2015 Outlaw XP Owner/Parts Manual - Bad Boy Mowers

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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
©2014 11-17
OUTLAW XP MODELS
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 (page 10)
Storage and Transportation ............................................................................... Section 5 (page 10)
Troubleshooting and FAQ ....................................................................................Section 6 (page 11)
Controls ............................................................................................................. Section 7 (page 12)
Moving In-operable Mower ............................................................................... Section 8 (page 13)
Instrumentation ................................................................................................. Section 9 (page 13)
Mower Blade Maintenance ................................................................................Section 10 (page 14)
Greasing Bearings ...........................................................................................Section 11 (pages 14)
How to choose the right blade ..............................................................................................Page 15
Mowing Tips .........................................................................................................................Page 16
SERVICE SECTION BEGINS ON PAGE 17
PARTS SECTION BEGINS ON PAGE 25
LIMITED WARRANTY PAGE 46
PAGE 2
This manual applies to the following equipment:
Bad Boy Outlaw XP Series
Outlaw XP 5400 54˝ 852cc Kawasaki FX-850
Outlaw XP 6100 61˝ 852cc Kawasaki FX-850
Outlaw XP 7200 72˝ 852cc Kawasaki FX-850
Outlaw XP 6100 61˝ 993cc Vanguard
Outlaw XP 7200 72˝ 993cc Vanguard
72˝ Blade Hi-Lift Fusion Gator Blade Wave Blade
038-7230-00 038-5400-00 038-7215-00
61˝ Blade Hi-Lift Fusion Gator Blade Wave Blade
038-6080-00 038-6081-00 038-6090-00
54˝ Blade Hi-Lift Fusion Gator Blade Wave Blade
038-0001-00 038-0003-00 038-5220-00
Deck Belt 72˝ 61˝ 54˝
041-0202-00 041-0178-00 041-1650-00
Pump Belt 041-8411-00
Vanguard 993cc Oil Filter Air Filter Inner Air Filter Outer
063-8018-00 063-8020-00 063-8019-00
Kawasaki 852cc Oil Filter Air Filter Inner Air Filter Outer
063-8017-00 063-8020-00 063-8019-00
Motor Oil 10W-30 Motor Oil – Bad Boy Synthetic Blend Motor Oil Recommended
Hydro Oil 20W-50 Motor Oil – Bad Boy Hydrostatic Oil Recommended;
approximately 4 quarts/side
Hydraulic Filters 063-8014-00
COMMONLY USED ITEMS AND PART NUMBERS
PAGE 3
SECTION 1: BASIC INFORMATION
Congratulations on the purchase of your new Bad Boy Mower! The purpose of this manual is to assist
operators in maintaining and operating their machine. The information and instructions in this manual can
help you attain years of performance from your new Bad Boy. Also, check out our website to learn more
about the Bad Boy family.
1.1 All Bad Boy engines use 10W-30 engine oil. For maximum protection, Bad Boy synthetic blend
engine oil is recommended.
1.2 All Bad Boy hydraulic systems use 20W-50 engine oil (Conventional or Synthetic). Bad Boy
Hydrostatic oil is recommended.
1.3 All Bad Boy Mowers use hi-temp multi-purpose grease. NLGI No. 2 for the grease fittings.
1.4 Outlaw models have 12 psi in both front and rear tires.
1.5 Most Briggs, Kohler, Kawasaki, and Vanguard engines hold approximately two (2) quarts of motor oil.
Be careful not to over fill engine oil. Refer to the engine’s service manual.
Warranty Registration
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 non transferable. Warranty registration should be completed by the
selling dealership using the on-line registration site.
Model/Serial Number
Your Outlaw model serial numbers are found on the SIN plate underneath seat. Also, these numbers can
assist you in the ordering of new parts when replacements become necessary.
Parts/Service
Only Bad Boy replacement parts are to be used on your mower.
Replacement parts are available through your local Bad Boy Mower Dealer. Remember to always provide
the following information when ordering parts:
1. Correct part number
2. Correct serial number
All warranty repair and service must be handled through your authorized Bad Boy Mowers dealer.
To locate the nearest dealer, go to our website and click on Locate a Dealer.
EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT
Federal Evaporative Emission Control Warranty: Your Warranty Rights and Obligations
The Environmental Protection Agency (EPA), and Bad Boy Inc. are pleased to explain the evaporative emission control system’s warranty
on your 2015 equipment. New equipment that uses spark ignition engines for off-road use must be meet stringent anti-smog standards.
The evaporative emission control system on your equipment is designed, built, and equipped so it conforms at the time of sale to the
ultimate purchaser with the requirements of 40 CFR 1060. The evaporative emission control system is free from defects in materials and
workmanship that may keep it from meeting said requirements. Bad Boy Inc. must warrant the evaporative emission control system on
your equipment for two years provided there has been no abuse, neglect or improper maintenance. If an evaporative emission control
system component does fail in a manner that would cause the equipment to no longer meet the requirements of 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 4
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.
Seek additional training when possible to learn more about safety techniques and practices. This cutting machine is capable of
amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result
in serious injury or death.
GENERAL OPERATION
2.1 Read, understand, and follow all instructions on the machine and in the manual before starting.
2.2 Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.
2.3 Always remain seated while operating the machine. If the machine is equipped with Roll Over Protection (ROPs), always buckle
your seat belt.
2.4 Only allow responsible adults who are familiar with the instructions to operate this machine.
2.5 Clear the area of objects such as rocks, wire, toys, etc., which could be thrown by the blades.
2.6 Always maintain a safe distance from people and pets just prior to, and during, operation. Stop the machine if anyone enters the area.
2.7 Never carry passengers.
2.8 Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.
2.9 Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction as material may
ricochet back toward the operator. Stop the blades when crossing gravel surfaces.
2.10 Never operate the machine without the discharge chute, grass catcher, or other safety devices correctly in place and functioning
properly.
2.11 Slow down before turning.
2.12 Always disengage blades, place steering controls in neutral, engage parking brake, and remove ignition key when leaving
operators seat. Never leave a running machine unattended.
2.13 Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the
machine, inspecting the machine for damage, removing the grass catcher, or unclogging the discharge guard.
2.14 Always operate machine in daylight or with adequate working lights.
2.15 Do not operate the machine while under the influence of alcohol or drugs.
2.16 Watch for traffic when operating near or crossing roadways.
2.17 Always wear eye protection when operating or servicing the machine.
2.18 Always wear ear protection, such as earplugs, while mowing.
2.19 Use extra care when loading or unloading the machine into a trailer or truck.
2.20 Be alert of surroundings. Watch for rocks, stumps, mounds, depressions, and low hanging limbs or objects that could be
potentially hazardous while mowing.
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.
PAGE 5
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.
2.23 Watch for holes, ruts, bumps, rocks, or other hidden objects that tall grass can obscure. Uneven terrain could overturn the machine.
2.24 Choose a low ground spend when operating the machine on a slope.
2.25 Do not mow on wet grass, the tires may lose traction.
2.26 Do not attempt to coast down a slope in the neutral position.
2.27 Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly, straight
down the slope.
2.28 Keep all movement on slopes slow and gradual. Sudden changes in speed or direction could cause the machine to roll over.
2.29 Use extra care while operating machine with grass catchers or other attachments: they can affect the stability of the machine.
Do not use on steep slopes.
2.30 Do not try to stabilize the machine by putting your foot on the ground.
2.31 Do not mow near drop offs, ditches or embankments. The machine could suddenly roll over if a wheel goes over the edge or
the edge caves in.
2.32 Be aware of what is located at the bottom of slopes. For example: rocks water, cliffs, and roadways.
CHILDREN
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the
mowing activity. NEVER assume that children will remain where you last saw them.
2.33 Keep children out of the mowing area and in the watchful care of a responsible adult other that the operator.
2.34 Maintain alertness and turn machine off if a child enters the area.
2.35 Before and while backing, look behind and down for small children.
2.36 Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere
with safe machine operation. Children who have been given rides in the past may suddenly appear in the
mowing area for another ride and be run over or backed over by the machine.
2.37 Never allow children to operate the machine.
2.38 Never leave key in the ignition, especially around children.
2.39 Use extreme care when approaching blind corners, shrubs, trees, or other objects that may block your view
of a child.
TOWING
2.40 Tow only with a machine that has a hitch specifically designed for towing. Do not attach towed equipment except at the hitch
point.
2.41 Follow the manufacturer’s recommendation for weight limits for towed equipment and towing on slopes.
2.42 Never allow children or others in or on towed equipment.
2.43 On slopes, the weight of the towed equipment may cause loss of traction and loss of control.
2.44 Travel slowly and allow extra distance to stop.
PAGE 6
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.
2.48 Allow engine to cool before refueling.
2.49 Never fuel the machine indoors.
2.50 Do not store machine near open flame or source of ignition, such as a water heater or furnace.
2.51 Remove gas powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such
equipment with a portable container, rather than from a gasoline dispenser nozzle.
2.52 Never fill gasoline containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the
ground away from your vehicle before filling.
2.53 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete. Do not
use a nozzle lock-open device.
2.54 If fuel is spilled on clothing, change clothing immediately.
2.55 Never overfill fuel tank. Replace gas cap and tighten securely. Tank is full when level reaches bottom of fill tube.
GENERAL SERVICE
2.56 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect.
2.57 Keep all nuts and bolts tight to be sure the equipment is in safe working condition. Never operate a poorly maintained machine.
2.58 Do not touch hot areas of the machine.
2.59 Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their
proper operation regularly.
2.60 Keep the entire machine free of grass, leaves, or other debris build up. Clean up oil or fuel spillage and remove any fuel soaked
debris. Failure to do so can affect the safety and functionality of the machine, as well as increase the danger of a fire due to
contact with the hot surfaces of the machine.
2.61 Allow machine to cool before storing.
2.62 If you strike something with the mower, turn the mower and blades off, engage the parking brake, and inspect the machine for
damage. Repair, if necessary, before resuming.
2.63 Never make any adjustments or repairs with the engine running.
2.64 Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts,
when necessary.
2.65 Mower blades are sharp. Wrap the blade or wear gloves before servicing them.
2.66 Check parking brake operation frequently. Adjust and service as required.
2.67 Maintain or replace safety and instruction labels, as necessary.
2.68 Do not attempt to mount a tire without the proper equipment and experience to perform the job.
PAGE 7
2.69 Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel
and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken
or deform the wheel.
2.70 Park machine on level ground. Never allow untrained personnel to service machine. Understand service procedure before
doing work.
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.
These interlocks are vitally important and must be tested frequently. Following are instructions to test these very important safety
precautions. Note: the operator must be seated properly on the machine during these tests and the engine should
have been previously allowed to warm to operating temperature.
2.71 With the parking brake engaged, bring lever arms to their inward position, then attempt to start the machine (the blade actuator
should be in off position); the engine should not start.
2.72 On a level surface, disengage the parking brake and place lever arms to their outward position, then attempt to start the
machine (the blade actuator should be in off position); the engine should not start.
2.73 Engage parking brake and leave lever arms in outward position, put blade actuator in the on position, then attempt to start the
machine; the engine should not start.
2.74 Next, start the engine as stated in the “Mower Operation Section”, disengage parking brake, and Very Slowly begin to rise from
the seat; 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)
If your machine is equipped with ROPS, it is of utmost importance they are used properly. ROPS, when used correctly, dramatically
decrease the fatality rate in instances when the machine overturns.
2.75 Periodically ensure the bolts that attach the ROPS to the machine are securely fastened.
2.76 Always operated the machine with the ROPS secured in the upright position.
2.77 If the surrounding environment (e.g. low lying limbs, signage, etc.) makes it impossible to mow with the ROPS upright, lower
the ROPS at the hinge point, mow the area, then immediately secure the ROPS upright.
2.78 Upright ROPS are taller than then operators head. Be aware of this and your surrounding environment, as referenced above.
The mower and operator may clear low lying items, but the ROPS may not.
2.79 Always wear the provided seat belt when ROPS are utilized. Failure to use the seat belt severely handicaps the safety benefits
of the ROPS.
2.80 In the event of a roll-over, replace the ROPS before resuming use of the machine.
PAGE 8
SECTION 3: MOWER OPERATION
Never operate the machine with faulty equipment. Always be alert of sudden changes in landscape, as
the mower will react differently on slopes or embankments than it will on flat surfaces. Never operate
the mower with the discharge chute open. Do not cross terrain, other than grass, with blades turning.
This could cause damage to property or bystanders.
3.1 Place parking brake in up position
3.2 Drive arms must be in the “open” position. While sitting on the machine, each arm is
positioned away from the operator, to the right and left. Drive arms will lock into place and
must be in this position to start machine.
3.3 Put PTO switch in the OFF position.
3.4 Your machine has been equipped with ROPS (Roll Over Protection System). The operator
must fasten his or her seat belt while operating the mower.
3.5 If machine has not been started recently, engage the choke.
3.6 Make sure nothing is under or around machine.
3.7 Place key in ignition and turn.
3.8 Once machine is started, disengage the choke.
3.9 Increase RPM by sliding the throttle to fast position, toward the rabbit.
3.10 Owners must become familiar with the controls before operating a zero-turn radius vehicle.
3.11 Start slowly and build your skill level. Have ample practice before using the machine at full
capabilities.
3.12 Be comfortable with machine before engaging blades. Know what each component controls
before using machine.
3.13 Your mower will perform differently on an incline /decline. Be cautious, slow down, and do
not make any sudden jerking movements with control arms. 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 9
SECTION 4: MOWER MAINTENANCE
**Check each and provide maintenance when needed.
DAILY
4.1 Check Engine Oil
4.2 Check Engine Air Filter
4.3 Tire Pressure and Wheel Lug Nuts
4.4 Inspect Blades
Within FIRST five hours of usage, change engine oil and filter
EVERY 30 HOURS OF USAGE
4.5 Grease Machine
EVERY 50 HOURS OF USAGE
4.6 Replace Engine Oil and Filters
Replace filters once a year if under 50 hours
Check air and fuel filters more often in dry, dusty conditions
Within FIRST 50 hours of usage, change hydraulic oil and filters
EVERY 250 HOURS OF USAGE
4.7 Change Hydraulic Fluid and Filters
4.8 Refer to manufacturer manual for specific information on maintenance schedules.
SECTION 5: MOWER STORAGE & TRANSPORTATION
5.1 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.
5.3 Disconnect the negative battery cable when machine will be stored for more than 30 days.
5.4 Always secure machine properly when transporting machine.
5.5 Do not load machine on trailer with blades engaged.
5.6 Do not use ramps to load the machine.
5.7 Make sure Parking Brake is in “up” position.
5.8 In wet conditions tires may spin while loading / unloading. If necessary, wait for dry
conditions before loading / unloading.
5.9 Make sure mode of transportation is suitable to bear the weight of mower.
5.10 Deck height should be set at maximum before attempting to load.
5.11 Secure mower with at least two straps capable of securing weight of mower.
PAGE 10
SECTION 6: TROUBLESHOOTING
6.1 Q: How do I prevent an uneven cutting pattern and increase the quality of cut?
6.1 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.
6.2 Q: What should I do if my mower won’t start?
6.2 A: Check battery charge and connection (grounds), check your fuel (make sure fuel is less
than 30 days old and contains no water), make sure your spark plug is in good condition
and spark plug wire is attached, and make sure air filter is clean (a dirty filter makes it more
difficult for the engine to draw air). Check the integrity of the 25 amp main fuse; also check
for any bare wires and/or bad connections.
6.3 Q: What should I do if the blades won’t engage?
6.3 A: Make sure the safety switch is plugged in on the bottom of seat. Check the underside of
the PTO engager to ensure the plug is secure at switch.
6.4 Q: What type of fuel is recommended for my mower?
6.4 A: We recommend that you use a name brand fuel to ensure quality. Use fuel with an octane
rating near 87. Higher octane fuels offer no benefit. By law, E-15 fuel is not permitted. Usage
of E-15 will result in premature engine failure.
6.5 Q: Do you offer touch-up paint for your mowers?
6.5 A: Touch-up paint is available. Contact your local dealer for more information.
6.6 Q: How durable is the electric deck lift?
6.6 A: The actuator which controls the deck height is designed for moving loads of up to 1000
pounds and has a static holding capability which exceeds 3,000 pounds. Our ¼˝ deck weighs
approximately 250 pounds which is only 25% of working capability.
PAGE 11
SECTION 7: CONTROLS
7.1 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.
Switch will automatically return to he RUN position.
7.2 Throttle Control—A cable is connected to the engine throttle for controlling engine speed.
Move lever forward to increase engine rpm, move lever backward to decrease engine rpm.
7.3 Choke Control—A cable is linked to manually operate the engine choke. When the lever is
in the down position, the choke is in the off (run) position. When the lever is pulled up, the
choke is in the on (start) position. Do not operate the machine in the on (start) position. The
choke lever is behind the throttle control.
7.4 Deck Height Adjust—XP has a rocker switch for deck height adjustment.
7.5 Blade Engage Switch—This switch engages the blades. Pull the switch up to engage; push
the switch down to disengage.
7.6 Parking Brake (not pictured)—This lever engages the parking brake; it is located to the
operator’s left. Pull back fully to engage the parking brake; push forward to disengage.
7.7 Control Arms (not pictured)—These levers control the mower’s speed and direction (leftright and forward-reverse). Pushing the arms to their outward-most position places the
mower in neutral.
PAGE 12
SECTION 8: MOVING INOPERABLE MOWER
8.1 Do not tow machine. Use a winch to load on a trailer for transporting.
8.2 ATTENTION: RETURN BYPASS VALVES TO OPERATING POSITION BEFORE RUNNING
MOWER FOLLOWING REPAIRS.
8.3 If it is necessary to move mower when the engine is inoperable, the hydraulic drive pumps
are equipped with bypass valves. Before moving the mower, turn the bypass valves
counterclockwise one-half to one revolution. The bypass valve bolts are located on the side
of each pump and are easily identified by the hole through the bolt heads.
8.4 Your Bad Boy Mower Weighs: OUTLAW XP SERIES: 1180—1310 lbs
*** 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. This could cause serious bodily injury.
8.6 Hopefully, you’ll never need to use this section of the manual. However, if you do, use
extreme caution when moving machine!
SECTION 9: INSTRUMENTATION
9 .1 Electronic Hour Meter—Registers Hour increments up to 9,999.9 total hours. This meter
records the cumulative time the engine is running.
9 .2 Engine Oil Light—Alerts the user of a low oil level situation when lit.
PAGE 13
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.
10.2 NEVER attempt to straighten a bent blade by heating. NEVER attempt to weld a cracked
blade. The blades can break and cause serious injury or death.
10.3 NEVER work with blades while engine is running or deck clutch is engaged.
10.4 ALWAYS place deck clutch in DISENGAGE position while performing maintenance.
10.5 Use blocks when you MUST work under mower.
10.6 ALWAYS wear thick gloves when handling blades.
10.7 ALWAYS check for blade damage if mower strikes rock, branch, or other objects that could
potentially damage the blade.
(REMEMBER: NEVER CHECK BLADE WHILE ENGINE IS ON!
NEVER CHECK BLADES WHILE BLADES ARE ENGAGED!)
SECTION 11: GREASING THE BEARINGS
11.1 Park the machine on a level surface and disengage the blade control switch.
11.2 Move the motion control levers outward to the neutral position, engage parking brake, stop
the engine, remove the key, and wait for all moving parts to stop before leaving the operating
position.
11.3 Grease Type: NGLI grade #2 multi-purpose gun grease. Grease the front caster pivots.
11.4 Clean the grease fittings with a cloth. Scrape any paint off the front of the fitting(s).
11.5 Connect a grease gun to each fitting. Pump grease in fittings until grease begins to seep out
of the bearings. Wipe up excess grease.
11.6 Refer to service manual section for grease fitting locations.
PAGE 14
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.
Standard blades are also referred to as “2-in-1” (discharging & bagging ) or “high-lift” blades (because
they are designed to create a higher-lifting airflow).
2) Mulching blades generally have a more curved style surface and frequently include extra cutting
surfaces along the blade edges. These blades may also come in a “+” design (which is actually two
individual blades arranged in a perpendicular fashion to enhance mulching). The “+” blades are usually
found on older style mowers; newer ones utilize blades with more advanced mulching technology.
Mulching blades may also be referred to as “3-in-1” (mulching, discharging & bagging) or “all-purpose”
blades.
Bear in mind that the re-circulating airflow design of 3/1 blades makes them less efficient at discharging
grass clippings than a standard 2/1 blade. As with most all-purpose tools, there is some give and take as
opposed to using a tool designed for a more specific purpose.
If you’re experiencing less-than-desired cutting or discharging performance with a 3/1 blade, you may want
to check into using a 2/1 blade. Conversely, if you’re using a 2/1 blade and want to mulch clippings, you
should see about the availability of mulching blades or a mulching kit.*
The type of blade installed on a new mower is a decision the retailer makes for each model of mower, based
on the expected needs of most customers. If you’re unsure of which blade is on a particular model, inspect
the blade. Blades have part numbers stamped into them. Then compare these part numbers with the unit’s
Operator’s Manual or Parts List.
It is true there are many other styles of blades available. But since we don’t manufacture or recommend
using these other aftermarket styles, we will leave them out of this discussion. Should you want more
information on special application or aftermarket blades, you should contact the companies that make these
products. NOTE: Customers using non-OEM blades do so at their own risk. The use of unapproved (nonOEM) blades may void any or all of the mower and engine factory warranties.
* MULCHING KITS – These generally consist of mulching blades and a mulching plug (which closes off
the discharge opening to keep the clippings contained under the deck for re-cutting) plus any necessary
hardware for installation. Please check with your parts distributor regarding the contents of a particular
mulching kit.
PAGE 15
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.
• Don’t cut your grass too short, particular for cool season grasses. Higher heights usually provide for a deeper root system,
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 any one cutting. If circumstances arise that a lawn gets too tall and
you just have to lop off a bunch to get caught up, bite the bullet and break it down into several mowings to get caught up with 3
or so days between cuttings.
• NEVER SCALP YOUR LAWN. Scalping severely damages the root system 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 driveway where 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 for the first mowing of the season when it’s ok to remove more).
You can safely leave clippings that will quickly decompose and add nutrients back into the soil. Contrary to popular opinion,
grass clippings do not add to thatch buildup. Grass blades are made up of about 75% water.
• Mow your lawn in a different direction with each mowing, especially with lawns of shorter grass types. Altering the direction
ensures a more even cut since grass blades will grow more erect and less likely to develop into a set pattern.
• Keep your mower’s blade sharp, which means having it sharpened several times during the mowing season. Keep several
blades around so you’ll always have a sharp one on hand. Sharp blades cut the grass cleanly and help mulch clippings into
small pieces which break down quickly.
• Don’t forget to change your mower’s oil at least once during the mowing season. For brand new mowers, change the oil after
about 5 hours of operation during the initial break-in period.
• At the end of the mowing season use a fuel stabilizer in the remaining gasoline
• In the spring, don’t use that old gas unless you properly used a fuel stabilizer, it
can cause a number of problems. Better to use fresh gasoline to begin the new
mowing season.
• Leaf blade A demonstrates what a leaf blade should look like after mowing with
a sharp blade.
• Leaf blade B demonstrates a leaf blade that was injured by a dull mower blade.
• Leaf blade C was cut by the mower but indicates that the mower blade is not sharp enough. The shredded white tissue
protruding from the leaf blades C and D is the vascular tissue of the plant.
• Leaf blade D has been mown for quite some time with a dull mower blade.
The leading edge of the blade enclosure is equipped with an adjustable guard. When the
guard is set to a higher position, it allows incoming grass to remain in a more upright
position just prior to being cut. The result is a higher quality cut.
To bag or mulch?
Grass clippings do not contribute to thatch buildup or increase the chances of disease. If
you mow your lawn at the right height, without removing any more than 1/3 of it’s total height, clippings will quickly breakdown
without a trace. These clippings contribute additional nitrogen and other nutrients to the soil and supply it with additional
organic materials. Clippings from a 1000 sq. ft. lawn can add as much as 1 - 2 pounds of nitrogen back into the soil.
If you have a compost pile, then you may want to bag your clippings occasionally to add much needed green-matter to the
compost pile. Make sure it is mixed thoroughly with brown matter to avoid a strong ammonia odor. DO NOT COMPOST
CLIPPINGS after applying any weed control or weed-feed type product. Before adding clippings to the compost pile wait at
least 3 mowings after these products have been applied.
PAGE 16
SERVICE SECTION
SECTION 1: HYDROSTATIC SYSTEM
To change hydro oil on the Outlaw XP, remove oil
return lines from side of hydro tank and place them in
a disposable oil container. Start and run mower until oil
level is reduced to about 2˝ of oil remaining in the tank. Do
not allow air to enter the oil lines in the bottom of the tank.
Keep in mind that only about 75% of the hydro oil can be
changed at a time. Use only 20w-50 motor oil in the hydro
system (Bad Boy Hydrostatic oil is recommended). Bad
Boy recommends that the hydro oil and filters be changed
within the first 50 hours of use; then at intervals of 250
usage hours. Each side requires approximately four quarts
of oil to refill the system.
Change hydro oil filters by unscrewing them from the
filter head. Fill new filters with 20w-50 motor oil before
installing. Use only Bad Boy replacement filters. Use of
any other filters will result in damage to the hydro system
and void the warranty.
Once the system is refilled with oil, lift rear of mower
until tires are off the ground; then chock the front caster
tires. Loosen the bypass valve bolt (pictured) by one-half
to three-quarters of a turn. Next, with the bypass valves
open, slowly move the drive arms forward and rearward.
Keep away from the rear tires: they will be rotating and
present a safety hazard. After the drive arms have been
pushed forward and rearward five times, turn the engine
off and close the pumps’ bypass valves. Check the oil
level in each hydro reservoir after the first 15 minutes of
subsequent usage; it may be necessary to add more oil to
the reservoirs.
PAGE 17
SECTION 2: DRIVE BELT
Shown above is a typical pump belt tensioner for Outlaw
models.
Factory setting is about .030˝ (about the thickness of a
credit card) between coils as shown.
Shown to the right is a typical pump belt layout for most
models.
PAGE 18
SECTION 3: ENGINE
Most models have a drain hose installed on the engine
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. Consult your engine owner’s
manual for exact oil capacity. Bad Boy 10W-30 synthetic
blend engine oil is recommended for maximum protection.
The fuel filter is located in the fuel line about 12˝ from
the carburetor on the side of the engine. 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. Always use new hose clamps and ensure
the security of the new filter by lightly pulling on each
hose. Always perform maintenance outdoors or in a well
ventilated area. Do not smoke or allow any open flames in
the vicinity of any maintenance activities.
These engines are equipped with Donaldson® air filters.
These advanced technology filters utilize two air cleaner
elements to better protect the engine and extend its life.
The filter is the engine’s only defense against damaging
foreign particles; it is very important to inspect the air filter
elements before each use. To access the air filter elements,
unhook the two latches pictured to the right. Remove the
filter elements and tap each one on the side in order to
remove debris. Do not blow the filters out with compressed
air, doing so will greatly reduce the air filter’s effectiveness.
Replace yearly; more often in dusty environments.
Torque the clutch bolt to 50 ft. lbs. on all models. Retorque
at every oil change. (All Models)
PAGE 19
SECTION 4: ELECTRICAL SYSTEM
The 25 amp main fuse is located approximately 3” from the engine’s
starter. A blown fuse usually indicates a problem within the electrical
system or an electrical component. Never replace a fuse with one of a
higher amperage rating or ‘bypass’ a fuse in any way. Doing so creates
a significant fire hazard and can cause severe damage to the mower’s
electrical components. If the fuse is repeatedly blowing, contact your Bad
Boy dealer.
Always check the condition of the wiring harness ground
cable. Ensure that the ground is connected, clean, and
tight.
Check the condition and connection of the relays located
under the seat. Ensure that they are clean and connected.
Make sure that wire terminal ends have not been pushed
out of the relay block.
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.
PAGE 20
PAGE 21
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. lbs. Re-torque at every oil
change and check at every mowing.
There is one grease fitting in each front wheel and one in
each front caster bearing housing. Grease at every engine oil
change.
PAGE 22
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.
The control arm blocks have grease fittings located on the
top of each block. Grease one time a year.
SECTION 6: CUTTING DECK
Deck belt removal: (1) Remove ignition key. (2) Slide the
tension adjustment bolt to its most rearward position in
order to provide the lowest belt tension possible. (3) Raise
the deck to its highest position. (4) Remove either the right
or left blade pulley cover. (5) While lifting up on the belt (as
shown in the photograph), rotate the pulley until the belt is
free of the pulley. Exercise caution while performing this step as fingers can easily become caught between the belt
and pulley. For optimal cutting performance, the blade enclosure should be level from right to left and have a slight
forward tilt downward. To ensure proper deck orientation,
perform the following steps: (1) Move the mower onto a
flat surface such as a concrete pad. (2) Ensure all tires are
inflated to the recommended pressure. (3) Measure the
distance from the ground surface to the bottom of the blade
enclosure (as indicated in the photograph) at each of the
four corners. The rear corners should be equal in ground
clearance as should the forward corners. The forward
corners should be approximately 1/8” lower than the rear
corners. If adjustment becomes necessary, perform the
actions described below in order to return the mower to its optimum cutting state. The
deck brackets (pictured, 4 total) are the principal means for deck reorientation. Begin the
adjustment by leveling the deck; both front to back and left to right. This is accomplished by
shifting the position (upward/downward) of the deck brackets within the vertical slots located
on their respective deck tabs. Once the deck is parallel with ground, the proper forward tilt
must be obtained. This can be achieved by re-adjusting the forward or rearward deck bracket
pair. If necessary, the two turnbuckles may be used for slight position refinements.
PAGE 23
The deck spring tension is critical. If the tension is too high,
premature failure of the deck belt and blade spindles can
occur. If the tension is too low, the belt can ‘jump off’ or slip
on the pulleys. This results in reduced cut quality and early
belt failure. With the deck up, the spring coil gap should be
about .025˝ - .030˝ (about the thickness of a credit card).
Spring tension adjustments can be made by sliding the
bolt shown above forward or backward in the slot of the
deck. Belt tension should be 50- 55 lbs with the deck at its
highest setting.
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.
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. Bolts used have right-handed threads. Retorque the blade bolts to 90-110 lbs. The blade spindles
contain two sealed ball bearings inside the top and bottom
of the spindle. The bearings are replaceable for a more cost
effective repair.
PAGE 24
PARTS SECTION
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PAGE 45
2015 LIMITED WARRANTY
FOR
BAD BOY COMMERCIAL MOWER
(CZT, STAND ON, DIESEL, OUTLAW, OUTLAW EXTREME, and OUTLAWXP)
1. WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:
Bad Boy, Inc. will, at its option, repair or replace, without charge, any part covered by the warranty which is found to be defective in material and/or
workmanship within two (2) years* after date of sale to the original retail purchaser unless the product is used for rental purposes, in which case this
warranty is limited to ninety (90) days.
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.
Belts are warranted for a period of ninety (90) days against materials or workmanship defects.
Seats are warranted for a period of (6) months against material or workmanship defects.
At Bad Boy, Inc.’s request, customer will make the defective part available for inspection by Bad Boy, Inc. and/or return the defective part to Bad Boy, Inc.,
transportation charges prepaid.
2. WHAT THIS WARRANTY DOES NOT COVER:
A. This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper maintenance, improper use
or abuse of the product, alterations, or failure to follow the instruction contained in the Owner’s Manual for operation and maintenance.
B. The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place where the
inspection and/or warranty work is performed.
Bad Boy Inc. will not be responsible for the pickup and delivery of a machine for warranty purposes.
C. Engines are warranted separately by their respective manufacturer. The available warranties covering this item are furnished with each mower.
Bad Boy, Inc. does not assume any warranty obligation, liability or modification for this item, which is covered exclusively by the stated warranty
of the respective manufacturers.
D. Tires, blades, deck anti-scalping wheels are considered to be consumable wear items and are therefore not warranted.
E. Batteries are warranted for six months (free replacement) from the retail purchase date against materials or workmanship defects. The battery
warranty must be obtained through the battery manufacturer.
3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
A. Warranty service can be arranged by contacting the dealer where you purchased the mower. Proof of the date of purchase may be required to
verify warranty coverage.
B. Warranty claims will not be reviewed or paid unless the warranty registration is received by Bad Boy, Inc.
within 30 days of the retail purchase date.
C. Warranty claims requiring parts returned will be settled upon return of parts to Bad Boy for inspection.
D. All warranty issues must be handled through an authorized service center or dealership.
4. WARRANTY LIMITATION:
A. THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE INCLUDING MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED
BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts,
so the above limitations may not apply to you.
B. BAD BOY, INC. WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR EXPENSES IN CONNECTION
WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the exclusion or limitation of incidental or consequential damages,
so the above limitation(s) or exclusion(s) may not apply to you.
C. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to amend, modify, or
extend this warranty in any way. Accordingly, additional statements such as dealer advertising or presentations, whether oral or written, do not
constitute warranties by Bad boy, Inc., and should not be relied on.
D. This warranty extends only to turf equipment operated under normal conditions and properly serviced and maintained. The warranty expressly
does not cover (i) any defects, damage or deterioration due to normal use, wear and tear, or exposure; (ii) normal maintenance services such
as oil change, cleaning, lubrication, adjustment; (iii) replacement of services, items, such as oil, lubricants, spark plugs, belts, rubber hoses or
other items subject to normal service replacement; (iv) damage or defects arising out of or relating to misuse, neglect, alteration, negligence or
accident; (v) repair or replacement arising from operation of or use of the turf equipment which is not in accordance with operating instructions
as specified in the operator’s manual or other operational instructions provided by Bad Boy Inc.; (vi) repair or replacement arising as a result of
any operation from turf equipment that has been altered or modified so as to, indetermination of Bad Boy, Inc., adversely affect the operation,
performance or durability of the equipment or that has altered, modified or affected the turf equipment so as to change the intended use of the
product; (vii) repair or replacement necessitated by use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with
the turf equipment or other than as recommended in the operator’s manual or other operational instructions provided by Bad Boy, Inc.; (viii)
repairs or replacements resulting from parts or accessories which have adversely affected the operation, performance or durability of the turf
equipment; or (ix) damage or defects due to or arising out of repair of turf equipment by person or persons other than an authorized Bad Boy, Inc.,
service dealer or the installation of parts other than genuine Bad Boy, Inc., recommended parts.
As a condition to this warranty, customer shall have read the operator’s manual and ensured the mower has been registered within 30 days
of purchase.
E. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.
PAGE 46
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.
Serial # ______________________________________________________
Date of Purchase _______________________________________________
Dealer Information ______________________________________________
PAGE 47
For additional information, please see us at
www.badboymowers.com
Bad Boy, Inc.
102 Industrial Drive
Batesville, Arkansas 72501

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