Bad Boy MAVERICK Owner's, Service & Parts Manual
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Bad Boy MAVERICK Owner's, Service & Parts Manual

Bad Boy MAVERICK Owner's, Service & Parts Manual

Zero-turn mower
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MAVERICK
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
©2017 12-1

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  • Page 1 MAVERICK 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 ©2017 12-1...

  • 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 Oil Filter 063-5004-00 063-5006-00 Pre-cleaner Air Filter 063-5005-00 Spark Plug 015-8000-00 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: 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: Setting Deck Height

    SETTING DECK HEIGHT 2.22 If your machine is equipped with an actuator motor, raise the deck using the raise /lower switch. Refer to section 7 (Controls). When deck is raised, set desired height with the deck height control dial, then lower deck with the raise / lower switch.

  • Page 7: Safe Handling Of Gasoline

    TOWING Max pulling weight: 300 lbs. Max at 5°: 260 lbs. Max tongue weight: 48” = 45lbs; 54” = 55 lbs.; 60” = 60 lbs 2.42 Tow only with a machine that has a hitch specifically designed for towing. Do not attach towed equipment except at the hitch point.

  • Page 8: Safety Interlock System

    The engine should stop. If any of these tests fail to produce the results indicated and the problem cannot be identified, contact your Bad Boy Mower dealer or the support contacts in the rear of this manual ROLL OVER PROTECTION STRUCTURES (ROPS) This machine is not equipped with ROPS from the factory.

  • Page 9: Operation

    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. Avoid operating your mower on side hills of over 5 degrees, inclines of over 10 degrees, and declines of over 15 degrees.

  • Page 10: Mower Maintenance

    SECTION 4: MOWER MAINTENANCE Interval Every 50 Every 100 Every First 5 Daily Hours or Hours or Section Hours Annually* Annually* Hours Maintenance Check and add engine oil Section3  Section 2 Check all belts for proper alignment (Pump) 6 ...

  • Page 11: Maintenance Log

    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: Hours:...

  • Page 12: Troubleshooting

    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

    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 the RUN position.

  • Page 14: Moving Inoperable Mower

    890-950 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. Hopefully, you’ll never need to use this section of the manual. However, if you do, use extreme caution...

  • 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 SECTION 1: HYDROSTATIC SYSTEM 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 reservoirs and get an oil drain pan.
  • Page 19 CHANGING YOUR HYDRAULIC OIL AND FILTER (CONTINUED) 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). Install the top port plug into each transaxle as the oil level reaches this port.
  • Page 20 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 21: Drive Belt

    SECTION 2: DRIVE BELT Shown to the right is the MAVERICK pump belt tensioner. Using a 3/4" wrench, tightening the two jam nuts on the right side will increase the belt tension. The tension should be adjusted so that there is between 60-65 lbs.
  • 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 recommended for maximum protection. CHANGING YOUR ENGINE OIL AND OIL FILTER Remove oil dipstick and open oil drain.
  • Page 23 KOHLER CONFIDANT (CONTINUED) The fuel filter is located on the right side of the engine, approximately 12” from the carburetor, 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.
  • Page 24 KOHLER CONFIDANT (CONTINUED) 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 Gap

    KOHLER CONFIDANT (CONTINUED) CHANGING THE SPARK PLUGS AND CHECKING THE SPARK PLUG GAP Remove the wire on the spark plug and use a 5/8” socket to remove the spark plug. Check the gap on the spark plug to verify that it is 0.03 in using a feeler gauge.

  • Page 26: Electrical System

    If a fuse is repeatedly blowing, contact your Bad Boy dealer. In order to access the clutch fuse and the relays you will need to take off the control panel by removing four socket head screws using a 1/8"...
  • Page 27 ELECTRICAL SYSTEM (CONTINUED) 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. Check the condition and connection of the relays located under the control panel.
  • Page 28 ELECTRICAL SYSTEM (CONTINUED) WIRING DIAGRAM PAGE 28...
  • Page 29 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 30: Cutting Deck

    SECTION 6: CUTTING DECK DECK BELT REMOVAL Use proper safety precaution when performing procedures. Raise the deck to its highest position. Remove the right pulley cover. While lifting up on the belt (as shown in the photograph), rotate the pulley until the belt is free of the pulley.

  • Page 31: Leveling The Deck

    LEVELING THE DECK Before leveling the deck, please verify linkage bar is secured properly as described in the picture to the right. Start on a flat, level surface and set the air pressure in all four tires to 12 psi. Measure the deck at all four corners.

  • Page 32: Blade Sharpening

    Use a belt tension gauge to ensure the proper tension. Your dealer or service center will have a belt tension gauge or you can buy one from the Bad Boy Parts Department by calling 866-622-3269 and asking for the Parts Department (Part Number 041-9999-00).

  • Page 33: Blade Removal

    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 3/4"...

  • Page 34: Parts Section

    PARTS SECTION: MAVERICK FRONT FORK ASSEMBLY Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 025-0003-00 2016 Front Bearing Spacer 013-8050-00 1/2-13 Nylon Flange Nut 010-1050-00 Caster Bearing 2016 - 1641 Bearing 025-5202-00 Front Wheel Spanner 023-7913-00...
  • Page 35 PARTS SECTION: ADJUSTABLE DRIVE ARM ASSEMBLIES Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 034-8025-00 Drive Lever Spring 031-9010-00 Upper Tube-Adjustable Steering 019-8027-00 .515 ID Nylon Shoulder Washer 069-4010-00 Black Steering Grip 019-8054-00 .505 Nylon Spacer 031-9014-00 Lower Adjuster - Steering Arm- Left 024-6034-00...
  • Page 36 PARTS SECTION: MAVERICK GAS TANK ASSEMBLY DETAIL A DETAIL B PAGE 36...
  • Page 37 PARTS SECTION: MAVERICK GAS TANK ASSEMBLY Parts List ITEM PART NUMBER DESCRIPTION 018-2007-00 5/16" x 1" Bolt 019-8051-00 5/16" Lock Washer 019-8044-00 5/16" Flat Washer 018-2010-00 10-32 x 3/8" Button Socket Head Bolt 079-3460-00 Control Panel 077-8076-00 Ignition Switch 042-9000-00...
  • Page 38 PARTS SECTION: MAVERICK UPPER FRAME ASSEMBLY 15.3 15.1 15.2 PAGE 38...
  • Page 39 PARTS SECTION: MAVERICK UPPER FRAME ASSEMBLY Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 018-8065-00 5/16" x 1" Carriage Bolt 013-9005-00 5/16-18 Nylock Jam Nut 1/2 Nut 013-8049-00 5/16" Nylock Flange Nut 019-8040-00 1/4" x 3/4" Carriage Bolt...
  • Page 40 PARTS SECTION: MAVERICK LOWER FRAME ASSEMBLY 38.11 38.10 38.4 38.1 36.2 38.7 38.6 38.3 36.1 38.8 38.5 36.3 38.12 38.2 38.1 38.9 PAGE 40...
  • Page 41 1/2" x 3" Hex Bolt 38.11 013-7021-00 5/8 Std NC Nylock Nut 38.12 024-6034-00 1/4" Press in Grease Fitting 250-2700-00 2018 Maverick Suspension Arm Assembly-Left Short (48" Deck Only) 250-2750-00 2018 Maverick Suspension Arm Assembly-Right Short (48" Deck Only) PAGE 41...
  • Page 42 1/2-13 x 3 1/2 GR 5 Hex Bolt 042-6030-00 1/4" x 1" Key 018-7060-00 3/8-16 x 5 1/2 Hex Bolt 048-6000-00 2018 Maverick Turnbuckle (Top Link) 019-0007-00 .517 Square Hole Round Washer 060-6017-00 60 ZT Welded Deck Shell 019-5007-00 1/2" Lock Washer Zinc...
  • Page 43 037-8002-00 Dust Cover 048-6001-00 2018 Maverick Toplink Body 037-8050-00 Tube Spacer for Spindle Shaft 048-6002-00 2018 Maverick Bushing Retainer Left-Handed 037-9050-00 Collar Spacer - Top of Spindle 048-6003-00 2018 Maverick Bushing Retainer Right-Handed 039-2127-17 Parts List 048-6004-00 2018 Maverick Bushing Sleeve...
  • Page 44 1/4-20 Nylon Insert flange Nut 019-5702-00 1/2" Washer (Grade 8) 064-3000-00 Brake Cable 018-1055-00 1/2" x 3/4" Hex Bolt 050-2075-00 Fan/Pully Kit for ZT and Maverick 032-9000-00 Vibration Mount-Green Dot 013-3000-00 Acorn Lug Nut 032-9002-00 Vibration Mount-Red Dot (48" Maverick Only) 022-5466-00 12"...
  • Page 45 PARTS SECTION: 747CC KOHLER Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 033-5035-00 4 3/4 Motor Pulley 019-8051-00 5/16" Lock Washer 018-1075-00 3/8 x 1 1/8 bolt 019-8053-00 7/16" Lock Washer 042-5020-00 1/4 x 2 Square key Stock 018-5300-00 7/16"...
  • Page 46 PARTS SECTION: DECALS 091-8001-00 091-0019-00 091-0339-18 091-0313-00 Deck Impact Patent Patent Decal Brake Decal Frong Logo Decal 091-0022-00 Maverick Kick Plate Decal 091-0021-00 Steering Speed Control Decal 091-0905-18 091-0379-18 60" Deck Decal 747cc Decal 091-3017-50 091-3309-00 Pump Belt Route Decal...
  • Page 47 You are responsible for presenting your Small Spark-Ignited equipment to a Bad Boy, Inc.® service center as soon as the problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact Bad Boy, Inc.®...
  • Page 48 If the part fails during the period of warranty coverage, the part will be repaired or replaced by Bad Boy, Inc.®. Any such part repaired or replaced under warranty will be warranted for the remainder of the warranty period.

  • Page 49: Limited Warranty

    The leading edge of the deck shell will be warranted for the entire life time 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 the first year and at the unite owner’s expense during the balance of the lifetime of the machine.

  • Page 50: Warranty Registration

    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 51 NOTES:_______________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ PAGE 51...
  • Page 52 MAVERICK MODEL For additional information, please see us at www.badboymowers.com Bad Boy, Inc. 102 Industrial Drive Batesville, Arkansas 72501...

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