Bad Boy WALK-BEHIND Series Owner's Operator Service And Parts Manual
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Bad Boy WALK-BEHIND Series Owner's Operator Service And Parts Manual

Zero-turn mower with 36" fs541v, 48" fs541v, 54" fs600v 603cc kawasaki engines
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WALK-BEHIND
MODEL
ZERO-TURN MOWER
OWNER'S OPERATOR
SERVICE AND PARTS MANUAL
For additional information, please see us at
www.badboymowers.com
©2020 3-10

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Summary of Contents for Bad Boy WALK-BEHIND Series

  • Page 1 WALK-BEHIND MODEL ZERO-TURN MOWER OWNER’S OPERATOR SERVICE AND PARTS MANUAL For additional information, please see us at www.badboymowers.com ©2020 3-10...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Basic Information ..................... Section 1 Page 4 Bad Boy Safety Guidelines ..................Section 2 Page 5 Operation ......................... Section 3 Page 9 Maintenance ......................Section 4 Page 10 Storage and Transportation ..................Section 5 Page 10 Troubleshooting and FAQ ..................Section 6 Page 12 Controls ........................
  • Page 3 Air Filter 063-2097-00 Oil Filter 063-8017-00 10W-30 Motor Oil - Bad Boy Synthetic Blend Motor Oil Recommended. Motor Oil 085-6015-00 20W-50 Motor Oil- Bad Boy Hydrostatic Oil Recommended (Approximately 2.5 Quarts/Transaxle) Hydraulic Oil 085-6000-00       PAGE 3   ...

  • Page 4: Basic Information

    The Warranty Registration form must be completed within 30 days to validate your warranty. As the new equipment owner, you are expected to see that the form is completed and forwarded to Bad Boy Inc. at time of delivery. Warranty is nontransferable. Warranty registration should be completed by the selling dealership using the on-line registration site.
  • Page 5   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   2.21 Data indicates that operators 60 years of age and above are involved in a large percentage of riding mower related injuries. These operators should periodically evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury. 2.22 Prevent fires by keeping engine and exhaust areas clear of grass clippings and other debris.
  • Page 7   TOWING 2.41 Tow only with a machine that has a hitch specifically designed for towing. Do not attach towed equipment except at the hitch point. 2.42 Follow the manufacturer’s recommendation for weight limits for towed equipment and towing on slopes. 2.43 Never allow children or others in or on towed equipment.
  • Page 8 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 handlebar, the parking brake, speed control neutral position, the mower deck PTO switch, and the ignition switch.

  • Page 9: Operation

    The machine could lose traction on a decline or tip backwards on an incline. 3.13 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing time will decrease. Avoid operating your mower on side hills of over 5 degrees, inclines of over 10 degrees, and declines of over 15 degrees.

  • Page 10: Maintenance

      SECTION 4: MOWER MAINTENANCE Interval Every 50 Every 100 Every First 8 Daily Hours or Hours or Section Hours Annually* Annually* Hours Maintenance Check and add engine oil Section3      Section 2 (Pump) Check all belts for proper alignment ...
  • Page 11   MAINTENANCE LOG Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date: Hours: Performed: Date:...
  • Page 12   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 13: Controls

    RPM, move lever toward operator to decrease RPM. Key Switch: Bad Boy WALK-BEHIND mowers have two position key switch: off and on. With key inserted, rotate it clockwise to on position. Your WALKBEHIND mower is now ready to be started.

  • Page 14: Moving Inoperable Mower

    OUTLAW WALK-BEHIND SERIES: 590 lbs. ***Weights fluctuate with the addition of accessories. As you can see by the weights of the machines, you shouldn’t ever try to push or pull a Bad Boy Mower by hand. This could cause serious bodily injury.

  • Page 15: 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.

  • Page 16: 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: 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 17: 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 18: Service Section

      SERVICE SECTION Hydraulic Fluid SECTION 1: HYDROSTATIC SYSTEM Reservoirs The hydraulic fluid reservoirs are accessed by raising the seat forward. 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 Remove the caps from the hydraulic fluid...
  • Page 19   CHANGING YOUR HYDRAULIC OIL AND FILTER (CONTINUED) Fill with 20W-50 motor oil (Bad Boy Hydrostatic Top Port Plug 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 20   Under the front of the mower engine plate, 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 using the cotter pin to activate the bypass.
  • Page 21   SECTION 2: DRIVE BELT Shown below is the pump belt tensioner. Using a 3/4" wrench, tightening the two jam nuts will increase the belt tension. Pump Belt Spring Tension Adjustment The tension should be adjusted so that there is between 60 to 65 lbs. of tension on the belt. This can be checked with a belt tension gauge (Part Number 041-9999-00) as shown to the right.
  • Page 22 8 hrs. of use, and at intervals of 50 usage hours or yearly, whichever occurs first after that. The oil capacity is 2 quarts. Bad Boy 10W-30 synthetic blend engine oil is Fuel Filter recommended for maximum protection.
  • Page 23   FUEL FILTER The fuel filter is located in the fuel line. Replace the filter yearly. Prior to the removal of the old filter, note the direction of fuel flow as indicated on the filter. Have Fuel Line towels readily available in order to quickly remove any Clamp fuel leakage.
  • Page 24   AIR CLEANER 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   SPARK PLUG CHANGING THE SPARK PLUGS AND CHECKING THE SPARK PLUG GAP In order to access the spark plugs it is recommended to remove the rear engine cover. Spark Plugs This can be accomplished by removing the four carriage bolts using a 1/2” ratcheting wrench. Remove the wire on the spark plug and use an appropriate socket to remove the spark plug.
  • Page 26   SECTION 4: ELECTRICAL SYSTEM WIRING DIAGRAM (For a larger version of the below diagram please visit badboymowers.com and click the parts manuals section) PAGE 26  ...
  • Page 27   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. To access the recessed front fork nuts, remove the dust cap by prying gently using a flat-head screwdriver.
  • Page 28   SECTION 6: CUTTING DECK Remove DECK BELT REMOVAL Pulley Cover Remove ignition key. Raise the deck to its highest position. Belt Route Decal Remove the deck cover. While lifting up on the belt (as shown in the photograph), rotate the pulley until the belt is free of the pulley.
  • Page 29 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 29 ...
  • Page 30   LEVELING THE DECK Make sure that each tire is at 12PSI. Remove pins from deck height adjustment rods and raise or lower deck to desired height by using the handles located on each side of the deck. Deck Height Pins Once the desired deck height is achieved, replace the pins back in the deck height adjustment rods making sure...
  • Page 31   15/16” Socket Blade Bolts are Right and Impact or a Hand Thread BLADE REMOVAL Wrench with and Extension To change blades, it may be best to use a piece of wood positioned between the blade and mowing deck to keep the blade from turning. Use a 15/16"...
  • Page 32 PARTS SECTION: FRONT END PART PART ITEM DESCRIPTION ITEM DESCRIPTION NUMBER NUMBER 010-1050-00 1641 BEARING W/2 CONTACT RUBBER SEALS 72.2 022-2012-00 11x4.00 - 5 Tire Only 013-8050-00 1/2-13 NYLON INSERT FLANGE LOCKNUT ZINC 72.3 022-7009-00 Ball Bearing w/Retainer, 99502H-NR, .625 Bore x 1.375 OD x .4375 Width 013-9004-00 1"-14 NYLON INSERT JAM LOCKNUT ZINC 023-0002-00...
  • Page 33 PARTS SECTION: CONTROL PANEL PART PART ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION NUMBER NUMBER 013-5019-00 10-24 NYLON INSERT LOCKNUT ZINC 077-0001-00 Brake switch 4 prong 013-6051-00 3/8-24 HEX NUT ZINC YELLOW 077-0002-00 safety Switch 018-5200-00 10-24 X 5/8 BUTTON SOCKET CAP SCREW 18-8 STAINLESS STEEL 077-0003-00 Ignition Switch 042-9000-00...

  • Page 34: Parts Section

    PARTS SECTION: PODIUM ASSEMBLY Parts List Parts List PART PART ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION NUMBER NUMBER 013-5019-00 10-24 NYLON INSERT LOCKNUT ZINC 031-0039-70 2020 Walk Handle Bar 013-5041-00 3/8-16 NYLON INSERT LOCKNUT ZINC 031-0042-00 2020 Walk-Behind Control Lever Assembly - Left 013-8049-00 5/16-18 NYLON INSERT FLANGE LOCKNUT ZINC 031-0043-00...
  • Page 35 PARTS SECTION: PODIUM CONTINUED ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 013-0012-00 3/8-16 HEX JAM 2-WAY REVERSIBLE CENTER LOCKNUT ZINC 106.1 013-0016-00 3/8" Left-Handed Fine Threaded Jam Nut 013-5041-00 3/8-16 NYLON INSERT LOCKNUT ZINC 106.2 013-6051-00 3/8" Fine Threaded Jam Nut 013-8049-00 5/16-18 NYLON INSERT FLANGE LOCKNUT ZINC 106.3...
  • Page 36 PARTS SECTION: PODIUM SUBASSEMBLIES 031-0042-00 Parts List 031-0043-00 Parts List PART PART ITEM DESCRIPTION ITEM DESCRIPTION NUMBER NUMBER 95.1 024-6034-00 1/4 DRIVE-TYPE STRAIGHT GREASE FITTING ZINC YELLOW) 96.1 024-6034-00 1/4 DRIVE-TYPE STRAIGHT GREASE FITTING ZINC YELLOW) 95.2 031-0032-00 2019 Drive Arm Bushing 96.2 031-0032-00 2019 Drive Arm Bushing...
  • Page 37 UPPER FRAME PARTS SECTION: PART PART ITEM DESCRIPTION ITEM DESCRIPTION NUMBER NUMBER 013-0004-00 5/16-18 ACORN NUT HIGH-CROWN ZC 114.4 018-6036-00 1/2-13 X 2-3/4 HEX CAP SCREW (GR.5) ZINC 013-5202-00 3/8-16 NYLON INSERT FLANGE LOCKNUT (GR.F) ZINC 114.5 019-6017-00 .635 ID X 1.120 OD X .140 THICK FLAT WASHER NYLON 013-7018-00 1/2-13 HEX NUT ZINC 114.6...
  • Page 38 PARTS SECTION: TRANSAXLE & REAR WHEELS ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 013-3000-00 Acorn Lug Nut 71.1 022-8022-00 10" Wheel Only-36" Stand On 013-5041-00 3/8-16 NYLON INSERT LOCKNUT ZINC 71.2 022-8023-00 Walk Behind 36" Tire Only 21 X 7-10 013-8047-00 5/16-18 NYL INS L/N ZC 024-1200-00...
  • Page 39 PARTS SECTION: ENGINE ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 013-5202-00 3/8-16 NYLON INSERT FLANGE LOCKNUT (GR.F) ZINC 018-1075-00 3/8-16 X 1-1/8 HEX WASHER UNSLOT SERRATED (TRI-LOB) TRS 015-0541-00 Kawasaki FS541V Pull Start Engine ZINC YELLOW 015-0543-00 Exhaust Assembly 018-5450-00 7/16-20 X 1-1/2 HEX CAP SCREW (GR.8) ZINC YELLOW 24.9...
  • Page 40 PARTS SECTION: 36" Walk Deck ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 013-5201-00 3/8-16 HEX SERRATED FLANGE NUT HARD/ZINC 026-0025-00 Deck Spindle Support Plate 013-5301-00 5/8-11 NYLON INSERT JAM LOCKNUT ZINC 030-0050-00 5/16-24 X 1/4 SOCKET SET SCREW (CUP PT) PLAIN 013-6014-00 3/8-16 HEX NUT ZINC 031-0023-00...
  • Page 41 5/8-11 X 4 HEX CAP SCREW (GR.8) ZINC YELLOW 037-6015-50 Spindle Assembly 018-6012-00 3/8-16 X 1-1/2 HEX CAP SCREW (GR.5) ZINC 038-5350-00 16 1/4" Bad Boy Blade 018-6019-00 1/2-20 X 1-1/2 HEX CAP SCREW (GR.5) ZINC 039-6945-17 2017 MZ/ZT Deck Idler Assembly 018-6020-00 5/8-18 X 1-1/2 HEX CAP SCREW (GR.8) ZINC YELLOW...
  • Page 42 54" Walk Deck PARTS SECTION: ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 013-0004-00 5/16-18 ACORN NUT HIGH-CROWN ZC 019-6050-00 .360 ID X .983 OD X .120 THICK FLAT WASHER NYLON BLACK 013-5201-00 3/8-16 HEX SERRATED FLANGE NUT HARD/ZINC 022-1000-00 Deck Wheel 013-5301-00 5/8-11 NYLON INSERT JAM LOCKNUT ZINC...
  • Page 43 PARTS SECTION: DECK SUBASSEMBLIES 037-6015-50 Parts List 210-6005-48 Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 109.1 037-6017-50 Aluminum Spindle Housing -2010 181.1 013-8049-00 5/16-18 NYLON INSERT FLANGE LOCKNUT ZINC 109.2 037-6023-00 Spindle Bearing, 2004 and up 181.2 018-2007-00 5/16-18 X 1 HEX CAP SCREW (GR.5) ZINC 109.3...
  • Page 44 PARTS SECTION: DECALS 091-3601-18 091-0314-00 36" DECK DECAL FLOORBOARD LOGO DECAL 091-0903-18 48" DECK DECAL 091-0904-18 54" DECK DECAL 091-4055-00 CONTROL PANEL DECAL 091-0412-18 603cc PODIUM DECAL 091-3309-00 091-0418-00 48" DECK BELT ROUTE DECAL 36" DECK BELT ROUTE DECAL 091-3012-00 091-1020-00 091-0023-00 091-0024-00...
  • Page 45 PAGE 45 ...

  • Page 46: 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 47 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 48 Bad Boy, Inc. 102 Industrial Drive Batesville, Arkansas 72501...

This manual is also suitable for:

Bwk 3600Bwk 4800Bwk 5400

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