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Summary of Contents for Bad Boy 550cc
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Page 2: Introduction
Bad Boy Bandit 550/750cc Utility Vehicle INTRODUCTION Congratulations on your purchase of the 550/750cc utility vehicle. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions will provide the knowledge needed for safe and enjoyable UTV operation. -
Page 3: Important Manual Information
Introduction 550/750cc Utility IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS Particularly important information is distinguished in this manual by the INJURY OR DEATH. following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, bystander or a person inspecting or repairing the machine. -
Page 4: Important Notice
Introduction 550/750cc Utility IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrestor laws and regulations in effect at the time of manufacture. -
Page 5: Universal Symbols
Introduction 550/750cc Utility UNIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Safety Alert Symbol Lift Cylinder-Retract Diesel Fuel Lift Cylinder-Extend Engine Coolant-Temperature Lift Cylinder-Float... -
Page 6: Table Of Contents
Introduction 550/750cc Utility Table of Contents Subject Page Subject Page Introduction Starting Important manual information Seat belt Important notice Head light switch Universal symbols Emergency light switch Location of parts Turn signal light switch 1-11 Illustrated contents Brake pedal Safe operation Range gear shift lever Safety instructions 4WD lever Operation... - Page 7 Introduction 550/750cc Utility 10-8 Anti-freeze 10-20 Checking head lights & turn signals 10-8 Replacing radiator hose (water pipes) 10-21 Checking seat belt and ROPS Replacing fuel hose 10-22 10-8 Checking joint boot Replacing brake master cylinder (inner 10-22 10-9 Checking tire inflation pressure parts) 10-9 Every 50 hours...
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Page 8: Location Of Parts
Introduction 550/750cc Utility LOCATION OF PARTS Bench seat... -
Page 9: Illustrated Contents
Introduction 550/750cc Utility ILLUSTRATED CONTENTS Bench seat... - Page 10 Introduction 550/750cc Utility Bench seat 1-11...
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Page 11: Safe Operation
Safe Operation Bucket seat All operators, including experienced UTV drivers or passengers, should carefully read and fully understand this User's Manual, and operate strictly as the manual states in order to achieve the best performance and avoid accidents. Others who will use your UTV should be trained how to operate the UTV and be required to read this manual before operation. -
Page 12: Operation
Safe Operation the surroundings. 5) Check and keep vehicle clean. Sludge, grease and debris can cause a fire and severe injury. Passenger quantity and loading: 1) Only the driver and one passenger inside cab. It is suggested that children under age of 5 not be allowed as a passenger. -
Page 13: Children Safety Instructions
Safe Operation 4. If you start to lose momentum or need to park 17. Do not tow passengers or attempt to jump the vehicle. when climbing, use the parking brake to come to a stop. Release the brake and begin 3. -
Page 14: Instructions For Cargo Bed
Safe Operation Do not use DIFF.LOCK when driving at high stopping on a slope make sure the vehicle is speed. This may cause vehicle loss of stationary before exiting. control. 9. Transporting vehicle When driving at high speed, suddenly turning the steering wheel will reduce vehicle Avoid dragging the vehicle behind another vehicle. - Page 15 Safe Operation ① Battery Do not open radiator cap before coolant has cooled down. When the coolant is cold, open slowly to ensure no pressure is on the system, and then open cap. Check for the coolant level in the coolant reservoir. If necessary, add coolant.
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Page 16: Warning And Caution Labels
Warning Labels Warning and caution labels （1） （2） （3） （4） （5） （6） （7） （8） （9） （10）... - Page 17 Warning Labels （11） (12） (13） (14) (15)
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Page 18: Servicing Of Vehicle
Vehicle Identification Number SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find you can do some of the regular maintenance yourself. -
Page 19: Specifications Table
Specifications SPECIFICATION TABLE Make Specification 1 cylinder, 4-cycle, gasoline, SOHC, liquid Type cooled 546CC for 550cc Displacement 735CC for 750cc Engine 20.2（27.1）for 550cc Horsepower Kw(HP) 28.8（38.6）for 750cc 5500 for 550cc Rated revolution 6000 for 750cc Low idling revolution rpm 1350 to 1500 Fuel Capacity L(U.S.gal) 28（7.4）... - Page 20 The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires in the table above. The company reserves the right to change the specifications without notice. TRAVELING SPEEDS For 550cc Range gear shift lever km/h (mph) 61（37.9） High 72（44.7）...
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Page 21: Vehicle Limitations
Specifications VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with equipment sold or approved by manufacturer. Use with equipment that is not sold or approved and which exceeds the maximum specifications listed below, or which are otherwise unfit for use, may result in vehicle malfunction or failures with a possibility of vehicle damage, property damage and injury to the operator or others. -
Page 22: Pre-Operation
Pre-Operation DAILY CHECK To better prevent issues, familiarize yourself with the operation of the vehicle prior to driving. CAUTION： To avoid personal injury： Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake set. -
Page 23: Operating The Engine
Operating the Engine NOTE： CAUTION： The parking brake warning lamp (P) comes To avoid personal injury： on while parking brake is applied and goes Read "SAFE OPERATION" in front of this off when it is released. manual. Read the danger, warning and caution labels located on the vehicle. -
Page 24: Cold Starting
Operating the Engine 1. Insert the key into the key switch and turn to “START”. (Stop the Engine) (Engine runs or headlights on) START (Start the Engine) IMPORTANT : It is not sufficient to do daily checks on dash board only. Always conduct daily checks carefully by referring to DAILY CHECK PERIODIC... -
Page 25: Warming Up Engine
Operating the Engine Warming Up Engine For 5 minutes after engine start-up, allow the engine to warm up without applying any load. This allows sufficient oil protection for all internal wear components. If load is applied to the engine without warming-up, engine damage may occur. -
Page 26: Operating The Vehicle
Operating the Vehicle OPERATING NEW VEHICLE The lubricating oil is especially important for a new vehicle. Various parts need time How a new vehicle is handled and maintained determines the life of the vehicle. to wear and polish themselves to the correct operating clearances. -
Page 27: Head Light Switch
Operating the Vehicle ① Head light switch Bench seat ② Head lights “OFF” ③ High beam lights "ON" ④ Low beam lights "ON" ⑤ 4WD button ⑥ 2WD button ⑦ Front axle differential lock ⑧ Front axle differential unlock ⑨ Emergency light "ON" ⑩... -
Page 28: Brake Pedal
Operating the Vehicle the turn toggle switch. ③ Tail turn signal lamp To indicate a left turn, push on the upper half Bucket seat of the turn toggle switch. When the left or right signal is activated, the indicated turning light will flash and the other will stay on. -
Page 29: Range Gear Shift Lever
Operating the Vehicle ① Range gear shift lever ① Brake pedal (L) LOW Range (H) HIGH Range 4. Selecting the travel speed. (N) NEUTRAL” POSITION ■ Range Gear Shift Lever (R) “REVERSE” Bucket seat CAUTION: To avoid personal injury: Avoid changing gears when ascending or descending a slope. -
Page 30: 4Wd Lever
Operating the Vehicle ■ Accelerator Pedal Damage may occur with wrong shifting The accelerator pedal is used to increase the operation. engine and vehicle speed. Push down on it for higher speed. ■ 4WD Lever CAUTION: To avoid personal injury: When traveling at road speed, use only ... -
Page 31: Fuel Gauge
Operating the Vehicle ① Coolant temperature gauge ② Fuel gauge ■ Fuel Gauge Park the vehicle on a flat place. When the key switch is “START”, the fuel gauge indicates the fuel level. Be careful not to fully empty the fuel tank. Otherwise air may enter the fuel system. -
Page 32: Winch Mount Plate
Maintenance and Adjustment WINCH OPERATIONS Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■ Transporting Vehicle Pay attention to the following points when transporting the vehicle. Use a suitable truck and trailer. -
Page 33: Service Intervals
Maintenance and Adjustment CAUTION: To avoid personal injury and vehicle damage: Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer. - Page 34 Maintenance and Adjustment MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS Hours Frequency Miles (KM) Routine Maintenance Check (performed at each interval below, whichever comes first) Air filter Inspect; replace as needed Brake pad wear 20 H Monthly 250 (402) Inspect periodically Throttle Body Intake 20 H 250 (402)
- Page 35 Maintenance and Adjustment LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart above, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
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Page 36: Periodic Service
Periodic Service ■ Operator’s Seat To open the seat, raise the seat to the forward CAUTION: position. To avoid personal injury: OPEN FRONT HOOD COVER AND SEAT CAUTION To avoid personal injury from contact with moving parts: Never open operator’s seat while the engine is running. -
Page 37: Conventional Strut Adjustment
Periodic Service NOTE: vehicle. Pull up the cargo bed handle to raise the cargo Adjust the spring preload as follows. bed with the gas spring assist. To increase the spring preload, turn the adjusting ring in direction To decrease the spring preload, turn the adjusting ring in direction ①... -
Page 38: Reservoir Strut Adjustment
Periodic Service The spring preload, rebound damping and WHAT CAN HAPPEN compression damping forces of the front and Uneven adjustment can cause poor rear shock absorber assemblies can be handling and loss of stability, which could adjusted to suit the operating conditions. lead to an accident. -
Page 39: Jack-Up Point
Periodic Service increase the compression damping force and thereby harden the damping, and in direction ⓑ to decrease the compression damping force and thereby soften the damping. 1. Distance A ① 3. Tighten the locknut. Compression damping force adjusting screw NOTE ①... -
Page 40: Front End
Periodic Service ■ Front End CAUTION Jack up at the front frame tube only. To avoid personal injury: Be sure to check and service the vehicle on a level ground with the engine off and the parking brake “ON”. ■... -
Page 41: Checking Coolant Level
Periodic Service ■ Checking Coolant Level IMPORTANT If oil level is low, do not run the engine. CAUTION Checking engine oil level TO avoid personal injury Park the vehicle on a flat surface with Do not remove radiator cap while engine off, raise the cargo bed, mount the coolant is hot . -
Page 42: Cleaning Radiator Screen
Periodic Service Use clean fresh water and anti-freeze to synthetic resin or rubber installed in fill the recovery tank. brake system components and may If water should leak, consult your local cause brake failure. dealer. Avoid contamination of the brake fluid thoroughly cleaning ■... -
Page 43: Checking Parking Brake
Periodic Service ■ Checking gauges and indicator lights smooth operation. Adjust if incorrect measurement is found. (see Inspect the instrument panel for proper c h e c k i n g b r a k e p e d a l i n ” E V E RY 2 0 0 operation. -
Page 44: Checking Tire Inflation Pressure
Periodic Service ① Joint boot ② Drive shaft ■ Checking tire inflation pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time, thus check it every day and inflate as necessary. tire sizes inflation pressure 100kPa (1.0kgf/cm2,... -
Page 45: Checking Engine Start System
Periodic Service Bench seat ① Range gear shift lever pivot (spray type grease ) ■ Checking engine start system CAUTION TO avoid personal injury Do not allow anyone near the vehicle while testing. If the vehicle does not pass the test, do not operate the vehicle. -
Page 46: Cleaning Air Cleaner Primary Element
Periodic Service ■ Cleaning air cleaner primary element Remove the air cleaner cover and primary element. Remove the sponge material from its ① Air filter element ② Locating pad frame. Wash the sponge material gently but thoroughly in solvent. Squeeze the excess solvent out of the sponge material and let it dry. -
Page 47: Checking Battery Condition
Periodic Service CAUTION To avoid personal injury: Be sure to stop the engine and remove the key when attempting to make the following checks and changes. Check the fuel lines periodically. The fuel lines are subject to wear and aging fuel may leak out onto the running engine causing a fire. -
Page 48: Adjusting Toe-In
Periodic Service engine is running. Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention. Wear eye protection and rubber gloves when working around the battery. factory–installed battery non-... -
Page 49: Cleaning Muffler
Periodic Service Retighten the lock nut. Park vehicle on flat place. Turn steering wheel so front wheels are in IMPORTANT the straight ahead position. Keep the equal length of the left and right Lock the park brake and stop the engine. tie-rod. -
Page 50: Every 200 Hours
Periodic Service (See “LUBRICANTS, FUEL IMPORTANT: COOLANT” in “MAINTENANCE” section.) Visually check the muffler for cracks or holes in the body, weldment or pipes at regular with filter change 2.0L (2.2U.S. qts.) intervals. Oil capacity without filter change 1.8L (1.89U.S. qts.) ... -
Page 51: Replacing Transmission Oil
Periodic Service Quickly tighten the filter until it contacts Tighten the filter quickly until it contacts the mounting surface, then tighten the mounting surface. it an additional 1 turn only. Tighten filter by hand an additional 1/2 turn After running the engine for a few minutes, only. -
Page 52: Checking Brake Hose And Pipe
Periodic Service ■ Checking Radiator Hose and Clamp ◆ Checking the brake pedal stroke Park the vehicle on a flat surface and raise the Less than 120mm (4.7in.) cargo bed. Check to see if radiator hoses are Pedal stroke properly fixed every 200 hours of operation or On the pedal six months, whichever comes first. -
Page 53: Checking Intake Air Tube
Periodic Service Don’t stop the engine suddenly, but stop it depth is worn to minimum allowable. after about 5 minutes of idling. Do not open radiator cap until engine has sufficiently cooled down. Inspect radiator for debris in screen, clogged radiator fins, coolant level in radiator, and proper coolant fan operation. -
Page 54: Changing Front And Rear Axle Case Oil
Periodic Service ① Drain plug IMPORTANT: Do not operate the vehicle immediately after changing the transmission fluid. Run the engine at medium speed for a few minutes prevent damage transmission. ■ Changing Front and Rear Axle Case Oil ①... -
Page 55: Flushing Cooling System And Changing Coolant
Periodic Service ■ Flushing Cooling System and Changing Coolant CAUTION To avoid personal injury: Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. - Page 56 Periodic Service When draining fluids from the engine, place 1.013×10 (760mmHg) pressure some container underneath the engine (atmospheric). body. A higher boiling point is obtained by using Do not pour waste onto the grounds, down a radiator pressure cap which permits the a drain, or into any water source.
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Page 57: Replacing Fuel Hose
Periodic Service (See “Checking Radiator Hose and Clamp” in 5) Close the Mini fuse box cover. “EVERY HOURS” “PERIODIC 6) Connect the negative battery cable. SERVICE” section.) ■ Replacing Fuel Hose Consult your local dealer for this service. ■ Replacing Brake Master Cylinder (Inner parts) Consult your local dealer for this service. -
Page 58: Storage
Periodic Service STORAGE Store the battery following the battery storage procedures. CAUTION Keep the vehicle in a dry place where the To avoid personal injury: vehicle is sheltered from the elements. Do not clean the vehicle when the Cover the vehicle. Keep the vehicle indoors in a dry area that engine is running. - Page 59 Periodic Service reading normal, move the vehicle outside. Once outside, park the vehicle and let the engine idle for at least five minutes. Shut the engine off and work around vehicle and make a visual inspection looking for evidence of oil or water leaks. 6.
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Page 60: Troubleshooting
Troubleshooting ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause Countermeasure Check the fuel tank and fuel filter。 Check the electric fuel pump. Check the injector. -
Page 61: Diagnostic Trouble Code Table
Troubleshooting Diagnostic Trouble Code Table Mt05 Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open P0122... -
Page 62: Battery Troubleshooting
Troubleshooting BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure Battery overused until lights are dim. Charge the battery Charge the battery sufficiently. properly. Battery been recharged. Keep the terminal Starter does not function Clean the terminal terminal ... -
Page 63: Machine Troubleshooting
Troubleshooting MACHINE TROUBLESHOOTING Trouble Cause Countermeasure Replace throttle cable High idling speed of engine Replace throttle pedal Replace the throttle Replace the junior clutch spring High rotary speed for clutch connection. Replace the primary clutch. ... - Page 64 ACCESSORIES Consult your local dealer for additional accessories to add to your vehicle: Heavy Duty Front and Rear Bumpers Front Basket Hard Cab Enclosure Soft Cab Enclosure Snow Plow LED Lights Spare Tire Carrier 12-1...
- Page 65 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency and Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) are pleased to explain the emission control system warranty on your Off-Road vehicle. New off-road motor vehicles must be designed, built and equipped to meet U.S. EPA Federal and California anti-smog standards.
- Page 66 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new off-road vehicle: is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and is free from defects in material and workmanship which cause such vehicle to fail...
- Page 67 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System No express emission control system warranty is given by HISUN except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty.
- Page 68 United States should a safety recall notification under the Federal Safety Act be required. * You may change your registered address at any time, including at time of warranty claim, by calling Bad Boy or sending a letter with your name, old address, new address, and VIN number to Bad Boy warranty registration department.
- Page 69 Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Bad Boy to distribute the product in the country in which the sale occurred, and then only after Bad Boy specified Predelivery Inspection and Customer Orientation paperwork is completed and submitted to Bad Boy Inc.
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Page 70: Warranty
Genuine Bad Boy parts, used on approved warranty claims, will be reimbursed at MSRP. Bad Boy Inc. reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured. - Page 71 MAINTENANCE LOG Dealer/Service Date Miles Service Performed - Comments Company Name...
- Page 72 866-622-3269 COPYRIGHT© BAD BOY CORPORATION, USA. ALL INFORMATION CONTAINED WITHIN THIS PUBLICATION IS BASED UPON THE LATEST PRODUCT SPECIFICATIONS AND INFORMATION AT THE TIME OF PUBLICATION. BECAUSE OF THE CONSTANT ENHANCEMENT IN THE QUALITY AND DESIGN OF PRODUCTION COMPONENTS, MINOR DISCREPANCIES MAY VARY BETWEEN THE ACTUAL VEHICLE AND THE INFORMATION PRESENTED IN THIS PUBLICATION.
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