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THIS MANUAL APPLIES TO THE FOLLOWING EQUIPMENT:

BAD BOY WALK-BEHIND SERIES

WALK-BEHIND 3100 36” FS541V 603CC Kawasaki

WALK-BEHIND 3100 48” FS541V 603CC Kawasaki

COMMONLY USED ITEMS AND PART NUMBERS

36” WALK-BEHIND

Blade

Hi-Lift Fusion

Gator Blade

Wave Blade

038-0001-00

038-0003-00

038-5220-00

48” WALK-BEHIND

Blade

Hi-Lift Fusion

Gator Blade

Wave Blade

038-5350-00

038-5000-00

038-4825-00

36” WALK-BEHIND

Deck Belt

041-5200-00

48” WALK-BEHIND

Deck Belt

041-1560-00

WALK-BEHIND

Pump Belt

041-6500-00

Fuel Filter

063-6000-00

Spark Plug

015-8001-00

Air Filter

063-2097-00

Oil Filter

063-8017-00

Motor Oil

10W-30 Motor Oil -

Bad Boy Synthetic Blend Motor Oil Recommended.

085-6015-00

Hydraulic Oil

20W-50 Motor Oil-

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

085-6000-00

Содержание Mowers WALK-BEHIND

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 WALK BEHINDMODEL ...

Страница 2: ...rtation 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 Section 10 Page 15 Greasing Bearings Section 11 Page 15 How To Choose the Right Blade Page 16 Mowing Tips Page 17 Service Section Page 18 Parts Section Page 30 Limited Warranty Page 41 ...

Страница 3: ...0 48 WALK BEHIND Blade Hi Lift Fusion Gator Blade Wave Blade 038 5350 00 038 5000 00 038 4825 00 36 WALK BEHIND Deck Belt 041 5200 00 48 WALK BEHIND Deck Belt 041 1560 00 WALK BEHIND Pump Belt 041 6500 00 Fuel Filter 063 6000 00 Spark Plug 015 8001 00 Air Filter 063 2097 00 Oil Filter 063 8017 00 Motor Oil 10W 30 Motor Oil Bad Boy Synthetic Blend Motor Oil Recommended 085 6015 00 Hydraulic Oil 20W...

Страница 4: ... 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 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 cl...

Страница 5: ...k 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 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 do...

Страница 6: ...hine by putting your foot on the ground 2 31 Do not mow near drop offs ditches or embankments The machine could suddenly roll over if a wheel goes over the edge or the edge caves in 2 32 Be aware of what is located at the bottom of slopes 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 attra...

Страница 7: ...r or furnace 2 51 Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment with a portable container rather than from a gasoline dispenser nozzle 2 52 Never fill gasoline containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before fillin...

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 been previously allowed to warm to operating temperature 2 72 With the parking brake engaged bring lever arms to their inward position Attempt to start the machine with the blade actuator in off posit...

Страница 9: ...e the choke 3 7 Increase RPM by sliding the throttle to fast position 3 8 Owners must become familiar with the controls before operating a zero turn radius vehicle 3 10 Start slowly and build your skill level Have ample practice before using the machine at full capabilities 3 11 Be comfortable with machine before engaging blades Know what each component controls before using machine 3 12 Your mowe...

Страница 10: ...ly 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 Keep machine from collecting debris by storing in a covered area while not in use 5 2 Fuel can harm your machine if left for more than 30 days without changing especially if the fuel contains ethanol Never use fuel w...

Страница 11: ...te 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 Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed ...

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 10 amps 6 4 Q What type of fuel is recommended for my mower A We recommend that you use a name brand fuel to ensure quality Use fuel with an octane rating near 87 Higher octane fuels offer no benefi...

Страница 13: ... mower operation 7 5 Blade Engage Switch This switch engages the blades Pull the switch up to engage the blades and push the switch down to disengage the blades 7 6 Choke Control A cable is linked to 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 machi...

Страница 14: ...on 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 need to use this section of the manual However if you do use extreme caution when moving machine SECTION 9 INSTRUMENTATION 9 1 Electronic Hour Meter Displays total operating hours 0 1 hour increments up ...

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 SECTION 11 EQUIPMENT LUBRICATION 11 1 Park the machine on a level surface and disengage the blade control switch 11 2 Move the motion control levers outward to the neutral position engage parking brak...

Страница 16: ...ore 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 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...

Страница 17: ...es during the mowing 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...

Страница 18: ... drain pan under the oil filter and remove the filter The oil filter serves as the drain for the transaxle 4 After the oil has drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter 5 Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface 6 Re install the filter guard with three1 4 ...

Страница 19: ... install the caps on the hydraulic fluid reservoirs 14 Now we need to purge the air from the transaxle With your mowers tires off the ground disengage the brake and start the engine 15 Pull the neutral bypass levers which are located on each side of the muffler Then slowly move the drive arms in the forward and reverse direction 5 to 6 times 16 Push the neutral bypass levers back into place Move t...

Страница 20: ...usted in ordered to change the tension in the spring Use a wrench and a deep socket in order to loosen the two nuts Tighten the outside nut if more belt tension is desired and loosen the outside nut if less belt tension is desired The pump belt tension should be set between 60 65 lbs This should be measured with a belt tension gauge Your dealer or service center will have a belt tension gauge or y...

Страница 21: ...ocated 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 10 ft lbs 3 Place new filter in shallow pan with open end up Fill with new oil until oil reaches the bottom of the threads Allow two minutes for oil to be absorbed by filter material 4 Apply a th...

Страница 22: ...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 maintenance activities 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 ...

Страница 23: ...ectiveness 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 and remove to access the air cleaner 2 Remove the paper element and precleaner 3 Replace or wash precleaner in warm water with detergent Rinse and allow to air dry 4 Lightly oil precleaner with ne...

Страница 24: ...lug 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 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 ...

Страница 25: ...only necessary if a repair requires it Torque rear wheel lugs to 65 75 ft lbs Re torque at every oil change and check at every mowing The front forks each have a grease zerk The actuator bar has two grease zerks and should be greased at every oil change The pump belt tensioner is located under the engine and has a grease fitting at its pivot point Grease at every engine oil change ...

Страница 26: ... rotate the pulley until the belt is free of the pulley Exercise caution while performing this step as fingers can easily become caught between the belt and pulley DECK BELT INSTALLATION 1 Use proper safety precaution when performing procedures 2 Take off deck covers and route the belt by following the belt route sticker 3 Verify that the belt is routed properly as improper routing can damage the ...

Страница 27: ...er deck to desired height by using the handles located on each side of the deck 3 Once the desired deck height is achieved replace the pins back in the deck height adjustment rods making sure that all four pins have the same number of empty holes above and below 4 Verify that the deck is level A 1 4 pitch is built into the deck ...

Страница 28: ...on 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 one from the Bad Boy Parts Department by calling 866 622 3269 and asking for the Parts Department Part Number 041 9999 00 BLADE SHARPENING The blade on the top see photo was utilized long after replacement was r...

Страница 29: ...Drill 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 used have right handed threads Re torque the blade bolts to 90 110 lbs The blade spindles contain a sealed ball bearing inside the top and bottom of the spindle The bearings are replaceable for a more cost effective repair ...

Страница 30: ... 00 2017 Bearing Cover 5 1 018 0005 00 1 14 x 5 Hex Bolt Grade 8 Zinc Yellow 6 1 018 0035 00 1 2 13 x 7 5 Hex Bolt Grade 5 Parts List ITEM QTY PART NUMBER DESCRIPTION 7 2 022 7009 00 Wheel Bearing 8 1 022 8049 00 11x6 5 front tire wheel assembly 9 1 023 0002 00 2017 MZ Front fork 10 1 025 0003 00 2016 Front Bearing Spacer 11 1 025 0008 00 Front Wheel Spanner 12 1 058 1000 00 1 x 25 Spacer 4 3 1 10...

Страница 31: ...65 00 5 16 x 1 Carriage Bolt 6 1 042 9000 00 Ignition Key 7 1 054 8017 00 Choke Parts List ITEM QTY PART NUMBER DESCRIPTION 8 1 055 8020 00 Throttle Lever Assembly 9 1 056 8058 00 PTO Engager 10 1 077 0001 00 Brake switch 4 prong 11 1 077 0003 00 Ignition Switch 12 1 077 5300 00 Deck Stop Switch 13 1 079 0036 00 Walk Control Panel 14 1 083 4013 00 Tachometer PARTS SECTION Instrument Panel PAGE 31 ...

Страница 32: ...PARTS SECTION Podium PAGE 32 27 21 33 20 21 23 34 15 22 24 26 29 2 15 34 45 8 6 12 32 16 4 16 32 12 6 8 46 14 12 13 17 5 14 10 44 3 17 12 13 25 5 39 5 4 9 20 18 9 18 20 28 ...

Страница 33: ...alk Behind Control Pivot Rod 24 1 028 0012 00 2017 Walk Behind T Rod Parts List ITEM QTY PART NUMBER DESCRIPTION 25 1 028 0013 00 Walk Behind Rider Presence 26 1 030 0001 00 8 32 x 2 1 2 Hex Machine Screw 27 1 031 0021 00 2017 Drive Lever Control Right 28 1 031 0022 00 2017 Drive Lever Control Left 29 1 031 0024 00 2017 Neutral Lock 30 1 031 0036 00 Speed Control Lever 31 1 034 8025 00 Drive Lever...

Страница 34: ...ge Nut 12 3 1 018 5311 00 5 8 x 4 Hex Bolt 12 4 1 018 6036 00 1 2 x 2 3 4 Hex Bolt Parts List ITEM QTY PART NUMBER DESCRIPTION 12 5 2 019 6017 00 630 ID Plastic Washer 12 6 1 025 7036 00 1 2 x 1 2 Spacer 12 7 1 033 6001 00 4 3 4 Idler Pulley 12 8 1 039 5944 00 Pump Idler Bracket 13 4 040 6060 00 Seat latch pin 14 2 051 8063 00 3 8 Clear Hose 15 2 066 5050 00 Hydraulic Tank Cap 16 1 066 8083 00 Fue...

Страница 35: ...ind 17 2 022 8023 00 21x7 10 Tire Only 36 Walk Behind 18 2 024 1200 00 45 degree fitting Parts List ITEM QTY PART NUMBER DESCRIPTION 19 1 025 0016 00 2017 Transaxle Spacer MZ 20 2 025 0070 00 2017 Transaxle Spacer 21 2 026 3440 00 Walk Trans Skid Plate 22 2 028 0070 00 Neutral Rod 23 1 034 9080 00 Transaxle Spring 24 1 039 1917 00 Walk Brake Pull Bracket 25 1 041 6500 00 Pump Belt 26 2 044 2004 00...

Страница 36: ... 5037 00 3 8 Lock Washer 16 2 019 5038 00 5 8 Flat Washer Parts List ITEM QTY PART NUMBER DESCRIPTION 17 2 019 6017 00 630 ID x 1 122 OD x 142 THK Plastic Washer 18 2 019 6020 00 1 2 Belleville Washer 19 2 019 6042 00 360 ID Plastic Washer 20 2 026 0025 00 Deck Spindle Support Plate 21 2 030 0050 00 5 16 Set Screw 22 4 031 0023 00 2017 Walk Behind Deck Hanger 23 2 033 6003 00 5 Spindle Deck Pulley...

Страница 37: ...630 ID x 1 122 OD x 142 THK Plastic Washer Parts List ITEM QTY PART NUMBER DESCRIPTION 22 3 019 6020 00 1 2 Belleville Washer 23 2 019 6042 00 360 ID Plastic Washer 24 4 019 6050 00 360 ID Plastic Washer Black 25 2 025 5338 00 Idler Pulley Standoff 26 1 025 5339 00 1 3 4 Pulley Spacer 27 3 026 0025 00 Deck Spindle Support Plate 28 3 030 0050 00 5 16 Set Screw 29 4 031 0023 00 2017 Walk Behind Deck...

Страница 38: ... Flange Nut 013 8050 00 1 12 1 2 x 2 3 4 Hex Bolt 018 6036 00 1 13 Spacer 3 4 OD x 1 2 ID x 3 4 Length 025 5203 00 1 14 5 Idler Pully 033 8050 00 1 15 Deck Idler 039 6945 00 1 16 039 6945 05 Parts List DESCRIPTION PART NUMBER QTY ITEM 1 2 13 Nylon Flange Nut 013 8050 00 1 7 1 2 13 x GR 5 Hex Bolt Zinc 018 7016 00 1 8 Spacer 3 4 OD x 1 2 ID x 3 4 Length 025 5203 00 1 9 5 3 4 Deck Idler Pulley 033 5...

Страница 39: ...1 6500 00 Pump Belt 14 1 042 6030 00 1 4 x 1 Key 15 1 051 5404 00 Oil drain Hose 16 1 063 2097 00 Air Filter 17 1 063 6000 00 Fuel Filter 18 1 063 8017 00 Oil Filter 19 1 070 0056 00 Clutch 20 1 070 2000 00 Clutch Pigtail 21 1 070 5100 00 2017 Walker Frame 015 0543 00 Parts List ITEM QTY PART NUMBER DESCRIPTION 22 4 013 0075 00 M8 1 25 Zinc Nut 23 1 015 0543 01 MUFFLER 24 1 015 0543 02 Exhaust Pip...

Страница 40: ...314 00 FLOORBOARD LOGO DECAL 091 0411 18 CONTROL PANEL DECAL 091 0903 18 48 DECK DECAL 091 0412 18 603cc PODIUM DECAL 091 0418 00 36 DECK BELT ROUTE DECAL 091 3601 18 36 DECK DECAL 091 3012 00 DANGER DECAL 091 1020 00 CAUTION DECAL 091 3309 00 48 DECK BELT ROUTE DECAL 091 2150 00 CAUTION DANGER DECAL ...

Страница 41: ...PAGE 41 ...

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