Bad Boy 2013 INSTINCT Owner'S Manual Download

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INSTINCT

OWNER'S MANUAL

630839

ISSUED SEPTEMBER 2012

Summary of Contents for 2013 INSTINCT

Page 1: ...INSTINCT OWNER S MANUAL 630839 ISSUED SEPTEMBER 2012...

Page 2: ...d Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Servi...

Page 3: ...gineering 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 BB...

Page 4: ...tteries by setting the RUN MAINTENANCE STORAGE switch located under the seat on the passenger side to the MAINTENANCE STOR AGE position The batteries must be cleaned and all deposits neutralized and r...

Page 5: ...his manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SECTION PAGE NO SAFETY 1 1 GENERAL SPECIFICATIONS 2 1 INTRODUCTION 3 1...

Page 6: ...Page iv TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Page 7: ...oughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO GENERAL 1 2 NOTICES CAUTIONS WARNINGS AND DANGERS 1 2 GENERAL OPERATION 1 3 MAIN...

Page 8: ...customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dealer has rea son to believe may be operated in personal transportation appl...

Page 9: ...NANCE ALWAYS Maintain the vehicle in accordance with the manufacturer s periodic service schedule Ensure that repairs are performed by those that are trained and qualified to do so Follow the manufact...

Page 10: ...ycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchange...

Page 11: ...l expel electrolyte and result in component damage 1 quart 1 liter Clear Water 2 Teaspoons 10 ml Sodium Bicarbonate Baking Soda Plastic Spray Bottle Spray top and sides of batteries with a solution of...

Page 12: ...batteries are recyclable Return batteries to distributor manufacturer or lead smelter for recycling For neutralized spills place residue in acid resistant containers with absorbent material sand or e...

Page 13: ...to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO INSTINCT VEHICLE SPECIFICATIONS 2 2 INSTINCT VEHICLE DIMENSIONS 2...

Page 14: ...n cm Vehicle load capacity lb kg Wheel Base in cm Gross Axle Weight Rating F lb kg Gnd Clearance Frame in cm Gross Axle Weight Rating R lb kg Gnd Clearance Differential in cm Outside Clearance Circle...

Page 15: ...particular attention to all Notices Cautions Warnings and Dangers 2 VEHICLE DIMENSIONS Maximum Recommended Side Tilt 25 or 14 Max Maximum Recommended Ramp Grade 25 or 14 Max 76 5 194 3 cm 110 279 5 cm...

Page 16: ...Page 2 4 SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Page 17: ...ATOR CONTROLS 3 2 Key Switch Direction Selector 3 2 Accelerator Pedal 3 2 Brake Pedal 3 2 Park Brake 3 2 Differential Lock 3 2 FEATURES 3 3 State of Charge Meter 3 3 Headlight 3 3 Winch Switch 3 3 12...

Page 18: ...ition the direction selector must be set to neu tral The switch should always be left in N neutral when vehicle is unattended 3 Accelerator Pedal With the key switch ON depressing the accelerator peda...

Page 19: ...he right of the brake light The switch has two positions ON and OFF In the ON posi tion the headlights and all dash panel lights will be on the OFF position will turn off the lights 4 Max Range Max Sp...

Page 20: ...eptacle for the electric battery pack is located in the seat wrap panel below the seat on the driver side Always check to be sure the receptacle is free from dirt and debris before connecting the char...

Page 21: ...bber pads to protect the head when driving over rough terrain 13 Side Nets Side nets are a standard safety feature provided with the vehicle and must be properly secured before operating vehicle 14 Re...

Page 22: ...Page 3 6 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Page 23: ...O VIN AND SERIAL NUMBER LOCATION 4 2 BEFORE INITIAL USE 4 2 PORTABLE CHARGER 4 3 Using the Charger 4 4 OPERATING THE VEHICLE 4 5 COMMON SENSE OPERATION 4 5 ENVIRONMENTAL CONCERNS 4 6 STARTING AND DRIV...

Page 24: ...in a safe speed when driving up or down a hill Use service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control To prevent loss of c...

Page 25: ...er charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces PORTABLE CHARGER Use charger ONLY on 72 volt battery syst...

Page 26: ...ord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The DC plug can be damaged by driving over or catching the cord on t...

Page 27: ...o reduce the possibility of severe injury or death resulting from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for seating capacity Depressing acc...

Page 28: ...e injury or death while driving be aware of the following Environmental hazards such as steep slopes overhanging limbs etc Danger of fire when vehicle is operated over dry combustible organic material...

Page 29: ...SHIELD if equipped The top does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects Remove windshield and store secure...

Page 30: ...is affixed to the inside of the bed on the front panel This label must be understood and observed at all times for safe operation of the vehicle The dump bed is limited to a maximum load of 500 lbs Th...

Page 31: ...ch pull straight only Do not permit the cable to contact the side of the drum Do not pull vehicle at an angle If the vehicle is pulled at an angle it could turn over causing severe injury or death to...

Page 32: ...k around the winch drum or the winch cable while it is under tension Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation When operating winch take up sla...

Page 33: ...Page 4 11 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers OPERATION 4...

Page 34: ...Page 4 12 OPERATION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Page 35: ...l Installation 5 6 Unidirectional Tires 5 6 Wheel alignment 5 6 BRAKES 5 8 Master Cylinder 5 8 Bleeding Brake System 5 8 Parking Brake Adjustment 5 9 POWERTRAIN 5 9 AXLE 5 9 Checking the Lubricant Lev...

Page 36: ...this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Page 5 2 5 HARDWARE 5 18 CAPACITIES AND REPLACEMENT PARTS 5 18 PERIODI...

Page 37: ...commercial plastic pol ish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution appl...

Page 38: ...ting process When lifting the vehicle position the jacks and jack stands at the areas indicated Remove payload from vehicle before lifting No person s should be in or on the vehicle while lift ing To...

Page 39: ...will have to be replaced WHEELS AND TIRES A tire explosion can cause severe injury or death Never exceed the inflation pressure rating on the tire sidewall To reduce the possibility of tire explosion...

Page 40: ...rtant to follow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug...

Page 41: ...f fluid leaks are noticed or the brake pedal seems soft check the fluid level immediately If the brake pedal is soft the brake system should be bled to remove air from the brake lines Instruc tions fo...

Page 42: ...ng the following procedure a Build pressure in the brake system if possible by slowly pumping the brake pedal b Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal...

Page 43: ...Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion It is in the best interest of both vehicle owner and service technician to ca...

Page 44: ...zed with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being spilled fr...

Page 45: ...ery under the cowl is supplied with a battery fill system tube that is located in the passenger side glove box the remaining batteries are accessed by raising an removing the seat bottom and the batte...

Page 46: ...es exposed to air will be ruined beyond repair Also avoid filling with too much water which will result in electrolyte being forced out of the battery due to gassing and a decrease in volume of the el...

Page 47: ...the battery cells The watering device should only be used if the electrolyte level is less than 1 2 13 mm above top of plates The electrolyte in a storage battery is an acid solution which can cause s...

Page 48: ...1 quart 1 liter of water In addition to the batteries special attention should be paid to metallic components adjacent to the batteries these should also be sprayed with the baking soda solution Most...

Page 49: ...itions the battery must be fully charged to pre vent the possibility of freezing A fully charged battery will not freeze in temperatures above 75 F 60 C Although the chemical reaction is slowed in col...

Page 50: ...two distinct reasons First a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer s warranty...

Page 51: ...tery and is a sign that the battery is near ing the end of its life 2 Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without con tacting the top or bo...

Page 52: ...are is Grade 2 CAPACITIES AND REPLACEMENT PARTS ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware in ac...

Page 53: ...d before charging add only enough water to cover any exposed plates and fill after charging C A C A C A C A Brakes check fluid level in master cylinder 3000 mi 5000 km Brakes smooth operation of pedal...

Page 54: ...Page 5 20 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5...

Page 55: ......

Page 56: ...For parts and repair contact your local dealer To locate a local dealer please go online to our website www BADBOYBUGGIES COM 2011 E Z GO Division of Textron Inc This manual may not be reproduced in w...

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