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Bad Boy Mowers Service ManualSection 1 Hydrostatic System . Pg. 02Section 2 Drive Belt . Pg. 09Section 3 Engine . Pg. 12Section 4 Electrical System . Pg. 20Section 5 Frame Maintenance . Pg. 25Section 6 Cutting Deck Pg. 37Section 7 Mowing Tips . Pg. 461

SECTION 1: HYDROSTATIC SYSTEMTO CHANGE HYDRO OIL ON COMMERCIAL MODELS, REMOVE OILRETURN LINES FROM TOP OF HYDRO TANK AND PLACE THEM INA DISPOSABLE OIL CONTAINER. START AND RUN MOWERUNTIL OIL LEVEL IS REDUCED DOWN TO ABOUT 2” OF OILREMAINING IN THE TANK. DO NOT ALLOW AIR TO ENTER THEOIL LINES IN THE BOTTOM OF THE TANK. KEEP IN MIND THATONLY ABOUT 75% OF THE HYDRO OIL CAN BE CHANGED AT ATIME. USE ONLY 20W50 MOTOR OIL IN THE HYDRO SYSTEM.2

CHANGE HYDRO OIL FILTERS BY UNSCREWING THEM FROM THEFILTER HEAD. FILL NEW FILTERS WITH 20W50 MOTOR OILBEFORE INSTALLING. USE ONLY BAD BOY REPLACEMENTFILTERS. USING ANY OTHER FILTER WILL RESULT IN DAMAGETO THE HYDRO SYSTEM AND VOID THE WARRANTY.3

ONCE THE SYSTEM IS REFILLED WITH OIL, LIFT REAR OFMOWER UNTIL TIRES ARE OFF THE GROUND. START ENGINE,RELEASE PARKING BRAKE, STAY CLEAR OF MOVING REARTIRES, LOOSEN BYPASS BOLT ½ TO ¾ TURNS, MOVE DRIVEARMS FORWARD AND BACKWARD 4 TO 6 TIMES SLOWLY. THISWILL PURGE THE AIR FROM THE SYSTEM.(THE BYPASS BOLT HAS A HOLE DRILLED THROUGH THE SIDEOF THE BOLT HEAD). THIS VALVE ALSO SERVES AS A NEUTRALFOR MOVING THE MOWER WITHOUT THE ENGINE RUNNING.4

THE HYDRO OVERFLOW TANK ON A ZT MODEL IS LOCATEDBEHIND THE SEAT. NOTICE THE “FULL COLD” LINE AT THEBOTTOM OF THE TANK. USE ONLY 20W50 MOTOR OIL IN THISTANK.5

WHEN SERVICING A LIGHT DUTY COMMERCIAL MOWER WITH ASEALED TRANSAXLE UNIT, START BY REMOVING THE FILTERSKID PLATE ON THE BOTTOM OF EACH UNIT. THE SKID IS HELDON BY THREE 10MM BOLTS. NEXT, REMOVE THE FILTER. THEFILTER ALSO SERVES AS THE OIL DRAIN. EACH TRANSAXLEHOLDS ABOUT 2 QUARTS OF HYDRO OIL. REINSTALL NEWFILTERS AND SKID PLATES. USE ONLY HYDRO-GEAR FILTERS.USE OF ANY OTHER TYPE OF FILTER WILL RESULT IN DAMAGETO THE HYDRO SYSTEM AND VOID THE WARRANTY.6

THE CHECK PLUG IS LOCATED AT THE TOP CENTER OF THEINSIDE CASE OF EACH TRANSAXLE. THE TRANSAXLE CAN BEFILLED WITH OIL BY REMOVING THESE CHECK PLUGS FROMBOTH TRANSAXLES AND POURING THE OIL IN THE HYDROOVERFLOW TANK, LOCATED BEHIND THE SEAT. OIL WILLBEGIN TO RUN OUT OF THE CHECK PLUG HOLES WHEN THETRANSAXLES ARE FULL. USE ONLY 20W50 MOTOR OIL IN THEHYDRO SYSTEM.7

ONCE THE SYSTEM IS FILLED WITH OIL, LIFT REAR OF MOWERUNTIL REAR TIRES ARE OFF THE GROUND. START ENGINE,RELEASE PARKING BRAKE, STAY CLEAR OF MOVING REARTIRES. NEXT, PULL THE NEUTRAL BYPASS LEVERS (LOCATEDAT THE REAR OF THE FRAME, ON EITHER SIDE OF THEMUFFLER), MOVE THE DRIVE ARMS FORWARD AND BACKWARD4 TO 6 TIMES SLOWLY. THIS RELIEVES ANY AIR THAT MAY BETRAPPED IN THE SYSTEM. IT MAY BE NECESSARY TO ADDMORE OIL TO THE HYDRO OVERFLOW TANK AFTER 10-15MINUTES OF RUNNING. THESE BYPASS LEVERS ALSO SERVEAS A NEUTRAL FOR MOVING THE MOWER WITHOUT THE ENGINERUNNING.8

SECTION 2: DRIVE BELTSHOWN ABOVE IS THE AOS/DIESEL PUMP BELT TENSIONER.TIGHTENING THE TWO ¾”JAM NUTS ON THE LEFT SIDE WILLINCREASE THE BELT TENSION ON ALL MODELS. FACTORYSETTING IS ABOUT .030” (ABOUT THE THICKNESS OF A CREDITCARD) BETWEEN COILS AS SHOWN BELOW.9

SHOWN ABOVE IS A TYPICAL PUMP BELT TESIONER FOR PUP10

AND LIGHTENING MODELS.SHOWN ABOVE IS A TYPICAL PUMP BELT LAYOUT FOR MOSTCOMMERCIAL MODELS.11

SECTION 3: ENGINESHOWN ABOVE IS A KAWASAKI ENGINE WITH THE “QUICKDRAIN” OIL DRAIN LOCATED ON THE LEFT SIDE OF THE ENGINE.USE A FLAT SCREW DRIVER AS SHOWN TO LOOSEN THE DRAIN.12

MOST MODELS HAVE A DRAIN HOSE INSTALLED ON THEENGINE, FOR EASIER OIL CHANGES. ALL GAS ENGINES USEDBY BAD BOY HAVE AN OIL CAPACITY OF 2 QUARTS. BAD BOYRECOMMENDS THAT THE OIL AND FILTER BE CHANGED EVERY50-60 HOURS OF USAGE.13

THE FUEL FILTER IS LOCATED IN THE FUEL LINE ABOUT 12”FROM THE CARBURATOR ON THE SIDE OF THE ENGINE. NOTETHE DIRECTION OF FLOW ON THE SIDE OF THE FILTER.REPLACE ONCE A YEAR.14

MOST ALL MODELS HAVE A VACUUM OPERATED FUEL PUMPBOLTED TO THE SIDE OR TOP OF THE ENGINE. THE PUMP HASA “FUEL IN”, A “FUEL OUT”, AND A VACUUM LINE COMING FROMTHE ENGINE BLOCK. FUEL FLOW CAN BE CHECKED HERE IFTHE PUMP IS SUSPECTED TO BE DEFECTIVE.15

WHEN SERVICING THE FUEL SYSTEM ON THE CAT DIESEL, IT ISNECESSARY TO PURGE THE AIR FROM THE SYSTEM BYLOOSENING THE 9/16” BOLT ON TOP OF THE FUEL FILTER ANDPUMPING THE FUEL BULB (LOCATED UNDERNEATH THERADIATOR) UNTIL AIR BUBBLES ARE NO LONGER VISIBLE.16

REMOVE AND INSPECT AIR CLEANER WEEKLY. (MORE OFTEN INDUSTY CONDITIONS). DO NOT BLOW FILTER OUT WITH AIRPRESSURE, THIS WILL CAUSE THE FILTER TO BE FILLED WITHTINY HOLES THAT WILL ALLOW DIRT TO ENTER. INSTEAD, TAPFILTER ON SIDE TO REMOVE ANY DEBRIS. REPLACE AT LEASTONCE A YEAR, MORE OFTEN IN DUSTY CONDITIONS.17

TORQUE THE CLUTCH BOLT TO 50 FT. LBS. ON ALL MODELS.RETORQUE AT EVERY OIL CHANGE.18

KEEP RADIATOR SCREEN CLEAN AND FREE OF DEBRIS ONLIQUID COOLED MODELS. CHECK SCREEN HOURLY DURINGDRY CONDITIONS. SLIDE RADIATOR SCREEN UP TO REMOVE.19

SECTION 4: ELECTRICAL SYSTEMON MOST LARGER COMMERCIAL ENGINES (27 HP AND UP). THE25 AMP MAIN FUSE IS LOCATED ABOUT 3” FROM THE STARTERON THE ENGINE.20

ON SMALLER COMMERCIAL AND LIGHT DUTY COMMERCIALMOWERS, THE 25 AMP MAIN FUSE IS LOCATED JUST BEHINDTHE BATTERY CONNECTED TO THE STARTER SOLINOID.21

ALWAYS CHECK THE CONDITION OF THE WIRING HARNESSGROUND CABLE. THE GROUND IS LOCATED JUST INSIDE OFTHE RIGHT SIDE FUEL TANK ON MOST MODELS. ENSURE THATTHE GROUND IS CONNECTED, CLEAN, AND TIGHT. ON SOMEMODELS, THIS WIRE MAY BE CONNECTED TO THE NEGATIVESIDE OF THE BATTERY.22

CHECK THE CONDITION AND CONNECTION OF THE RELAYSLOCATED UNDER THE SEAT. ENSURE THAT THEY ARE CLEANAND CONNECTED. MAKE SURE THAT WIRE TERMINAL ENDSHAVE NOT BEEN PUSHED OUT OF THE RELAY BLOCK.23

ON MOST MODELS, THE RED WIRE COMING OUT OF THE ENGINEIS THE CHARGING WIRE FROM THE ALTERNATOR. CHECK FOR13.6 - 14.2 VOLTS DC AT THIS WIRE WITH ENGINE AT FULLTHROTTLE.24

SECTION 5: FRAMEFOR NON-SUSPENSION MODELS, TORQUE FRONT FORK CASTLENUT TO 40 FT.LBS. BE SURE TO SPIN THE FORK WHILETORQUING THE NUT TO ENSURE THAT NO BEARING DAMAGE ISDONE.25

BE SURE TO REINSTALL THE COTTER PIN INTO THE CASTLENUT. ALWAYS TRY TO GO TIGHTER ON THE NUT TO FIND ACASTLATION FOR THE PIN TO FIT IN. NEVER BACK THEBEARING TENSION OFF AFTER TORQUING THE NUT, THIS WILL“SPRING” THE BEARING CAGE.26

PICTURED ABOVE IS THE BEARING ASSEMBLY FOR MOWERSEQUIPPED WITH SUSPENSION 2009 AND NEWER. THIS SETUPREQUIRES A TORQUE OF 53 FT LBS. NEVER BACK THE BEARINGTENSION OFF AFTER TORQUING THE NUT, THIS WILL “SPRING”THE BEARING CAGE.27

TORQUE REAR WHEEL LUGS TO 65-75 FT.LBS. RETORQUE ATEVERY OIL CHANGE.28

THERE IS ONE GREASE FITTING IN EACH FRONT WHEEL ANDONE IN EACH FRONT CASTER BEARING HOUSING. GREASE ATEVERY ENGINE OIL CHANGE.29

THERE IS ONE GREASE FITTING ON EACH OF THE ACTUATORBAR PILLOW BLOCKS LOCATED UNDER THE FUEL TANKS.GREASE TWICE A SEASON.30

THE PUMP BELT TENSIONER IS LOCATED UNDER THE ENGINEAND HAS A GREASE FITTING AT ITS PIVOT POINT. GREASE ATEVERY ENGINE OIL CHANGE.31

THE DECK BELT TENSIONER IS LOCATED AT THE REAR OF THEDECK AND HAS A GREASE FITTING ON ITS PIVOT POINT.GREASE AT EVERY ENGINE OIL CHANGE.32

THE CONTROL ARM BLOCKS HAVE GREASE FITTINGS LOCATEDON THE TOP AND BOTTOM OF EACH BLOCK. GREASE ONE TIMEA YEAR.33

WHEN ADJUSTING THE TRACKING ON THE MOWER, THELENGTH OF THE PUSHRODS CAN BE CHANGED BY SCREWINGTHE SWIVEL JOINT IN OR OUT ON THE ENDS OF THE RODS.SHORTENING THE OVERALL LENGTH OF THE ROD SLOWS THEPUMP DOWN. LENGTHENING THE ROD WILL INCREASE THESPEED OF THE PUMP.34

ON COMMERCIAL MODELS, THE REACTION OF THE HYDROPUMPS AND THE RESISTANCE FELT IN THE CONTROL ARMSCAN BE ADJUSTED BY MOVING THE PUSHRODS OR THEDAMPENERS UP OR DOWN IN THE MOUNTING HOLES.MOVING DAMPENERS UP, LESS RESISTANCE.DAMPENERS DOWN, MORE RESISTANCE.MOVING PUSHRODS UP, SLOWER REACTION.PUSHRODS DOWN, FASTER REACTION.35

TO SERVICE THE PARKING BRAKE SYSTEM, THE REAR BRAKEASSEMBLY REQUIRES A HUB PULLER TO REMOVE THE BRAKEDRUM AS SHOWN ABOVE. THE AXLE NUT MUST BE REPLACEDAND TORQUED TO 200 FT.LBS. BE SURE TO REINSTALL THECOTTER PIN.36

SECTION 6: CUTTING DECKTO REMOVE THE DECK BELT, LIFT UP ON THE BELT WHILEROTATING THE PULLEY TO ROLL THE BELT UP AND OFF OF THEPULLEY. (BE SURE NOT TO GET YOUR FINGERS BETWEEN BELTAND PULLEY).37

TO CHECK THE LEVEL OF THE DECK, START ON A FLATSURFACE AND SET THE AIR PRESSURE IN ALL FOUR TIRES.RAISE THE DECK UP, AND MEASURE ALL FOUR CORNERS OFTHE DECK TO SEE IF IT IS LEVEL FROM LEFT TO RIGHT ANDFRONT TO BACK. ALL DECKS SHOULD BE LEVEL FROM LEFT TORIGHT AND HAVE A ¼” PITCH DOWN IN THE FRONT.38

IF DECK ADJUSTMENTS ARE NECESSARY, START WITH THECHAIN LENGTH ADJUSTERS. THESE ADJUSTERS AFFECT THEOVERALL HIEGHT OF THE DECK AND THE LEVEL FROM LEFT TORIGHT.39

THE LARGE TURN BUCKLES ON THE FRONT OF THE DECK ONLYAFFECT THE PITCH OF THE DECK OR THE LEVEL FROM FRONTTO BACK.40

THE DECK SPRING TENSION IS CRITICAL. IF THE TENSION ISTOO MUCH, IT WILL CAUSE THE SPRING TO BREAK. IF TOOLOOSE, THE BELT CAN JUMP OFF OR SLIP ON THE PULLEYSAND CAUSE A CUT QUALITY ISSUE. WITH THE DECK UP, THESPRING COIL GAP SHOULD BE ABOUT .025” - .030”(ABOUT THETHICKNESS OF A BUSINESS CARD). SPRING TENSIONADJUSTMENTS CAN BE MADE BY SLIDING THE BOLT SHOWNABOVE FORWARD OR BACKWARD IN THE SLOT OF THE DECK.41

ON AN AOS/DIESEL MODEL, ADDITIONAL DECK BELTADJUSTMENTS CAN BE MADE BY SLIDING THE REAR “V” IDLERPULLEYS UP OR DOWN IN THEIR SLOTS.42

THE CONDITION OF THE BLADES CAN DRASTICLY AFFECT THECUT QUALITY OF THE MOWER DECK. REPLACE AS NECESSARY.THESE BLADES WERE USED CONSIDERABLY TOO LONG.RESHARPENING IS RECOMMENDED BY PROFESSIONALS ONLYTO DETERMINE WHEN THE BLADE NEEDS TO BE REPLACED ANDBECAUSE OF THE NEED FOR REBALANCING.43

TO CHANGE BLADES, IT MAY BE EASIER TO USE A PIECE OFWOOD TO KEEP THE BLADE FROM TURNING SO THAT THE BOLTCAN BE LOOSENED. RETORQUE THE BLADE BOLTS TO 90 - 110FT.LBS.44

THE BLADE SPINDLES CONTAIN A SEALED BALL BEARING INTHE TOP AND BOTTOM OF THE SPINDLE. THE BEARINGS AREREPLACEABLE FOR A MORE COST EFFECTIVE REPAIR.45

Mowing tips: Mow header strips at the ends of the lawn and around flowerbeds first. Make them wide enough that you can turn the moweraround in the already mown section. Then mow back and forthbetween these header strips overlapping each lap by about 1/8the width of the mower's deck. Don't cut your grass too short, particular for cool seasongrasses. Higher heights usually provide for a deeper rootsystem, looks better, and is less likely to have weeds invading,particularly crabgrass. Don't remove any more than one third of the grass leaf at anyone cutting. If circumstances arise that a lawn gets too tall andyou just have to lop off a bunch to get caught up, bite the bulletand break it down into several mowings to get caught up with 3or so days between cuttings. NEVER SCALP YOUR LAWN. Scalping severely damages the rootsystem to such a degree that it may die. Avoid mowing when the grass is wet or when it's dark Avoid throwing grass clippings into the street and drivewaywhere they can be washed into the sewer system. After mowing,clean up driveway and walkways. When mowing remove only a third with each cutting (except forthe first mowing of the season when it's ok to remove more).You can safely leave clippings that will quickly decompose andadd nutrients back into the soil. Contrary to popular opinion,grass clippings do not add to thatch buildup. Grass blades aremade up of about 75% water. Mow your lawn in a different direction with each mowing,especially with lawns of shorter grass types. Altering thedirection ensures a more even cut since grass blades will growmore erect and less likely to develop into a set pattern. Keep your mower's blade sharp, which means having itsharpened several times during the mowing season. Keepseveral blades around so you'll always have a sharp one onhand. Sharp blades cut the grass cleanly and help mulchclippings into small pieces which break down quickly.46