Bad Boy Outlaw XP 5400 Owner's, Service & Parts Manual
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Bad Boy Outlaw XP 5400 Owner's, Service & Parts Manual

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OUTLAW XP
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 XP 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 This manual applies to the following equipment: Bad Boy Outlaw XP Series Outlaw XP 5400 54˝ 852cc Kawasaki FX-850 Outlaw XP 6100 61˝ 852cc Kawasaki FX-850 Outlaw XP 7200 72˝ 852cc Kawasaki FX-850 Outlaw XP 6100 61˝ 993cc Vanguard Outlaw XP 7200 72˝ 993cc Vanguard...
  • Page 4 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 Before moving the mower, turn the bypass valves counterclockwise one-half to one revolution. The bypass valve bolts are located on the side of each pump and are easily identified by the hole through the bolt heads. 8.4 Your Bad Boy Mower Weighs: OUTLAW XP SERIES: 1180—1310 lbs *** Weights fluctuate with the addition of accessories.

  • Page 16: Mower Blade Maintenance

    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

    50 hours of use; then at intervals of 250 usage hours. Use only Bad Boy replacement filters. Use of any other filters may result in damage to the hydraulic system and void the warranty. Each side requires approximately two quarts of oil to refill the system.
  • Page 20 Fill the new hydraulic oil filters with 20W-50 motor oil. Only use Bad Boy replacement filters. Place the hydraulic return lines back onto the Hydrogear pumps. Fill each hydraulic reservoir tank until the oil level reaches the bubble on the dipstick. Be careful not to overfill the hydraulic reservoir tanks.
  • 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.
  • Page 22 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 23 SECTION 3: ENGINE Kawasaki FX850V 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.
  • Page 24 4) Apply a thin film of clean oil to rubber gasket on new filter 5) Refer to instructions on oil filter for proper installation. 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.
  • Page 25 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 26 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 27 993cc 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.
  • 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 Doing so creates a significant fire hazard a nd can cause severe damage to the mower’s electrical components. If a fuse is repeatedly blowing, contact your Bad Boy dealer. On most m odels, the red wire coming out of the engine is the charging wire from the a lternator.
  • Page 32 PAGE 32...
  • Page 33 SECTION 5: FRAME The front fork nuts require a torque of 40ft-lbs. First remove the dust cap. 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.
  • 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.
  • Page 35 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 36 Leveling the Deck 1) Start on a flat level surface and set the air pressure in all four tires to 12 psi. 2) Get two 2x4s and make sure that the wider sides are similar length. 3) Take off the foot pedal and raise the floor plate.
  • Page 37 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 37...
  • Page 38 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 39: Parts Section

    PARTS SECTION Outlaw XP Suspension Fork Assembly Parts List ITEM PART NUMBER DESCRIPTION 023-0020-00 Suspension Fork Top/Side Combo 023-0012-00 Suspension Fork - Bottom Left 023-0013-00 Suspension Fork - Bottom Right 037-0010-00 Front Suspension Fork Spindle 013-5300-00 1/2" Flange Nut 018-2030-00 1/2"...
  • Page 40 Oultaw XP Drive Arms Welded to Frame PAGE 40...
  • Page 41 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 42 Outlaw XP Gas Tank Assemblies DETAIL A DETAIL B PAGE 42...
  • Page 43 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 44 DETAIL A DETAIL C DETAIL B PAGE 44...
  • Page 45 Parts List ITEM PART NUMBER DESCRIPTION 018-8064-00 1/4" x 5/8" BS C/S 18-8 SS 064-2006-00 Floor board Cable W/ Swivel Ends 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...
  • Page 46 DETAIL A DETAIL B PAGE 46...
  • Page 47 Parts List ITEM PART NUMBER DESCRIPTION 070-5380-00 2015 XP Frame 018-5043-00 3/8" x 1 1/4" Carriage Bolt 013-5041-00 3/8 Nylock Nut 018-4702-00 1/4-20 x 1-1/4 GR 5 Hex Bolt 029-7037-00 14" Rubber Bumper 019-7040-00 1/4" Flat Washer 026-2180-00 2015 Outlaw Rear Plate 019-8040-00 1/4"...
  • Page 48 DETAIL B DETAIL C PAGE 48...
  • Page 49 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" x 1" Carriage Bolt 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 50 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 041-8411-00 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 51 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 52 Outlaw 54" Deck DETAIL B DETAIL A DETAIL C DETAIL D PAGE 52...
  • Page 53 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 54 Outlaw 61" Deck DETAIL B DETAIL A DETAIL C DETAIL D PAGE 54...
  • Page 55 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 56 Outlaw 72" Deck DETAIL A DETAIL B DETAIL C DETAIL D PAGE 56...
  • Page 57 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 58 037-4000-50 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 58...
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  • Page 60 NOTES: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ PAGE 60...
  • Page 61 NOTES: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ PAGE 61...

  • Page 62: 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 63 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 64 For additional information, please see us at www.badboymowers.com Bad Boy, Inc. 102 Industrial Drive Batesville, Arkansas 72501...

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