Bad Boy COMPACT OUTLAW Owner's, Service & Parts Manual

Summary of COMPACT OUTLAW

  • Page 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 ©2015 12-11 compact outlaw model.

  • Page 2: Table of Contents

    Table of contents basic information ................................................................................................ Section 1 (page 4) bad boy safety guidelines ............................................................................. Section 2 (pages 5–8) operation ...............

  • Page 3

    This manual applies to the following equipment: page 3 bad boy compact outlaw series compact outlaw 4200 42” 726cc kawasaki fx691v compact outlaw 4800 48” 726cc kawasaki fx691v compact outlaw 4200 42” 810cc vanguard compact outlaw 4800 48” 810cc vanguard commonly used items and part numbers hydrauli...

  • Page 4: Section 1:

    Section 1: basic information congratulations on the purchase of your new bad boy mower! The purpose of this manual is to assist operators in maintaining and operating their machine. The information and instructions in this manual can help you attain years of performance from your new bad boy. Also, ...

  • Page 5: Section 2:

    Section 2: mower safety guidelines never allow untrained people to operate this machine. It is the owner’s responsibility to get training and see to it that anyone who has permission to use your machine receives the proper training. Do not mow around people. The factory discharge chute is designed t...

  • Page 6: Slope Operation

    Slope operation slopes are a major factor related to loss of control and tip over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope, or you feel uneasy on it, do not mow it. 2.22 mow up and down slopes, not across. ...

  • Page 7: Service:

    Service: safe handling of gasoline to avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. 2.45 extinguish all cigarettes, cigars, pipes, and all other sources of ignition. 2.46 use only an approved gasoline co...

  • Page 8: Safety Interlock System

    2.69 always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. 2.70 park machine ...

  • Page 9: Section 3:

    Section 3: mower operation never operate the machine with faulty equipment. Always be alert of sudden changes in landscape, as the mower will react differently on slopes or embankments than it will on flat surfaces. Never operate the mower with the discharge chute open. Do not cross terrain, other t...

  • Page 10: Section 4:

    Section 4: mower maintenance first every 50 every 100 every daily 8 hours or hours or 250 section maintenance hours annually* annually* hours check and add engine oil ● section 3 section 2 ● (pump) 6 (deck) check condition of blades ● section 6 check for fule and oil leakage ● section 3 initial oil ...

  • Page 11

    Page 11 performed: performed performed: performed performed performed: performed performed: performed performed performed: performed: performed performed performed performed performed: performed: performed: performed: performed: date: hours: date: hours: date: hours: date: hours: date: hours: date: ...

  • Page 12: Section 5:

    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 with more than 10% ethanol by volume...

  • Page 13: Section 6:

    Section 6: troubleshooting 6.1 q: how do i prevent an uneven cutting pattern and increase the quality of cut? 6.1 a: check tire pressure, check blade sharpness (replace blades or sharpen at least once per year or when needed), make sure blades are tightened properly, check spring and belt tension, c...

  • Page 14: Section 7:

    Section 7: controls 7.1 ignition switch—bad boy mowers have a three position ignition switch: off, run, and start. With key inserted, rotate it clockwise to start position and release key when engine starts, and switch will automatically return to he run position. 7.2 throttle control—a cable is con...

  • Page 15: Section 8:

    Section 8: moving inoperable mower 8.1 do not tow machine. Use a winch to load on a trailer for transporting. 8.2 attention: return bypass valves to operating position before running mower following repairs. 8.3 czt models are equipped with two neutral engage/disengage arms, located at the rear of t...

  • Page 16: Section 10:

    Section 10: mower blade maintenance 10.1 check mower blades after each use. This is essential for maintaining well-groomed turf. Keep the blades sharp. If a dull blade is used for cutting, the grass will tear rather than cut. This could damage the grass leaving a brown frayed top on the grass within...

  • Page 17

    How to choose the right blade essentially there are only two basic styles of mowing blades used or approved for use on our current products: 1) the standard style of mowing blade is essentially designed for cutting grass and effectively discharging the clippings out from the deck to fall onto the la...

  • Page 18: Mowing Tips:

    Mowing tips: • mow header strips at the ends of the lawn and around flower beds first. Make them wide enough that you can turn the mower around in the already mown section. Then mow back and forth between these header strips overlapping each lap by about 1/8 the width of the mower’s deck. • don’t cu...

  • Page 19: Service Section

    Service section section 1: hydrostatic system page 19 the hydraulic fluid reservoirs are located on the sides of the rear cover. Notice the “full cold” line at the bottom of the tank. Use only 20w-50 motor oil in this tank. (bad boy hydrostatic oil is recommended) changing your hydraulic oil and fil...

  • Page 20

    8) drain old oil filters of all free flowing oil prior to disposal. Place used oil in appropriate containers and deliver to an approved recycling collection facility. 9) remove the top port plug from the left side and right side transaxles prior to filling with oil. This will allow the transaxles to...

  • Page 21: Section 2: Drive Belt

    Once the system is filled with oil, lift rear of mower until rear tires are off the ground. Start engine, release parking brake, and stay clear of moving rear tires. Next, pull the neutral bypass levers (located at the rear of the frame, on either side of the muffler), then move the drive arms forwa...

  • Page 22: Section 3: Engine

    Section 3: engine page 19 810cc vanguard this machine has an oil drain hose installed on the engine to allow for easier oil changes. Bad boy recommends that the oil and filter be changed at intervals of 50 usage hours or yearly, whichever occurs first. The oil capacity is 2 quarts. Bad boy 10w-30 sy...

  • Page 23

    The fuel filter is located in the fuel line about 12˝ from the carburetor on the side of the engine. Replace the filter yearly. Prior to the removal of the old filter, note the direction of fuel flow as indicated on the filter. Have towels readily available in order to quickly remove any fuel leakag...

  • Page 24

    The air cleaner is the engine’s only defense against damaging foreign particles. It is very important that the air cleaner element is inspected prior to each use. Remove the element and tap its sides in order to remove debris. Do not blow the filter out using compressed air. Doing so will greatly re...

  • Page 25

    3.4 changing the spark plugs and checking the spark plug gap: 1) remove the wire on the spark 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 repl...

  • Page 26: Kawasaki Fx691V

    Kawasaki fx691v this machine has an oil drain hose installed on the engine to allow for easier oil changes. Bad boy recommends that the oil and filter be changed at intervals of 50 usage hours or yearly, whichever occurs first. The oil capacity is 2 quarts. Bad boy 10w-30 synthetic blend engine oil ...

  • Page 27

    The fuel filter is located in the fuel line on the left side of the engine by the starter motor. Replace the filter yearly. Prior to the removal of the old filter, note the direction of fuel flow as indicated on the filter. Have towels readily available in order to quickly remove any fuel leakage. A...

  • Page 28

    3.4 changing the spark plugs and checking the spark plug gap: 1) remove the wire on the spark plug 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 re...

  • Page 29: Section 4: Electrical System

    Section 4: electrical system page 29 this mower is equipped with three protective fuses: a 25 amp main fuse (pictured to the right) and a 10 amp clutch fuse (blade engagement). The main fuse is located on the left side of the unit; by the starter solenoid. The clutch fuse is located beside the contr...

  • Page 30

    Page 30

  • Page 31: Section 5: Frame

    Section 5: frame page 31 the front fork nuts require a torque of 40ft-lbs. While applying this torque, turn the fork itself to ensure no damage is done to the bearing. This operation is only necessary if a repair requires it. Torque rear wheel lugs to 65-75 ft. Lbs. Re-torque at every oil change and...

  • Page 32

    The pump belt tensioner is located under the engine and has a grease fitting at its pivot point. Grease at every engine oil change. The deck belt tensioner is located at the rear of the deck and has a grease fitting on its pivot point. Grease at every engine oil change. The control arm blocks have g...

  • Page 33: Section 6: Cutting Deck

    Section 6: cutting deck page 33 deck belt removal 1) remove ignition key. 2) raise the deck to its highest position. 3) remove the right pulley cover. 4) while lifting up on the belt (as shown in the photograph), rotate the pulley until the belt is free of the pulley. Exercise caution while performi...

  • Page 34

    Page 34 leveling the deck 1) start on a flat level surface and set the air pressure in all four tires to 12 psi. 2) get 2 2x4s and make sure that the wider sides are similar length. 3) take off the foot pedal and raise the floor plate. 4) lower the deck onto the 2x4s and pin the deck into its top av...

  • Page 35

    The deck spring tension is critical. If the tension is too high, premature failure of the deck belt and blade spindles can occur. If the tension is too low, the belt can ‘jump off’ or slip on the pulleys. This results in reduced cut quality and early belt failure. Spring tension adjustments can be m...

  • Page 36

    Blade removal: to change blades, it may be easier to use a piece of wood to keep the blade from turning so that the bolt can be loosened. Use a 15/16” socket and impact drill, or a wrench and an extension to gain more leverage. You might need to put a ¾” wrench on top of the pulley bolt to keep the ...

  • Page 37: Parts Section

    Parts section page 37 parts list description part number qty item front fork 023-7913-00 1 1 front wheel spanner 025-5202-00 1 2 1 3/8" wheel bearing 022-7009-00 2 3 1/2" x 9" gr 5 hex bolt 018-7010-00 1 4 1/2-13 nylon flange nut 013-8050-00 1 5 caster bearing spacer 025-0004-00 1 6 1" fine thread 1...

  • Page 38

    Page 38 adjustable drive arm assemblies 32 31 28 28 27 29 26 30 28 28 8 7 22 23 18 17 16 19 33 11 12 13 14 16 6 5 4 2 1 3 21 24 25 25 20 17 34 16 35 35 welded to frame 9 10 9 10 37 15 36 15 38 36 10 10 39 39.

  • Page 39

    Page 39 adjustable drive arm assemblies description part number qty item 2013 drive lever housing (right) 027-8901-00 1 1 steering arm elbow - right 031-9025-00 1 2 push rod - right 035-5450-00 1 3 lower adjuster - steering arm- right 031-9015-00 1 4 upper adjust steering arm- right 031-9016-00 1 5 ...

  • Page 40

    Page 40 detail a detail b a b 8 7 6 4 5 28 27 26 28 28 12 5 15 16 3 9 6 7 10 2 24 24 26 24 25 41 23 22 21 18 17 20 19 30 29 30 1 14 13 31 36 37 40 11 38 35 11 39 32 33 34 43 42.

  • Page 41

    Page 41 parts list description part number qty item 2016 compact outlaw frame 070-5500-00 1 1 right fuel tank/outlaw/2012/epa 067-5000-50 1 2 left fuel tank/outlaw/2012/epa 067-5001-50 1 3 .380x.735x.470 nylon spacer 025-2000-00 4 4 fuel cap 066-8083-00 2 5 1/4" flat washer 019-7040-00 8 6 5/16" loc...

  • Page 42

    Page 42 detail a 7 detail b a b 16 51 10 9 8 1 41 21 43 22 41 21 42 24 23 62 14 45 15 44 14 15 12 14 17 26 33 32 35 34 37 39 40 38 36 35 27 31 30 5 29 34 4 2 5 3 6 20 21 18 19 11 12 13 13 12 11 49 47 48 46 37 28 14 12 12 15 45 53 52 54 61 61 50 50 25 59 57 58 60 56 55 55 62 63 64 65.

  • Page 43

    Page 43 parts list description part number qty item 2016 compact outlaw frame 070-5500-00 1 1 3/8" x 1 1/4" hex bolt 018-5040-00 2 2 seat spring 034-8045-00 2 3 seat spring cap cover 014-8047-00 2 4 3/8" flat washer 019-5029-00 3 5 3/8" lock washer 019-5037-00 2 6 3/8-16 hex nuts zinc 013-6014-00 2 ...

  • Page 44

    Page 44 19 detail a detail b a b 2 3 8 7 5 17 20 18 11 16 26 31 27 30 28 29 5 24 22 22 25 6 4 10 35 34 9 15 14 13 33 12 32 23 21 36 37 11 17 4 5 1 18.

  • Page 45

    Page 45 parts list description part number qty item 2016 compact outlaw frame 070-5500-00 1 1 actuator bar front- 2016 compact outlaw 028-0005-00 1 2 actuator bar rear- 2016 compact outlaw 028-0006-00 1 3 1/2" x 4" bolt (grade 8) 018-5019-00 8 4 1/2-13 nylon flange nut 013-8050-00 9 5 two piece pill...

  • Page 46

    Page 46 18 detail a a 26 23 24 15 12 16 5 9 8 28 9 7 8 10 25 2 1 20 17 13 19 17 18 19 6 3 4 22 21 11 27 transaxle assembly 14 8 9.

  • Page 47

    Page 47 parts list description part number qty item left 3400 izt 050-6000-00 1 1 right 3400 izt 050-6001-00 1 2 fan/pully kit 050-2072-00 2 3 transaxle spring 034-9080-00 2 4 hydraulic filter 063-1050-00 2 5 crossover bar for zt 2016 028-4802-00 1 6 transaxle spacer 025-5340-00 2 7 5/16" flat washe...

  • Page 48

    Page 48 parts list description part number qty item fx-691v 015-0691-00 1 1 1/4 x 2 square key stock 042-5020-00 1 2 4 3/4 motor pulley 033-5035-00 1 3 clutch assembly 070-1000-00 1 4 7/16" x 2 1/2" hex bolt 018-5300-00 1 5 7/16" lock washer 019-8053-00 1 6 clutch pigtail 070-2000-00 1 7 oil drain 0...

  • Page 49

    Page 49 parts list description part number qty item 810 vanguard 015-0810-00 1 1 3/8" set screw 030-6029-00 1 2 4 3/4 motor pulley 033-5035-00 1 3 3/8 x 1 1/8 bolt 018-1075-00 3 4 ground cable 064-8061_00 1 5 5/16" x 1 3/4" hex bolt 018-8059-00 1 6 5/16" nut 013-8043-00 3 7 5/16" lock washer 019-805...

  • Page 50

    Page 50 detail a detail b a b 36 35 6 5 7 8 23 49 48 30 29 50 31 4 20 28 25 52 26 32 33 2 4 4 37 13 11 10 34 51 4 38 39 4 12 32 21 22 19 4 21 24 53 4 47 45 46 17 12 16 15 9 42 41 43 41 40 44 1 3 14 18 27 42" deck assembly 4 4 54 55.

  • Page 51

    Page 51 parts list description part number qty item 42" compact outlaw deck-welded shell 060-5442-00 1 1 1/2 x 2" carriage bolt 018-1050-00 1 2 .517 square hole round washer 019-0007-00 1 3 1/2-13 nylon flange nut 013-8050-00 20 4 spindle assembly 037-6015-50 3 5 3/8" x 1 1/4" hex bolt 018-5040-00 1...

  • Page 52

    Page 52 detail a detail b a b 46 12 8 10 9 11 40 41 4 35 4 36 49 48 47 20 20 21 18 4 22 19 4 7 6 52 38 4 53 29 32 33 28 26 50 27 33 4 39 4 2 3 17 16 11 15 14 13 45 43 42 1 34 48" deck assembly 24 25 23 31 37 30 51 5 4 48 49 44 54 55.

  • Page 53

    Page 53 parts list description part number qty item 48" compact outlaw deck-welded shell 060-5448-00 1 1 1/2 x 2" carriage bolt 018-1050-00 1 2 .517 square hole round washer 019-0007-00 1 3 1/2-13 nylon flange nut 013-8050-00 20 4 3/8" x 1 1/4" hex bolt 018-5040-00 12 5 3/8" lock washer 019-5037-00 ...

  • Page 54

    Page 54 parts list description part number qty item spindle housing 037-6017-50 1 1 locking collar w/ 1/4"-20 set screw 037-9050-00 1 2 spindle dust cap 037-8002-00 1 3 spindle shaft 037-6026-00 1 4 spindle spacer 037-8050-00 1 5 bearing - 6206 037-6023-00 2 6 4 3 6 1 5 6 2 037-6015-50 spindle assem...

  • Page 55

    Page 55 091-0919-00 armortek decal 091-3150-00 outlaw warning decal 091-1020-00 hydraulic tank 091-3012-00 danger decal – spindle/discharge 091-1102-00 left steering control decal 091-1103-00 right steering control decal 091-3309-00 deck belt route decal 091-3017-00 pump belt route decal 091-1110-00...

  • Page 56

    Notes: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ____...

  • Page 57

    Notes: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ____...

  • Page 58: 2016

    2016 limited warranty for bad boy commercial mower (stand on, diesel, outlaw, outlaw extreme, and outlawxp) 1. What this warranty covers, and for how long: bad boy, inc. Will, at its option, repair or replace, without charge, any part covered by the warranty which is found to be defective in materia...

  • Page 59: Warranty Registration

    Bad boy, inc. 102 industrial drive batesville, ar 72501 www.Badboymowers.Com technical support: ............................................................Techsupport@badboymowers.Com warranty: .....................................................................................Warranty@badboymower...

  • Page 60: Www.Badboymowers.Com

    For additional information, please see us at www.Badboymowers.Com bad boy, inc. 102 industrial drive batesville, arkansas 72501.