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- Bad Boy
- Lawn Mower
- Outlaw BBS 4800
- Owner's, Service & Parts Manual
Bad Boy Outlaw BBS 4800 Owner's, Service & Parts Manual
Summary of Outlaw BBS 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 ©2015 12-11 outlaw stand-on 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: bad boy stand-on series bbs 3600 36” 726cc kawasaki fx691v bbs 4800 48˝ 726cc kawasaki fx730v bbs 5400 54˝ 726cc kawasaki fx730v bbs 6100 61˝ 726cc kawasaki fx730v page 3 commonly used items and part numbers 61" blade 54" blade 48" blade 36" blade deck...
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:
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 change ● section 3 change eng...
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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 stand-on 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...
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
11) install and torque the top port plugs to 180 in. Lbs. (20.3 nm). 12) continue to fill the transaxle through the hydraulic fluid reservoirs until the “full cold” line is reached on the hydraulic fluid reservoirs. 13) re-install the caps on the hydraulic fluid reservoirs. 14) now we need to purge ...
Page 21: Section 2: Drive Belt
Section 2: drive belt page 21 shown on the right is a typical pump belt tensioner for your model mower. This is how you can adjust the belt pump belt tension on your mower. There are two jam nuts on an all thread that need to be adjusted in ordered to change the tension in the spring. Use a ¾” wrenc...
Page 22: Section 3: Engine
Section 3: engine page 22 kawasaki fx691v and fx730v 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 b...
Page 23
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 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 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 26: Section 4: Electrical System
Section 4: electrical system this mower is equipped with two protective fuses: a 25 amp main fuse (pictured to the right) and a 15 amp clutch fuse (blade engagement). The main fuse is located on the right side of the unit; towards the rear of the engine. The clutch fuse is located just underneath th...
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Page 28: Section 5: Frame
Section 5: frame page 28 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 29: Section 6: Cutting Deck
Section 6: cutting deck page 29 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 30
Page 30 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 u p, and measure all f our corners of the deck to see i f i t i s l evel f rom left to right and front to back. A ll decks s hould be level from left to right and h ave ...
Page 31
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 32
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. Blade removal: to change blades, it may be easier to use a piece of wood to keep the blade from turning s...
Page 33: Parts Section
Parts section page 33 parts list description part number qty item front fork 023-7913-00 1 1 seal 012-7003-00 1 2 1/2-13 nylon flange nut 013-8050-00 1 3 1/2" x 9" gr 5 hex bolt 018-7010-00 1 4 dust cover 014-7005-00 1 5 bearing 010-7001-00 2 6 tire and wheel assembly 022-2006-00 1 7 front wheel spa...
Page 34
Page 34 detail b b 1 3 24 17 15 16 22 23 20 39 15 16 17 25 11 43 44 12 45 13 9 8 6 7 10 4 41 2 46 47 48 35 34 33 26 31 32 31 30 27 28 29 4 19 14 36 36 59 5 37 40 38 5 42 24 3 50 56 49 10 55 54 53 51 52 58 58 18 18 57 21.
Page 35
Page 35 parts list description part number qty item 2015 stand-on frame 070-5220-00 1 1 48" front end (2015 stand-on) 070-9048-00 1 2 3/8" x 1 1/4" carriage bolt 018-5043-00 5 3 3/8 nylock nut 013-5041-00 12 4 1/4" press in grease fitting 024-6034-00 4 5 two piece pillow block (male) 017-9000-00 2 6...
Page 36
Page 36 26 detail a detail b detail c 41 detail d detail e a b c d e 20 21 27 16 17 14 12 13 27 32 28 25 29 38 37 39 35 34 33 42 35 40 6 6 25 7 25 12 24 22 23 13 8 19 5 4 12 3 15 14 1 10 31 30 18 11 9 2 13 47 46 45 43 44 36.
Page 37
Page 37 parts list description part number qty item 2015 podium panel left 079-4110-00 1 1 door panel assembly 079-4050-00 1 2 2015 podium panel right 079-4105-00 1 3 fender (right side) 074-0050-00 1 4 fender (left side) 074-0060-00 1 5 5/16" x 1" carriage bolt 018-8065-00 4 6 back cover hinge brac...
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Page 38 1 3 2 16 15 12 13 14 7 8 9 4 21 19 5 20 6 17 22 23 10 24 23 11 18 parts list description part number qty item 2015 podium panel left 079-4110-00 1 1 2015 podium panel right 079-4105-00 1 2 2015 podium front panel 079-4100-00 1 3 brake handle- stand on 069-2012-00 1 4 5/16" x 2 1/2" bolt 018-...
Page 39
Page 39 detail a a 1 13 14 12 30 29 28 19 19 23 21 20 23 23 22 23 20 24 10 18 2 10 27 25 18 3 14 17 16 26 15 1 26 15 6 8 9 12 5 25 10 24 5 12 11 7 4 10 27 welded to frame welded to frame.
Page 40
Page 40 parts list description part number qty item support handle stand up (front & back) 031-7120-00 2 1 left steering handle assembly 031-7130-00 1 2 right steering handle assembly 031-7140-00 1 3 safety kill switch assembly bracket 039-0210-00 1 4 stand on flange bushing-steering arms 032-5002-0...
Page 41
Page 41 detail a 8 23 detail b a b 25 20 16 11 16 10 19 7 12 18 6 15 5 9 24 23 17 8 21 23 22 14 13 29 30 31 3 4 39 40 36 stand-on transaxle assembly 26 27 28 32 33 34 37 38 1 2 35.
Page 42
Page 42 parts list description part number qty item left 3400 transaxle 050-6000-00 1 1 left 3100 transaxle (36" stand-on only) 050-2081-00 1 2 right 3400 transaxle 050-6001-00 1 3 right 3100 transaxle (36" stand-on only) 050-2080-00 1 4 crossover bar for zt 2016 028-4802-00 1 5 3/8'' x2'' hex bolt ...
Page 43
Page 43 parts list description part number qty item fx-691v 015-0691-00 1 1 fx-730v 015-0730-00 1 2 kawasaki oil filter 063-8017-00 1 3 1/4 x 2 square key stock 042-5020-00 1 4 4 3/4 motor pulley 033-5035-00 1 5 clutch assembly 070-1000-00 1 6 7/16" x 2 1/2" hex bolt 018-5300-00 1 7 7/16" lock washe...
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Page 44 4 54 53 48 52 58 49 51 31 30 32 42 43 27 27 26 25 21 22 24 9 56 20 45 21 23 18 19 15 14 13 5 7 6 18 35 34 3 46 28 1 44 55 33 18 60 55 17 8 12 18 16 10 11 18 8 36" deck assembly 18 39 38 36 37 40 41 40 51 50 47 2 29 58 61 59 18 31 32.
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Page 45 parts list description part number qty item 36 stand on deck 060-1136-00 1 1 spindle assembly 037-2000-00 2 2 3/8" x 1 1/4" hex bolt 018-5040-00 8 3 3/8" lock washer 019-5037-00 8 4 3/8" hex nut 013-6014-00 8 5 deck pulley 033-4820-00 2 6 36 deck spindle spacer 025-0060-00 2 7 1 3/4" pulley ...
Page 46
Page 46 detail a detail b a b 1 34 35 33 5 8 9 10 15 14 11 20 5 40 57 56 20 38 39 4 42 43 50 47 41 49 48 47 20 21 5 18 6 5 3 2 7 25 24 23 22 37 27 28 31 36 26 32 29 30 on right side spindle only 19 17 16 13 44 45 46 stand-on 48" deck 51 5 12 53 55 54 52.
Page 47
Page 47 parts list description part number qty item 48" 2015 stand-on deck (welded assembly) 060-1148-00 1 1 5/8" x 2 1/2" hex bolt 018-6059-00 4 2 5/8 std nc nylock nut 013-7021-00 4 3 1/2-13x 2-1/4 gr hex bolts 018-6037-00 4 4 1/2-13 nylon flange nut 013-8050-00 14 5 .502 id x .750 od x 1.500 long...
Page 48
Page 48 detail a detail b a b 32 6 7 5 34 61 33 4 54 35 38 37 36 52 40 41 44 51 39 42 43 57 20 19 16 33 34 6 45 47 1 9 2 3 8 21 6 48 49 50 17 13 14 18 10 6 11 12 15 46 stand-on 54" deck on right side spindle only 53 55 6 60 58 58 60 59 31 30 28 29 25 26 27 30 22 23 23 24 56.
Page 49
Page 49 parts list description part number qty item 54" 2015 stand-on deck (welded assembly) 060-1154-00 1 1 5/8" x 2 1/2" hex bolt 018-6059-00 4 2 5/8 std nc nylock nut 013-7021-00 4 3 1/2-13x 2-1/4 gr hex bolts 018-6037-00 4 4 deck arm assembly 031-6020-00 2 5 1/2-13 nylon flange nut 013-8050-00 2...
Page 50
Page 50 detail a detail b a b 6 21 8 49 48 47 17 13 14 18 10 6 11 12 15 32 34 7 5 61 6 6 33 52 4 53 2 3 20 19 16 37 36 35 56 51 43 40 39 38 60 42 41 on right side spindle only stand-on 61" deck 50 54 6 44 6 33 34 6 9 45 6 44 6 33 46 57 59 57 59 58 25 23 24 26 29 28 27 25 22 26 55 31 30
Page 51
Page 51 parts list description part number qty item 61" 2015 stand-on deck (welded assembly) 060-1161-00 1 1 5/8" x 2 1/2" hex bolt 018-6059-00 4 2 5/8 std nc nylock nut 013-7021-00 4 3 1/2-13x 2-1/4 gr hex bolts 018-6037-00 4 4 deck arm assembly 031-6020-00 2 5 1/2-13 nylon flange nut 013-8050-00 2...
Page 52
Page 52 parts list description part number qty item spindle housing 037-6027-00 1 1 spindle spacer-component 037-6028-00 1 2 spindle shaft 037-6025-00 1 3 spindle bearing 037-6024-00 2 4 037-2000-00 spindle assembly 36" deck only 4 2 1 4 3 parts list description part number qty item 4000 series spin...
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Page 54: 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 55: Warranty Registration
Bad boy, inc. 102 industrial drive batesville, ar 72501 www.Badboymowers.Com technical support: ............................................................Techsupport@badboymowers.Com warranty: .....................................................................................Warranty@badboymower...
Page 56: Www.Badboymowers.Com
For additional information, please see us at www.Badboymowers.Com bad boy, inc. 102 industrial drive batesville, arkansas 72501.