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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

OUTLAW

EXTREME

MODEL

Содержание Mowers OUTLAW

Страница 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 2017 12 6 OUTLAW EXTREMEMODEL...

Страница 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...

Страница 3: ...ift Fusion Gator Blade Wave Blade 038 7230 00 038 5400 00 038 7215 00 Hydraulic Filter 275 Yamaha Kawasaki FX751v Kohler Confidant 063 1070 00 Vanguard 993cc Kawasaki FX850v 063 8014 00 54 Deck Belt 0...

Страница 4: ...SERVICE Only Bad Boy replacement parts are to be used on your mower Replacement parts are available through your local Bad Boy Mowers Dealer Remember to always provide the following information when...

Страница 5: ...bsolutely necessary Always look down 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 ric...

Страница 6: ...he machine to roll over 2 31 Use extra care while operating machine with grass catchers or other attachments they can affect the stability of the machine Do not use on steep slopes 2 32 Do not try to...

Страница 7: ...he machine indoors 2 50 Do not store machine near open flame or source of ignition such as a water heater or furnace 2 51 Remove gas powered equipment from the truck or trailer and refuel it on the gr...

Страница 8: ...be tested frequently Following are instructions to test these very important safety precautions Note the operator must be seated properly on the machine during these tests and the engine should have b...

Страница 9: ...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 sliding the th...

Страница 10: ...hour or annually whichever comes first Check air and fuel filter more often in dusty conditions DealerGet maintenance performed at a registered dealership SECTION 5 MOWER STORAGE TRANSPORTATION 5 1 K...

Страница 11: ...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...

Страница 12: ...t engage 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 Also check PTO fuse underneath operator console...

Страница 13: ...the right of the operator s left 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 th...

Страница 14: ...dition of accessories 8 3 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 4 Hopefully you ll never...

Страница 15: ...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 S...

Страница 16: ...re 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 using a 2 1 blade and...

Страница 17: ...s 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 a...

Страница 18: ...ER 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 fro...

Страница 19: ...ight Fill the transaxle with new 20W 50 through the hydraulic reservoir tank until the oil reaches the oil fill vent port 5 Install the top oil fill vent port plug and continue filling the system with...

Страница 20: ...h 4400 transaxles the bypass valve is located on top of the unit next to the expansion tank port as shown in 1B 3 The bypass valves on either model are opened by turning the valve a quarter of a turn...

Страница 21: ...r loosen for less belt tension The tension should be adjusted so that there is between 60 to 65 lbs of tension on the belt This can be checked with a belt tension gauge as shown to the right Use a bel...

Страница 22: ...located on 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 Tor...

Страница 23: ...he security of 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...

Страница 24: ...veness Replace yearly more often in dusty environments Adhering to these practices will help prevent loss of power and premature engine failure CHANGING THE AIR CLEANER 1 Unlock the air cleaner cover...

Страница 25: ...k plug and use a 5 8 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 rep...

Страница 26: ...se old oil 2 The oil filter is located on 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 surfac...

Страница 27: ...ills 3 Remove the clops from each side of the fuel filter and remove the filter 4 Place the new fuel filter in the same direction as the old one and place the clips back into place and remove clamps T...

Страница 28: ...ug and use a 13 16 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 repla...

Страница 29: ...on 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 1...

Страница 30: ...sure the security of 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 mainte...

Страница 31: ...atly reduce the air cleaner s effectiveness Replace yearly more often in dusty environments Adhering to these practices will help prevent loss of power and premature engine failure CHANGING THE AIR CL...

Страница 32: ...e 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 The Kohler Command Pro EFI ECV870 has a dif...

Страница 33: ...se old oil 2 The oil filter is located on 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 surfac...

Страница 34: ...ills 3 Remove the clops from each side of the fuel filter and remove the filter 4 Place the new fuel filter in the same direction as the old one and place the clips back into place and remove clamps T...

Страница 35: ...ug and use a 13 16 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 repla...

Страница 36: ...d on 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...

Страница 37: ...ensure the security of 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 main...

Страница 38: ...so will greatly reduce the air cleaner s effectiveness Replace yearly more often in dusty environments Adhering to these practices will help prevent loss of power and premature engine failure CHANGIN...

Страница 39: ...lug and use a 5 8 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 replac...

Страница 40: ...rd and can cause severe damage to the mowers electrical components If a fuse is repeatedly blowing contact your Bad Boy dealer On most models the red wire coming out of the engine is the charging wire...

Страница 41: ...PAGE 41 ELECTRICAL SYSTEM CONTINUED WIRING DIAGRAM...

Страница 42: ...d check at every mowing There are two grease zerks located on each of the two turnbuckles 4 Total Grease at every oil change The pump belt tensioner is located under the engine and has a grease fittin...

Страница 43: ...s fingers can easily become caught between the belt and pulley DECK BELT INSTALLATION 1 Use proper safety precaution when performing procedures 2 Raise the deck to its highest position 3 Take off both...

Страница 44: ...se are the lower bolts in the slots of the deck as shown Do not loosen the upper bolts that attach the deck hangers to the actuator lift bars 6 The deck is now loose from the frame and movement of the...

Страница 45: ...Belt tension should be 60 65 lbs with the deck at its lowest setting 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...

Страница 46: ...ill or a wrench and an extension to gain more leverage You might need to put a 3 4 wrench on top of the pulley bolt to keep the blade from spinning Bolts used have right handed threads Re torque the b...

Страница 47: ...PAGE 47...

Страница 48: ...e Bore Front Rim 6 1 013 9004 00 1 Fine Thread 1 2 Nylock Nut Parts List ITEM QTY PART NUMBER DESCRIPTION 7 2 010 1050 00 Caster Bearing 2016 1641 Bearing 8 1 025 0003 00 2016 Front Bearing Spacer 9 1...

Страница 49: ...Hex Flange GR G ZC 19 2 087 0001 00 Steering Damper 20 2 013 6014 00 3 8 16 Hex Nuts Zinc 21 1 031 9017 70 Upper adjuster Steering Arm Left 22 1 031 9014 70 Lower Adjuster Steering Arm Left 23 2 018...

Страница 50: ...A DETAIL B A B PARTS SECTION OUTLAW GAS TANK ASSEMBLIES PAGE 50 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 13 14 11 36 34 17 37 13 13 13 16 22 1...

Страница 51: ...0 3 16 Vinyl Clamp 17 3 051 8072 00 1 4 Vinyl Tubing 18 1 067 1180 50 Outlaw 2015 Fuel Tank Right 19 1 079 3360 00 Analog Control Panel Outlaw 20 1 077 8076 00 Ignition Switch 21 1 056 8058 00 PTO Swi...

Страница 52: ...PAGE 52 10 54 12 11 9 5 4 9 7 6 41 32 34 32 42 45 9 4 4 9 14 33 44 37 38 35 36 19 65 20 16 55 23 39 18 43 25 6 6 21 17 16 14 15 28 31 30 27 26 14 17 15 16 2 8 3 29 40 13 25 24 25 46 47 50 52 9 51 5 4...

Страница 53: ...1 2 Nut Parts List ITEM QTY PART NUMBER DESCRIPTION 35 1 069 1000 00 Brake Handle Cam Over 36 1 069 7000 00 Rubber Brake Grip cZT ZT 2013 37 1 032 5053 00 Bronze Bushing SF 1220 8 38 1 013 0009 00 3...

Страница 54: ...DETAIL A PARTS SECTION OUTLAW FLOORBOARD BATTERY PAGE 54 A 27 18 13 12 18 15 20 19 19 3 17 13 19 2 16 12 17 18 14 21 22 23 3 3 11 10 1 2 2 6 5 8 9 7 2 4 3 24 25 26 19 1 30 29 28...

Страница 55: ...86 0003 00 Red Battery Cable Alternator to Starter Cable Kohler Engine Only 15 1 064 5301 00 12 in red battery cable 16 1 068 8049 00 Battery 17 2 103 5400 00 Black Boot For Ground Cable 18 1 3 Kohler...

Страница 56: ...8 3 5 6 5 4 38 22 36 19 35 2 9 10 5 21 41 22 20 39 40 7 1 11 37 24 16 13 13 15 11 17 12 18 34 33 26 25 27 32 34 29 30 31 30 DETAIL B OUTLAW EXTREME DETAIL B OUTLAW 58 58 55 54 59 64 62 57 60 60 65 63...

Страница 57: ...aided Hose 32 2 066 5050 00 Hydraulic Tank Cap 33 4 019 8040 00 1 4 x 3 4 Carriage Bolt 34 6 013 2050 00 1 4 20 Nylon Insert flange Nut 35 1 026 0013 00 Outlaw Deck Lift Pedal 36 1 040 5000 00 Pull Pi...

Страница 58: ...54 DECK PAGE 58 4 41 44 64 42 42 61 8 4 51 7 58 57 57 32 56 60 55 59 16 15 35 34 45 13 12 20 18 17 33 19 54 52 4 47 43 41 57 58 4 57 32 24 28 23 65 27 22 26 25 3 21 2 28 1 37 36 14 4 18 30 29 4 46 29...

Страница 59: ...00 1 2 x 4 Bolt Grade 8 33 3 033 6006 00 5 25 Deck Spindle Pulley Parts List ITEM QTY PART NUMBER DESCRIPTION 34 12 018 5040 00 3 8 x 1 1 4 Hex Bolt 35 3 038 0001 00 54 Deck Fusion Blade For Outlaw 36...

Страница 60: ...N OUTLAW 61 DECK PAGE 60 8 50 7 53 4 42 45 64 43 44 4 4 58 57 48 60 57 33 56 55 59 17 20 34 19 18 12 13 21 46 36 35 15 16 54 48 47 30 31 18 4 5 32 61 4 4 61 6 5 9 10 48 11 51 52 4 49 62 40 41 39 1 38...

Страница 61: ...1 3 4 Pulley Spacer 33 4 018 5019 00 1 2 x 4 Bolt Grade 8 Parts List ITEM QTY PART NUMBER DESCRIPTION 34 3 033 6004 00 6 1 4 Drive Pulley 35 3 038 6080 00 61 inch Fusion Blade 36 12 018 5040 00 3 8 x...

Страница 62: ...ECK PAGE 62 20 19 21 61 44 26 13 14 24 23 22 25 6 52 3 3 48 7 41 3 42 40 43 65 3 58 57 57 37 60 56 55 59 54 53 46 40 41 42 3 58 3 57 37 46 30 29 66 33 28 32 12 18 31 15 17 3 23 35 34 3 3 17 1 51 50 39...

Страница 63: ...olt 33 7 013 8049 00 5 16 Nylock Flange Nut Zinc Parts List ITEM QTY PART NUMBER DESCRIPTION 34 6 018 0010 00 Deck Wheel Bolt 35 6 022 1000 00 Anti Scalp Roller 36 1 025 5339 00 1 3 4 Pulley Spacer 37...

Страница 64: ...Y PART NUMBER DESCRIPTION 1 1 037 4000 01 4000 Series Spindle Housing 2 1 037 4002 00 4000 Series Spindle Spacer 3 1 037 9050 00 Locking Collar w 1 4 20 Set Screw 4 2 037 8002 00 Spindle Dust Cap 5 1...

Страница 65: ...Transaxles Only Parts List ITEM QTY PART NUMBER DESCRIPTION 11 8 019 5007 00 1 2 Lock Washer 12 4 018 2006 00 5 16 x 1 1 4 Hex Bolt 4400 Transales Only 13 1 050 1000 00 4400 Transaxle Left Base Outlaw...

Страница 66: ...8019 00 Canister Air Filter Outer 14 4 013 0075 00 M8 1 25 Zinc Nut 15 1 086 0005 00 Ground Cable Parts List ITEM QTY PART NUMBER DESCRIPTION 16 1 019 8053 00 7 16 Lock Washer 17 1 018 5300 00 7 16 x...

Страница 67: ...019 8051 00 5 16 Lock Washer 14 1 019 6029 00 1 1 8 Flat Spacer Parts List ITEM QTY PART NUMBER DESCRIPTION 15 1 019 8053 00 7 16 Lock Washer 16 1 018 5300 00 7 16 x 2 1 2 Hex Bolt 17 1 070 1000 00 C...

Страница 68: ...19 5037 00 3 8 Lock Washer 13 2 013 6014 00 3 8 Hex Nut 14 1 015 0050 00 Yamaha Muffler Parts List ITEM QTY PART NUMBER DESCRIPTION 15 2 015 0053 01 Exhaust Gasket for yamaha 16 4 019 8051 00 5 16 Loc...

Страница 69: ...14 4 013 0075 00 M8 1 25 Zinc Nut 15 1 086 0005 00 Ground Cable Parts List ITEM QTY PART NUMBER DESCRIPTION 16 1 019 8053 00 7 16 Lock Washer 17 1 018 5300 00 7 16 x 2 1 2 Hex Bolt 18 1 070 1000 00 C...

Страница 70: ...5402 00 14 mm Oil drain Hose 993cc Vanguard 16 1 019 6029 00 1 1 8 Flat Spacer Parts List ITEM QTY PART NUMBER DESCRIPTION 17 1 041 5048 00 Pump Belt 18 1 019 8053 00 7 16 Lock Washer 19 1 018 5300 00...

Страница 71: ...04 18 THROTTLE DECAL 091 3012 00 DANGER DECAL 091 3017 00 PUMP BELT ROUTE DECAL 091 3309 00 DECK BELT ROUTE DECAL 091 3150 00 CAUTION DANGER DECAL 091 1114 00 STEERING SPEED CONTROL DECAL 091 0055 18...

Страница 72: ...PAGE 72...

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