 28 25 32 31 26 30 15 17 16 17 14 14 13 7 8 9 13 14 Outlaw Gas Tank Assemblies 11 36 34 17 16 37...

Page 57: ...8068 00 2 15 3 16 Vinyl Clamp 072 8070 00 6 16 1 4 Vinyl Tubing 051 8072 00 3 17 Outlaw 2015 Fuel Tank Right 067 1180 50 1 18 Analog Control Panel Outlaw 079 3360 00 1 19 Ignition Switch 077 8076 00 1...

Page 58: ...PAGE 58 DETAIL A A 21 13 12 14 15 19 19 19 30 20 22 18 14 13 17 16 23 6 5 25 2 24 3 4 2 8 9 7 1 3 10 11 2 26 27 28 29 31...

Page 59: ...Zinc w Serrations 013 9001 00 4 13 1 4 20 x 3 4 GR 5 Hex Bolts Zinc 018 8052 00 4 14 Red Battery Cable Alternator to Starter Cable 086 0003 00 1 15 12 in red battery cable 064 5301 00 1 16 Battery 06...

Page 60: ...OUTLAW A B C 43 41 38 39 40 42 33 32 43 35 36 34 37 54 1 19 27 25 23 22 24 21 20 28 26 58 5 10 9 8 11 2 3 44 24 47 31 45 5 6 7 30 55 29 49 50 13 14 12 18 15 16 17 4 46 20 28 DETAIL C OUTLAW EXTREME 2...

Page 61: ...00 1 27 1 2 Nylock Nut 1 2 Jam 018 4010 00 2 1 Extreme 28 200 lb Gas Spring 54 Deck outlaw 087 5400 00 1 29 10mm Damper Ball Stud Steering 018 2050 00 2 30 5 16 Flange Nut 013 9002 00 3 31 3 8 x 1 1 4...

Page 62: ...11 9 5 4 9 7 6 41 32 34 32 42 45 9 4 4 9 14 33 44 37 25 38 35 36 19 64 20 16 53 23 22 1 39 9 5 4 18 43 25 6 6 21 17 16 14 15 28 31 30 27 26 14 17 15 16 21 6 2 8 3 29 40 13 25 24 6 25 46 47 50 52 9 51...

Page 63: ...2 31 Brake Cable Adapter Bracket 039 0150 00 1 32 12 24x 1 2 HWH Bolt 018 1080 00 2 33 5 16 18 Nylock Jam Nut 1 2 Nut 013 9005 00 2 34 Brake Handle Cam Over 069 1000 00 1 35 Rubber Brake Grip cZT ZT...

Page 64: ...8 2015 Outlaw Brake Adapter 4400 Transaxles Only 039 2135 00 2 9 5 16 x 1 1 4 Hex Bolt 4400 Transaxles Only 018 2006 00 4 10 5 16 Flange Nut Zinc W Serrations 4400 Transaxles Only 013 8049 00 4 11 1...

Page 65: ...049 00 3 14 Universal Inline Fuel Filter 063 6000 00 1 15 5 16 Set Screw 030 0050 00 1 16 Black Boot For Ground Cable 103 5400 00 1 17 Ground Cable 064 0030 00 1 18 M8x1 20x20MM Hex head bolt 018 5321...

Page 66: ...11 Black Boot For Ground Cable 103 5400 00 1 12 5 16 Lock Washer 019 8051 00 4 13 1 1 8 Flat Spacer 019 6029 00 1 14 7 16 Lock Washer 019 8053 00 1 15 7 16 x 2 1 2 Hex Bolt 018 5300 00 1 16 Clutch Ass...

Page 67: ...bolt 018 1075 00 5 15 Ground Cable 086 0005 00 1 16 Pump Belt 041 5048 00 1 17 Canister Air Filter Outer 063 8019 00 1 18 25 26 HP Kohler Fuel Filter 063 5001 00 1 19 Harness Adaptor 824cc EFI Kohler...

Page 68: ...er 063 8019 00 1 13 Canister Air Filter Inner 063 8020 00 1 14 7 16 Lock Washer 019 8053 00 1 15 7 16 x 2 1 2 Hex Bolt 018 5300 00 1 16 Clutch Assembly 070 1000 00 1 17 Clutch Pigtail 070 2000 00 1 18...

Page 69: ...r Air Filter Outer 063 8019 00 1 14 M8 1 25 Zinc Nut 013 0075 00 4 15 Ground Cable 086 0005 00 1 16 7 16 Lock Washer 019 8053 00 1 17 7 16 x 2 1 2 Hex Bolt 018 5300 00 1 18 Clutch Assembly 070 1000 00...

Page 70: ...19 00 1 14 14 mm Oil drain Hose 993cc Vanguard 051 5402 00 1 15 1 1 8 Flat Spacer 019 6029 00 1 16 Pump Belt 041 5048 00 1 17 7 16 Lock Washer 019 8053 00 1 18 7 16 x 2 1 2 Hex Bolt 018 5300 00 1 19 C...

Page 71: ...TAIL D A B C D 4 43 41 42 44 49 8 4 52 7 47 4 59 58 58 32 57 61 63 56 60 16 15 35 34 45 13 12 20 18 17 28 24 23 46 26 25 27 22 26 2 3 21 37 30 4 29 14 1 5 31 54 4 5 4 51 50 47 9 10 11 38 39 40 36 6 54...

Page 72: ...28 Deck Wheel Bolt 018 0010 00 6 29 Anti Scalp Rollers 022 1000 00 6 30 1 3 4 Pulley Spacer 025 5339 00 1 31 1 2 x 4 Bolt Grade 8 018 5019 00 4 32 5 Spindle Deck Pulley 033 6003 00 3 33 3 8 x 1 1 4 He...

Page 73: ...DETAIL D A B C D 8 50 7 53 4 42 45 43 44 4 4 58 57 48 60 57 33 56 63 55 59 14 4 30 31 38 1 37 26 27 3 22 2 28 23 24 25 29 47 5 32 61 4 5 6 61 9 10 11 4 52 51 40 41 39 17 20 34 19 18 12 13 21 46 36 35...

Page 74: ...ck Flange Nut Zinc 013 8049 00 7 29 Deck Wheel Bolt 018 0010 00 6 30 Anti Scalp Rollers 022 1000 00 6 31 1 3 4 Pulley Spacer 025 5339 00 1 32 1 2 x 4 Bolt Grade 8 018 5019 00 4 33 6 1 4 Drive Pulley 0...

Page 75: ...DETAIL D A B C D 33 30 29 28 32 27 12 18 31 11 45 4 36 62 4 5 3 62 10 9 8 3 2 46 50 39 38 15 3 17 16 34 35 1 20 19 21 61 44 26 13 14 24 23 22 25 6 52 3 3 48 7 41 3 42 40 43 3 58 57 46 57 37 60 64 55 5...

Page 76: ...210 6005 00 1 29 60 Discharge Lower Bracket 039 4863 00 1 30 360 ID Plastic Washer 019 6042 00 2 31 5 16 x 1 1 4 Carriage Bolt 018 4703 00 5 32 5 16 Nylock Flange Nut Zinc 013 8049 00 7 33 Deck Wheel...

Page 77: ...Housing 037 4001 00 1 1 4000 Series Spindle Spacer 037 4002 00 1 2 Locking Collar w 1 4 20 Set Screw 037 9050 00 1 3 Spindle Dust Cap 037 8002 00 2 4 ZT AOS Spindle Shaft 037 6026 00 1 5 Bearing 6206...

Page 78: ...tled 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...

Page 79: ...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 80: ...For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501...

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