Bad Boy maverick 4800 Owner's, Service & Parts Manual - Section 2:

Manual is about: zero-turn

Summary of maverick 4800

  • 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 maverick models ©2015 12-5.

  • 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

    Page 3 this manual applies to the following equipment: bad boy maverick series maverick 4800 48” 747cc kohler confidant maverick 5400 54” 747cc kohler confidant maverick 6000 60” 747cc kohler confidant maverick 4800 48” 726cc kawasaki fs730v maverick 5400 54” 726cc kawasaki fs730v maverick 6000 60” ...

  • 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 page 10 daily first 8 hours every 50 hours or annually* every 100 hours or annually* every 200 hours every 250 hours section check and add engine oil • section 3 check all belts for proper alignment • section 2 (pump) 6 (deck) check tire pressure and wheel lug nuts • sec...

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    Page 13 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 maverick models are equipped with two neutral engage/disengage arms, located at the rear...

  • 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...

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    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 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) page 19 changing your hydraulic oil and fil...

  • Page 20: 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 21

    Page 21 when adjusting the tracking on the mower, the length of the pushrods can be changed by screwing the pivot joint in or out on the ends of the rods. Shortening the overall length of the rod slows the pump down. Lengthening the rod will increase the speed of the pump. Section 2: drive belt show...

  • Page 22

    Page 22 section 3: engine kohler confidant 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 ...

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    Page 23 6) fill crankcase with approximately 2 quarts of new oil. Level should top of indicator on dipstick. 7) reinstall oil fill/dipstick and tighten securely. 8) start engine; check for oil leaks. Stop engine; correct oil leaks. Recheck oil level 9) dispose of used oil and filter in accordance wi...

  • Page 24

    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 gr...

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    Page 25 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 replace the spark plug. 4) install the plug into cylinder ...

  • Page 26: Kawasaki Fs730V

    Kawasaki fs730v 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...

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    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 29

    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 30

    The large turn buckles on the front of the deck only affect the pitch of the deck or the level from front to back. 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 s...

  • Page 31

    Page 31 check the condition and connection of the relays located under the control panel. Ensure that they are clean and connected. Make sure that wire terminal ends have not been pushed out of the relay block. The linear actuator is the mechanism that raises and lowers the deck. If it ever starts t...

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  • Page 33: Section 5: Frame

    Page 33 section 5: frame 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 an...

  • Page 34

    Page 34 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 block...

  • Page 35

    Page 35 section 6: cutting deck deck belt removal 1) remove ignition key. 2) raise the deck to its highest position. 3) remove either 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 p...

  • Page 36

    Page 36 leveling the deck 1) start on a flat level surface and set the air pressure in all four tires to 12 psi. 2) raise the deck up, and measure all four corners of the deck to see if it is level from left to right and front to back. All decks should be level from left to right and have a 1/8" pit...

  • Page 37

    Page 37 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 ...

  • Page 38

    Page 38 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 blade from spinning. Bolts used have right-handed t...

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    Notes: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ____...

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    Notes: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ____...

  • Page 62: 2016 Limited Warranty

    2016 limited warranty for bad boy maverick mowers 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 material and/or workmanship within the lesser of two (2) year* or...

  • Page 63: Warranty Registration

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

  • Page 64: Maverick

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