Bad Boy REBEL Series Service Manual Download Page 3 | Manualshive

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THIS MANUAL APPLIES TO THE FOLLOWING EQUIPMENT:

BAD BOY REBEL SERIES

Rebel 54” 747cc Kohler Command [BRB54CV725]
Rebel 61” 747cc Kohler Command [BRB61CV725]
Rebel 54” 824cc Yamaha [BRB54275YA]
Rebel 61” 824cc Yamaha [BRB61275YA]
Rebel 54” FX850 Kawasaki [BRB54FX850]
Rebel 61” FX850 Kawasaki [BRB61FX850]
Rebel 61” 993cc Vanguard [BRB6136VA]
Rebel 72” 993cc Vanguard [BRB7236VA]
Rebel 61” FX1000 Kawasaki [BRB6135KA]
Rebel 72” FX1000 Kawasaki [BRB7235KA]

COMMONLY USED ITEMS AND PART NUMBERS

54” Blade

Hi-Lift Fusion

038-0001-00

Gator Blade

038-0003-00

Wave Blade

038-5220-00

61” Blade

Hi-Lift Fusion

038-6080-00

Gator Blade

038-6081-00

Wave Blade

038-6090-00

72” Blade

Hi-Lift Fusion

038-7230-00

Gator Blade

038-5400-00

Wave Blade

038-7215-00

Hydraulic Filter

063-1070-00

54” Deck Belt

041-1650-00

61” Deck Belt

041-0178-00

72” Deck Belt

041-0202-00

Pump Belt

041-8411-00

Oil Filter

Vanguard 993cc

063-8018-00

824cc Yamaha

015-0053-02

Kawasaki FX

063-8017-00

Kohler Command

063-5400-00

Air Filter

Inner Filter

063-8020-00

Outer Filter

063-8019-00

Spark Plug

Vanguard 993cc

015-8000-00

Kawasaki FX

015-8001-00

Kohler Command

018-8000-00

824cc Yamaha

015-0053-06

Motor Oil

10W-30 Motor Oil -

Bad Boy Synthetic Blend Motor Oil Recommended. (Approximately 2 Quarts)

085-6015-00

Hydraulic Oil

20W-50 Motor Oil-

Bad Boy Hydrostatic Oil Recommended (Approximately 2.5 Quarts/Transaxle)

085-6000-00

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Summary of Contents for REBEL Series

Page 1: ...2021 Rebel...

Page 2: ...tation Section 5 Page 10 Troubleshooting and FAQ Section 6 Page 12 Controls Section 7 Page 13 Moving In operable Mower Section 8 Page 14 Instrumentation Section 9 Page 14 Mower Blade Maintenance Secti...

Page 3: ...8 6080 00 Gator Blade 038 6081 00 Wave Blade 038 6090 00 72 Blade Hi Lift Fusion 038 7230 00 Gator Blade 038 5400 00 Wave Blade 038 7215 00 Hydraulic Filter 063 1070 00 54 Deck Belt 041 1650 00 61 Dec...

Page 4: ...ordering parts 1 Part number 2 Serial number All warranty repair and service must be handled through your authorized Bad Boy dealer To locate the nearest dealer go to the website listed above and cli...

Page 5: ...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 mower without the discharge chute grass catcher or...

Page 6: ...changes in speed or direction could cause the mower to roll over 2 32 Use extra care while operating the mower with grass catchers or other attachments they can affect the stability of the mower Do n...

Page 7: ...If this is not possible then refuel such equipment with a portable container rather than from a gasoline dispenser nozzle 2 55 Never fill gasoline containers inside a vehicle or on a truck or trailer...

Page 8: ...tion Attempt to start the mower with the PTO switch in the OFF position The engine should not start Continue test 2 76 On a level surface disengage the parking brake and place lever arms to their outw...

Page 9: ...s will lock into place and must be in this position to start the mower 3 5 Put PTO switch in the OFF position 3 6 If your mower has been equipped with a ROPS Roll Over Protection System then you must...

Page 10: ...st Check air and fuel filter more often in dusty conditions DealerGet maintenance performed at a registered dealership SECTION 5 MOWER STORAGE TRANSPORTATION 5 1 Keep the mower from collecting debris...

Page 11: ...the blades won t engage A Make sure the safety switch is plugged in on the bottom of the seat Check the underside of the blade power switch to ensure the plug is secure at the switch Also check PTO fu...

Page 12: ...vers These levers control the mower s speed direction and neutral lock These levers are used to steer accelerate decelerate and change direction 7 5 Blade Engage Switch This switch engages the blades...

Page 13: ...h to load on a trailer for transporting Your Mower Weighs REBEL SERIES 1180 1310 lbs Weights fluctuate with the addition of accessories 8 3 If it becomes necessary to move an inoperable mower the driv...

Page 14: ...ing underneath your mower 9 6 ALWAYS wear thick gloves when handling blades 9 7 ALWAYS check for blade damage if mower strikes rock branch or other objects that could potentially damage the blade SECT...

Page 15: ...l designed for a more specific 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 us...

Page 16: ...ng 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 ch...

Page 17: ...C OIL AND FILTER HYDRO GEAR 4400 TRANSAXLE 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 t...

Page 18: ...e running slowly move the handlebars in the forward and reverse directions 5 to 6 times Stop engine check the oil level and add oil as required 4 It may be necessary to repeat steps 2 and 3 until the...

Page 19: ...jam nuts and either tighten for more belt tension or loosen for less belt tension The tension should be adjusted so that there is between 60 and 65 lbs of tension on the belt and recheck belt tension...

Page 20: ...er the oil filter to capture any oil and remove filter Reinstall oil drain cap and tighten 3 Place new filter in shallow pan with open end up Fill with new oil until oil reaches the bottom of the thre...

Page 21: ...e vicinity of any maintenance activities CHANGING YOUR FUEL FILTER 1 Locate your fuel filter and note the direction of fuel flow 2 Clamp the fuel line on both sides of the fuel filter using fuel line...

Page 22: ...effectiveness Reference section 4 for the recommended replacement interval of the air cleaner Adhering to these practices will help prevent loss of power and premature engine failure CHANGING THE AIR...

Page 23: ...park plug cap and use an appropriate socket to remove the spark plug 3 Check the gap of the spark plug by using a feeler gauge and set gap to the recommend value in the engine s service manual 4 If th...

Page 24: ...ates a significant fire hazard and can cause severe damage to the mower s electrical components If a fuse is repeatedly blowing contact your Bad Boy dealer To check for proper charging 13 6 14 2 volts...

Page 25: ...PAGE 25 ELECTRICAL SYSTEM CONTINUED WIRING DIAGRAM For a larger version of the below diagram please visit badboymowers com and click the parts manuals section Fig 26...

Page 26: ...orque rear wheel lugs to 65 75ft lbs Re torque at every oil change and before each use SECTION 16 GREASE LOCATIONS There are two grease fittings located on each of the two turnbuckles 4 total Grease a...

Page 27: ...Raise the deck to its highest position If needed loosen the deck belt tensioner to its weakest installed position 3 Take off both pulley covers and route the belt by following the belt route decal Ve...

Page 28: ...ing height When tensioning a new belt recheck belt tension after 1 2 hour of cutting time Use a belt tension gauge to ensure the proper tension Your dealer or service center will have a belt tension g...

Page 29: ...proximately 3 1 2 off the ground to achieve the proper 1 4 pitch down in the front it may be necessary to use some 1 4 spacers under the rear of the deck as shown in Fig 41 4 Using a pair of 3 4 wrenc...

Page 30: ...though component damage potential may be increased The bolt has right handed threads Re torque the blade bolts to 90 110 ft lbs upon re installation The blade spindles contain a sealed bearing inside...

Page 31: ...e Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Per...

Page 32: ...nc within 30 days of the retail purchase date C Warranty claims requiring parts returned will be settled upon return of parts to Bad Boy for inspection D All warranty issues must be handled through an...

Page 33: ...ANTY REGISTRATION 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 r...

Page 34: ...PAGE 34 2021 Commercial...

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