Bad Boy Outlaw 6100 Owner's, Service & Parts Manual
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Bad Boy Outlaw 6100 Owner's, Service & Parts Manual

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OUTLAW
OUTLAW EXTREME
ZERO-TURN MOWER
OWNER'S, SERVICE & PARTS MANUAL
For additional information, please see us at
www.badboymowers.com
&
MODELS
Bad Boy, Inc.
102 Industrial Drive
Batesville, Arkansas 72501
©2015 12-11

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  • Page 1 OUTLAW & OUTLAW EXTREME MODELS 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Basic Information ....................Section 1 (page 4) Bad Boy Safety Guidelines ................Section 2 (pages 5–8) Operation ......................Section 3 (pages 9) Maintenance ...................... Section 4 (page 10) Storage and Transportation ................Section 5 (page 12) Troubleshooting and FAQ ..................Section 6 (page 13) Controls ......................
  • Page 3 Outlaw Extreme 6100 61˝ 824cc Kohler EFI Outlaw 5400 54˝ 747cc Kohler Confidant Outlaw Extreme 5400 54˝ 852cc Kawasaki FX-850 Outlaw 6100 61˝ 747cc Kohler Confidant Outlaw Extreme 6100 61˝ 852cc Kawasaki FX-850 Outlaw 5400 54˝ 726cc Kawasaki FX-730 Outlaw Extreme 7200 72˝ 852cc Kawasaki FX-850 Outlaw 6100 61˝...

  • Page 4: Warranty Registration

    40 CFR 1060 within the first two years Bad Boy Inc. will replace the defective component. Your evaporative emission control system may include parts such as fuel tanks, fuel lines, carbon canisters, fuel caps, valves, vapor hoses, clamps, or connectors.

  • Page 5: General Operation

    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 to deflect debris downward, but it could be possible for debris to be thrown in a way that can cause damage to people or property.

  • 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: 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 container. 2.47 Never remove gas cap or add fuel with the engine running.

  • Page 8: Safety Interlock System

    SAFETY INTERLOCK SYSTEM Your Bad Boy mower is equipped with a safety interlock system. This system is designed to prevent serious injury or death to the operator and other people or property damage. The system consists of an operator presence switch in the seat, the parking brake, drive lever neutral position, the mower blade engagement switch, and the ignition switch.
  • Page 9 The machine could lose traction on a decline or tip backwards on an incline. 3.14 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing time will decrease.
  • Page 10 SECTION 4: MOWER MAINTENANCE Interval First Every 50 Every 100 Every Daily hours or hours or Section Maintenance hours annually* annually* hours Check and add engine oil ● Section 3 Section 2 Check all belts for proper alignment ● (Pump) 6 (Deck) Check tire pressure and wheel lug ●...
  • Page 11 Maintenance Log Date: Hours: Performed: Performed Date: Hours: Date: Hours: Performed: Performed Date: Hours: Performed Date: Hours: Date: Hours: Performed: Performed Date: Hours: Date: Hours: Performed: Performed Date: Hours: Performed Date: Hours: Performed: Date: Hours: Date: Hours: Performed: Performed Date: Hours: Performed Date:...
  • Page 12 SECTION 5: MOWER STORAGE & TRANSPORTATION 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. E-15 is not permitted.
  • Page 13 SECTION 6: TROUBLESHOOTING Q: How do I prevent an uneven cutting pattern and increase the quality of cut? 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, check the underside of the deck to ensure the mower deck is free of grass build-up and debris, make sure your machine is at full throttle, and vary your mowing pattern each time you cut your grass.
  • Page 14 SECTION 7: CONTROLS 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. Switch will automatically return to he RUN position.
  • Page 15 These bypass valves are located on top of the Outlaw’s transaxles and on the inner side of the Outlaw Extreme’s transaxles. Each require a quarter turn to allow for proper bypass. 8.4 Your Bad Boy Mower Weighs: OUTLAW SERIES: 1180—1310 lbs *** Weights fluctuate with the addition of accessories.

  • Page 16: Greasing Bearings

    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 a few hours. A dull blade will also require more power from the engine.

  • Page 17: How To Choose The Right Blade

    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 lawn or to be captured in a grass collection system.

  • 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.

  • Page 19: Service Section

    PERFORMED ON A LEVEL SURFACE. Outlaw transaxles hold 4 quarts of 20W-50 moto oil each. Bad Boy Hydrostatic Oil is recommended. Transaxle service is recommended after the first 75 hours of use; then at intervals of 250 usage hours. Use only Hydro-Gear ®...
  • Page 20 Outlaw Extreme transaxles hold 4.75 quarts each. Bad Boy Hydrostatic Oil is recommended. Transaxle service is recommended after the first 75 hours of use; then at intervals of 250 usage hours. Use only Hydro- Gear ®...
  • Page 21 Changing your hydraulic oil and filter Extreme 5400 1) Place an oil drain pan (12” or more in diameter and 8 qt. capacity is optimal) beneath the oil filter. Remove the oil filter cover from the transaxle to drain the oil. Remove the O-ring from the cover and discard the O-ring.
  • Page 22 Under the rear of the mower, you will find the two levers shown in the image. These bypass levers serve as a neutral for moving the mower while the engine is not running. Pull the levers out and lock them into place to activate the bypass.
  • Page 23 SECTION 2: DRIVE BELT Shown on the right is the tensioner for your pump belt. Adjusting this will either increase or decrease tension on the belt. Use a ¾” wrench to loosen the jam nuts and either tighten for more belt tension or loosen for less belt tension.
  • Page 24 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 is recommended for maximum protection.
  • Page 25 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 leakage.
  • Page 26 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.
  • Page 27 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 is recommended for maximum protection.
  • Page 28 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 leakage.
  • Page 29 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.
  • Page 30 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.
  • Page 31 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 is recommended for maximum protection. 3.1 Changing your engine oil and oil filter...
  • Page 32 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.
  • Page 33 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.
  • Page 34 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 is recommended for maximum protection.
  • Page 35 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 leakage.
  • Page 36 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.
  • Page 37 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.
  • Page 38 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 is recommended for maximum protection.
  • Page 39 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.
  • Page 40 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.
  • Page 41 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 is recommended for maximum protection.
  • Page 42 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 leakage.
  • Page 43 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 reduce the air cleaner’s effectiveness.
  • Page 44 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.
  • Page 45 If a fuse is repeatedly blowing, contact your Bad Boy dealer. On most models, the red wire coming out of the engine is the charging wire from the alternator.
  • Page 46 PAGE 46...
  • Page 47 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 and check at every mowing.
  • Page 48 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.
  • Page 49 SECTION 6: CUTTING DECK 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.
  • Page 50 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.
  • Page 51 The blade on the top (see photo) was utilized long after replacement was required. In addition to a decline in cut quality, failure to replace a worn or damaged blade creates a major safety hazard. Bad Boy recommends that blade sharpening be performed by a professional. PAGE 51...
  • Page 52 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.

  • Page 53: Parts Section

    PARTS SECTION Outlaw & Outlaw Extreme Front Wheel Assembly Parts List ITEM PART NUMBER DESCRIPTION 023-7913-00 Front Fork 012-7003-00 Seal 013-8050-00 1/2-13 Nylon Flange Nut 018-7010-00 1/2" x 9" GR 5 Hex Bolt 014-7005-00 Dust Cover 010-7001-00 Bearing 025-5202-00 Front Wheel Spanner 022-7009-00 1 3/8"...
  • Page 54 Outlaw Drive Arms Welded to Frame PAGE 54...
  • Page 55 Parts List ITEM PART NUMBER DESCRIPTION 034-8025-00 Drive Lever Spring 032-5055-00 Bushing for 2012 Drive Arms 019-8027-00 .515 ID Nylon Shoulder Washer 024-6034-00 1/4" Press in Grease Fitting 013-8050-00 1/2-13 Nylon Flange Nut 013-8043-00 5/16" Nut 018-8063-00 5/16" x 3/4" Hex Bolt 013-6051-00 3/8"...
  • Page 56 Outlaw Gas Tank Assemblies DETAIL A DETAIL B PAGE 56...
  • Page 57 Parts List ITEM PART NUMBER DESCRIPTION 080-5116-00 2016 Outlaw Seat Bracket 018-8065-00 5/16-18 x 1 Carriage Bolts Zinc 019-6042-00 .360 ID Plastic Washer 013-5202-00 3/8" Nylock Flange Nut 018-5043-00 3/8" x 1 1/4" Carriage Bolt 013-8049-00 5/16-18 Nylon Insert Flange Nut Zinc Orange Nylon 018-2007-00 5/16"...
  • Page 58 DETAIL A PAGE 58...
  • Page 59 Parts List ITEM PART NUMBER DESCRIPTION 070-5370-00 2015 Standard/Extreme Outlaw Frame 013-8049-00 5/16" Nylock Flange Nut Zinc 018-8065-00 5/16" x 1" Carriage Bolt 019-6042-00 .360 ID Plastic Washer 030-3050-00 #10 x 1/2" Self Tapping Screw 029-4010-00 Button Bumper 029-7038-00 8" Rubber Bumper 030-7039-00 1/4"...
  • Page 60 DETAIL C DETAIL B OUTLAW EXTREME DETAIL C OUTLAW DETAIL A PAGE 60...
  • Page 61 Parts List ITEM PART NUMBER DESCRIPTION 070-5370-00 2015 Standard/Extreme Outlaw Frame 028-6030-00 2015 Outlaw Act Bar Assembly (Front) 028-6040-00 2015 Outlaw Act Bar Assembly (Rear) 028-6050-00 Outlaw Deck Linkage Rod 013-8050-00 1/2-13 Nylon Flange Nut 032-3000-00 Bushing- SF-1620-4 018-0008-00 1/2 x 1-1/2 Carriage Bolt 017-9000-00 Two Piece Pillow Block (Male) 017-9050-00...
  • Page 62 DETAIL B DETAIL C PAGE 62...
  • Page 63 Parts List ITEM PART NUMBER DESCRIPTION 080-5116-00 2016 Outlaw Seat Bracket 014-2100-00 Outlaw Cooler Cover 026-2016-00 2016 Seat Plate Outlaw 018-8065-00 5/16-18 x 1 Carriage Bolts Zinc 019-6042-00 .360 ID Plastic Washer 013-5202-00 3/8" Nylock Flange Nut 018-5043-00 3/8" x 1 1/4" Carriage Bolt 030-7042-00 5/16 x 3/4 washer head type F screw 013-8049-00...
  • Page 64 Parts List ITEM PART NUMBER DESCRIPTION 203-0100-00 Outlaw Transaxle Cross Brace 018-5006-00 1/2" x 1 1/2" Hex Bolt 050-7000-00 ZT - 5400 - Left (Extreme Only) 018-2030-00 1/2" x 1" Hex Bolt 050-7001-00 ZT - 5400 - Right (Extreme Only) 013-3000-00 Acorn Lug Nut 022-5349-00...
  • Page 65 Kawasaki FX-730V Parts List ITEM PART NUMBER DESCRIPTION 015-0730-00 FX-730V 042-5020-00 1/4 x 2 Square key Stock 033-5035-00 4 3/4 Motor Pulley 070-1000-00 Clutch Assembly 018-5300-00 7/16" x 2 1/2" Hex Bolt 019-8053-00 7/16" Lock Washer 070-2000-00 Clutch Pigtail 015-5404-00 oil drain 015-5403-00 O-Ring...
  • Page 66 Kohler 747cc Assembly Parts List ITEM PART NUMBER DESCRIPTION 033-5035-00 4 3/4 Motor Pulley 018-1075-00 3/8 x 1 1/8 bolt 042-5020-00 1/4 x 2 Square key Stock 015-2751-00 Exhaust Gasket 015-5401-00 Oil drain Valve 018-8067-00 5/16-18 x 3/4 Socket C/S 030-0050-00 5/16 Set Screw 086-0005-00...
  • Page 67 824cc EFI Kohler Parts List ITEM PART NUMBER DESCRIPTION 015-0824-00 824cc EFI Kohler 042-5020-00 1/4 x 2 Square key Stock 030-6029-00 3/8" Set Screw 051-5401-00 Oil drain Hose 033-5035-00 4 3/4 Motor Pulley 019-6029-00 1 1/8" Flat Spacer 019-8053-00 7/16" Lock Washer 018-5300-00 7/16"...
  • Page 68 810cc Vanguard Parts List ITEM PART NUMBER DESCRIPTION 015-0810-00 810 Vanguard 030-6029-00 3/8" Set Screw 033-5035-00 4 3/4 Motor Pulley 018-1075-00 3/8 x 1 1/8 bolt 086-0005-00 Ground Cable 018-8059-00 5/16" x 1 3/4" Hex Bolt 013-8043-00 5/16" Nut 019-8051-00 5/16"...
  • Page 69 Kawasaki FX 850-V Parts List ITEM PART NUMBER DESCRIPTION 015-0031-00 Kawasaki Engine FX-850-V-CS09R 033-5035-00 4 3/4 Motor Pulley 041-5048-00 Pump Belt 030-6029-00 3/8" Set Screw 042-5020-00 1/4 x 2 Square key Stock 018-1075-00 3/8 x 1 1/8 bolt 015-5404-00 oil drain 103-5400-00 Black Boot For Ground Cable 018-5321-00...
  • Page 70 993cc Vanguard 993cc Vanguard ITEM PART NUMBER DESCRIPTION 042-6030-00 1/4" x 1" Key 030-0050-00 5/16 Set Screw 086-0005-00 Ground Cable 019-8051-00 5/16" Lock Washer 013-8043-00 5/16" Nut 103-5400-00 Black Boot For Ground Cable 018-8059-00 5/16" x 1 3/4" Hex Bolt 018-1075-00 3/8 x 1 1/8 bolt 015-0025-00...
  • Page 71 Outlaw 54" Deck DETAIL B DETAIL A DETAIL C DETAIL D PAGE 71...
  • Page 72 Parts List ITEM PART NUMBER DESCRIPTION 060-5550-00 2015 54" Deck 018-5250-00 3/8" x 3/4" Hex Bolt 013-5201-00 3/8" Flange Nut 013-8050-00 1/2-13 Nylon Flange Nut 018-2018-00 1/2 x 3 1/2 Flange Bolt Grade 8 025-5338-00 .502 ID X .750 OD X 1.500 Long Spacer 018-1050-00 1/2 x 2"...
  • Page 73 Outlaw 61" Deck DETAIL B DETAIL A DETAIL C DETAIL D PAGE 73...
  • Page 74 Parts List ITEM PART NUMBER DESCRIPTION 060-6150-00 2015 61" Deck 018-5250-00 3/8" x 3/4" Hex Bolt 013-5201-00 3/8" Flange Nut 013-8050-00 1/2-13 Nylon Flange Nut 018-2018-00 1/2 x 3 1/2 Flange Bolt Grade 8 025-5338-00 .502 ID X .750 OD X 1.500 Long Spacer 018-1050-00 1/2 x 2"...
  • Page 75 Outlaw 72" Deck DETAIL A DETAIL B DETAIL C DETAIL D PAGE 75...
  • Page 76 Parts List ITEM PART NUMBER DESCRIPTION 060-7250-00 2015 72" Deck 033-7201-00 5-3/4 Idler Pulley-Don Dye 013-8050-00 1/2-13 Nylon Flange Nut 018-2018-00 1/2 x 3 1/2 Flange Bolt Grade 8 025-5338-00 .502 ID X .750 OD X 1.500 Long Spacer 018-1050-00 1/2 x 2"...
  • Page 77 037-4000-50 Double Bearing Spindle Parts List ITEM PART NUMBER DESCRIPTION 037-4001-00 4000 Series Spindle Housing 037-4002-00 4000 Series Spindle Spacer 037-9050-00 Locking Collar w/ 1/4"-20 Set Screw 037-8002-00 Spindle Dust Cap 037-6026-00 ZT-AOS Spindle Shaft 037-6023-00 Bearing - 6206 PAGE 77...

  • Page 78: Limited Warranty

    The leading edge of the deck shell will be warranted for the entire lifetime of the machine to the original purchaser against defects in materials and workmanship. Labor required to repair or replace the leading edge of the deck shell will be covered by Bad Boy Inc. for two years and at the unit owner’s expense during the balance of the lifetime of the machine.
  • Page 79 Bad Boy, Inc. 102 Industrial Drive Batesville, AR 72501 www.badboymowers.com Technical Support: ............techsupport@badboymowers.com Warranty: ..................warranty@badboymowers.com Parts: ....................partsdept@badboymowers.com WARRANTY REGISTRATION Ensure selling dealership has registered mower within 30 days of purchase to validate warranty. Please record your serial number, date of purchase and dealership information for your records.
  • Page 80 For additional information, please see us at www.badboymowers.com Bad Boy, Inc. 102 Industrial Drive Batesville, Arkansas 72501...

This manual is also suitable for:

Outlaw 5400Outlaw extreme 5400Outlaw extreme 6100Outlaw extreme 7200

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