Bad Boy COMPACT OUTLAW Owner's, Service & Parts Manual
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Bad Boy COMPACT OUTLAW Owner's, Service & Parts Manual

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

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  • Page 1 COMPACT OUTLAW MODEL 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 Compact Outlaw Series Compact Outlaw 4200 42” 726cc Kawasaki FX691V Compact Outlaw 4800 48” 726cc Kawasaki FX691V Compact Outlaw 4200 42” 810cc Vanguard Compact Outlaw 4800 48” 810cc Vanguard COMMONLY USED ITEMS AND PART NUMBERS...
  • 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, and switch will automatically return to he RUN position.
  • Page 15 By pulling the arms out, the mower can be put in a neutral position. Return the arms to the “forward position” for normal operation. 8.4 Your Bad Boy Mower Weighs: SERIES: 862—925 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

    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 filter 1) Remove the tops from the hydraulic fluid reservoirs and get an oil drain pan.
  • Page 20 10) Fill with 20W-50 motor oil (Bad Boy Hydrostatic oil is recommended) through the hydraulic fluid reservoirs until it just appears at the bottom of each transaxle’s top port (approximately 2 quarts per transaxle, 4 quarts total).
  • Page 21 Once the system is filled with oil, lift rear of mower until rear tires are off the ground. Start engine, release parking When adjusting the tracking on the mower, the brake, and stay clear of moving rear tires. Next, pull the length of the pushrods can be changed by neutral bypass levers (located at the rear of the frame, on screwing the swivel joint in or out on the ends...
  • Page 22 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 23 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 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.
  • 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 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 26 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 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.
  • Page 28 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 29 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. Check for 13.6 - 14.2 volts dc at this wire with engine at full throttle.
  • Page 30 PAGE 30...
  • Page 31 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 32 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 33 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 34 Leveling the Deck 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 35 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.
  • Page 36 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. You might need to put a ¾”...

  • Page 37: Parts Section

    PARTS SECTION Front Fork Assembly Parts List ITEM PART NUMBER DESCRIPTION 023-7913-00 Front Fork 025-5202-00 Front Wheel Spanner 022-7009-00 1 3/8" Wheel Bearing 018-7010-00 1/2" x 9" GR 5 Hex Bolt 013-8050-00 1/2-13 Nylon Flange Nut 025-0004-00 Caster Bearing Spacer 013-9004-00 1"...
  • Page 38 Adjustable Drive Arm Assemblies Welded to Frame PAGE 38...
  • Page 39 Adjustable Drive Arm Assemblies ITEM PART NUMBER DESCRIPTION 027-8901-00 2013 Drive Lever Housing (Right) 031-9025-00 Steering Arm Elbow - Right 035-5450-00 Push Rod - Right 031-9015-00 Lower Adjuster - Steering Arm- Right 031-9016-00 Upper Adjust Steering Arm- Right 031-9010-00 Upper Tube-Adjustable Steering 027-8900-00 2013 Drive Lever Housing (Left) 031-9020-00...
  • Page 40 DETAIL B DETAIL A PAGE 40...
  • Page 41 Parts List ITEM PART NUMBER DESCRIPTION 070-5500-00 2016 Compact Outlaw Frame 067-5000-50 Right Fuel Tank/Outlaw/2012/EPA 067-5001-50 Left Fuel Tank/Outlaw/2012/EPA 025-2000-00 .380x.735x.470 Nylon Spacer 066-8083-00 Fuel Cap 019-7040-00 1/4" Flat Washer 019-8051-00 5/16" Lock Washer 018-2006-00 5/16 x 1 1/4 Hex Bolt 019-6042-00 .360 ID Plastic Washer...
  • Page 42 DETAIL B DETAIL A PAGE 42...
  • Page 43 Parts List ITEM PART NUMBER DESCRIPTION 070-5500-00 2016 Compact Outlaw Frame 018-5040-00 3/8" x 1 1/4" Hex Bolt 034-8045-00 Seat Spring 014-8047-00 Seat Spring Cap Cover 019-5029-00 3/8" Flat Washer 019-5037-00 3/8" Lock Washer 013-6014-00 3/8-16 Hex Nuts Zinc 030-3050-00 #10 x 1/2"...
  • Page 44 DETAIL B DETAIL A PAGE 44...
  • Page 45 Parts List ITEM PART NUMBER DESCRIPTION 070-5500-00 2016 Compact Outlaw Frame 028-0005-00 Actuator Bar Front- 2016 Compact Outlaw 028-0006-00 Actuator Bar Rear- 2016 Compact Outlaw 018-5019-00 1/2" x 4" Bolt (Grade 8) 013-8050-00 1/2-13 Nylon Flange Nut 017-9000-00 Two Piece Pillow Block (Male)
  • Page 46 Transaxle Assembly DETAIL A PAGE 46...
  • Page 47 Parts List ITEM PART NUMBER DESCRIPTION 050-6000-00 Left 3400 IZT 050-6001-00 Right 3400 IZT 050-2072-00 Fan/Pully kit 034-9080-00 Transaxle Spring 063-1050-00 Hydraulic Filter 028-4802-00 Crossover Bar for ZT 2016 025-5340-00 Transaxle Spacer 019-8044-00 5/16" Flat Washer 013-8049-00 5/16" Nylock Flange Nut 018-5355-00 5/16"...
  • Page 48 Kawasaki FX-691V Parts List ITEM PART NUMBER DESCRIPTION 015-0691-00 FX-691V 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 49 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 064-8061_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 50 42" Deck Assembly DETAIL B DETAIL A PAGE 50...
  • Page 51 Parts List ITEM PART NUMBER DESCRIPTION 060-5442-00 42" Compact Outlaw Deck-Welded Shell 018-1050-00 1/2 x 2" Carriage Bolt 019-0007-00 .517 Square Hole Round Washer 013-8050-00 1/2-13 Nylon Flange Nut 037-6015-50 Spindle Assembly 018-5040-00 3/8" x 1 1/4" Hex Bolt 019-5037-00 3/8"...
  • Page 52 48" Deck Assembly DETAIL B DETAIL A PAGE 52...
  • Page 53 Parts List ITEM PART NUMBER DESCRIPTION 060-5448-00 48" Compact Outlaw Deck-Welded Shell 018-1050-00 1/2 x 2" Carriage Bolt 019-0007-00 .517 Square Hole Round Washer 013-8050-00 1/2-13 Nylon Flange Nut 018-5040-00 3/8" x 1 1/4" Hex Bolt 019-5037-00 3/8" Lock Washer 013-6014-00 3/8"...
  • Page 54 037-6015-50 Spindle Assembly Parts List ITEM PART NUMBER DESCRIPTION 037-6017-50 Spindle Housing 037-9050-00 Locking Collar w/ 1/4"-20 Set Screw 037-8002-00 Spindle Dust Cap 037-6026-00 Spindle Shaft 037-8050-00 Spindle Spacer 037-6023-00 Bearing - 6206 PAGE 54...
  • Page 55 091-1111-00 091-1110-00 091-1048-00 091-0903-00 810cc Decal 726cc Decal 42” Deck Decal 48” Deck Decal 091-3012-00 Danger Decal – Spindle/Discharge 091-3017-00 091-3309-00 Pump Belt Route Decal Deck Belt Route Decal 091-0901-00 Instrument Panel Decal 091-1102-00 091-1103-00 Left Steering Right Steering Control Decal 091-0201-00 Control Decal Logo Decal Front...
  • Page 56 NOTES: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ PAGE 56...
  • Page 57 NOTES: __________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ PAGE 57...

  • Page 58: 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 59 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 60 For additional information, please see us at www.badboymowers.com Bad Boy, Inc. 102 Industrial Drive Batesville, Arkansas 72501...

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