Bad Boy 2011 User manual

1

2011 BAD BOY MOWERS SERVICE MANUAL

This Manual contains general maintenance and service procedures

that may not be specific to your model.

Section 1- Hydrostatic System …………………………. Pg. 02

Section 2- Drive Belt ……………………………………….. Pg. 09

Section 3- Engine ……………………………………………. Pg. 11

Section 4- Electrical System ……………………………. Pg. 19

Section 5- Frame Maintenance ……………………….... Pg. 24

Section 6- Cutting Deck …………………………………… Pg. 36

Section 7- Mowing Tips ……….…………………………… Pg. 45

2

SECTION 1: HYDROSTATIC SYSTEM

To change hydro oil on Pup, Lightning, AOS, and Diesel models,

remove oil return lines from top of hydro tank and place them in a

disposable oil container. Start and run mower until oil level is

reduced down to about 2” of oil remaining in the tank. Do not allow

air to enter the oil lines in the bottom of the tank. Keep in mind that

only about 75% of the hydro oil can be changed at a time. Use only

20w50 motor oil in the hydro system.

(conventional or synthetic oil may be used)

Bad Boy recommends that the hydro oil and filters be changed within

the first 50 hours of usage and every 500 hours thereafter or once a

year.

3

(Pup, Lightning, AOS, and Diesel Models)

Change hydro oil filters by unscrewing them from the filter head. Fill

new filters with 20w50 motor oil before installing. Use only bad boy

replacement filters. Using any other filter will result in damage to the

hydro system and void the warranty.

4

(Pup, Lightning, AOS, and Diesel Models)

Once the system is refilled with oil, lift rear of mower until tires are

off the ground. Start engine, release parking brake, stay clear of

moving rear tires, loosen bypass bolt ½ to ¾ turns, move drive arms

forward and backward 4 to 6 times slowly. This will purge the air

from the system.

(the bypass bolt has a hole drilled through the side of the bolt head).

This valve also serves as a neutral for moving the mower without the

engine running.

5

(ZT and Outlaw Models)

The hydro overflow tank on a zt or outlaw model is located behind the

seat. Notice the “full cold” line at the bottom of the tank. Use only

20w50 motor oil in this tank. Conventional or synthetic oil may be

used.

6

(ZT and Outlaw models)

When servicing a mower with a sealed transaxle unit, start by

removing the filter skid plate on the bottom of each unit. The skid is

held on by three 10mm bolts. Next, remove the filter (Outlaws have

one large nut on the filter cover). The filter also serves as the oil

drain. Each transaxle holds about 2 quarts of hydro oil. (Outlaw holds

4 quarts in each transaxle) reinstall new filters and skid plates. Use

only hydro-gear filters. Use of any other type of filter will result in

damage to the hydro system and void the warranty. Transaxle

service recommended within the first 50 hours of usage and every

250 hours thereafter or once a year.

7

(ZT and Outlaw Models)

The check plug is located at the top center of the inside case of each

transaxle (outlaw transaxles have this plug on the top). The

transaxle can be filled with oil by removing these check plugs from

both transaxles and pouring the oil in the hydro overflow tank, located

behind the seat. Oil will begin to run out of the check plug holes

when the transaxles are full. Use only 20w50 motor oil in the hydro

system.

8

(ZT model shown)

Once the system is filled with oil, lift rear of mower until rear tires are

off the ground. Start engine, release parking brake, 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), move the drive arms

forward and backward 4 to 6 times slowly. This relieves any air that

may be trapped in the system. It may be necessary to add more oil to

the hydro overflow tank after 10-15 minutes of running. These bypass

levers also serve as a neutral for moving the mower without the

engine running.

9

SECTION 2: DRIVE BELT

Shown above is the AOS/Diesel pump belt tensioner. Tightening the two ¾”jam

nuts on the left side will increase the belt tension on all models. Factory setting

is about .030” (about the thickness of a credit card) between coils as shown.

10

Shown above is a typical pump belt tesioner for ZT, Pup, Lightning,

and Outlaw models.

Shown above is a typical pump belt layout for most models.

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