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Summary of Contents for Bad Boy maverick 5400
- 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 ©2015 12-5...
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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 (pages 10-11) Storage and Transportation ................Section 5 (page 12) Troubleshooting and FAQ ...................Section 6 (page 13) Controls ...................... - Page 3 Element Kohler Engines Kawasaki Engines Oil Filter 063-8017-00 063-5004-00 Motor Oil 10W-30 Motor Oil – Bad Boy Synthetic Blend Motor Oil Recommended 20W-50 Motor Oil – Bad Boy Hydrostatic Oil Recommended Hydraulic Oil (Approximately 2.5 quarts per transaxle) PAGE 3...
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Page 4: Warranty Registration
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.
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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 Every 50 Every 100 Maintenance First 8 Every 200 Every 250 hours or hours or Daily Section hours hours hours annually* annually* Check and add engine oil • Section 3 Section 2 Check all belts for proper alignment •...
- 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 MAVERICK SERIES: 890 —9 50 lbs 8.4 Your Bad Boy Mower Weighs: *** Weights fluctuate with the addition of accessories. 8.5 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.
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Page 16: Greasing Bearings
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 10-15 minutes of subsequent usage. These bypass levers hydraulic fluid reservoirs until it just appears at also serve as a neutral for moving the mower without the the bottom of each transaxle’s top port (approximately 2 quarts per...
- 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 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 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. 8) Start engine; check for oil leaks. Stop Engine; correct oil leaks. Recheck oil level 9) Dispose of used oil and filter in accordance with local ordinances.
- 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. Doing so will greatly reduce the air cleaner’s effectiveness.
- Page 25 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. 3) If the spark plug is worn, overheated, wet or carbon fouled replace the spark plug.
- Page 26 Kawasaki FS730V 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. 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 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 29 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 30 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 On most models, the red wire coming out of the blade sharpening be performed by a professional.
- Page 31 Check the condition and connection of the relays located under the control panel. Ensure that they are clean and connected. Make sure that wire terminal ends have not been pushed out of the relay block. The linear actuator is the mechanism that raises and lowers the deck.
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- Page 33 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.
- 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 either 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) Raise the deck up, and measure all four corners of the deck to see if it is level from left to right and front to back.
- Page 37 The blade in the foreground (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.
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Page 39: Parts Section
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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 the first year 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 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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