SECTI ON 1: HYDROSTATI C SYSTEM

TO CHANGE HYDRO OI L ON COMMERCI AL MODELS, REMOVE OI L

RETURN LI NES FROM TOP OF HYDRO TANK AND PLACE THEM I N
A DI SPOSABLE OI L CONTAI NER. START AND RUN MOWER
UNTI L OI L LEVEL I S REDUCED DOWN TO ABOUT 2 OF OI L
REMAI NI NG I N THE TANK. DO NOT ALLOW AI R TO ENTER THE
OI L LI NES I N THE BOTTOM OF THE TANK. KEEP I N MI ND THAT
ONLY ABOUT 75% OF THE HYDRO OI L CAN BE CHANGED AT A
TI ME. USE ONLY 20W50 MOTOR OI L I N THE HYDRO SYSTEM.




CHANGE HYDRO OI L FI LTERS BY UNSCREWI NG THEM FROM THE
FI LTER HEAD. FI LL NEW FI LTERS WI TH 20W50 MOTOR OI L
BEFORE I NSTALLI NG. USE ONLY BAD BOY REPLACEMENT
FI LTERS. USI NG ANY OTHER FI LTER WI LL RESULT I N DAMAGE
TO THE HYDRO SYSTEM AND VOI D THE WARRANTY.









ONCE THE SYSTEM I S REFI LLED WI TH OI L, LI FT REAR OF
MOWER UNTI L TI RES ARE OFF THE GROUND. START ENGI NE,
RELEASE PARKI NG BRAKE, PUSH CONTROL ARMS FORWARD,
STAY CLEAR OF MOVI NG REAR TI RES, OPEN AND CLOSE THE
BYPASS VALVE ON EACH PUMP ABOUT 6-10 TI MES BY
LOOSENI NG AND TI GHTENI NG THE BOLT SHOWN I N THE ABOVE
PHOTO. THI S WI LL PURGE THE AI R FROM THE SYSTEM.
(THE BYPASS BOLT HAS A HOLE DRI LLED THROUGH THE SI DE
OF THE BOLT HEAD). THI S VALVE ALSO SERVES AS A NEUTRAL
FOR MOVI NG THE MOWER WI THOUT THE ENGI NE RUNNI NG.




WHEN SERVI CI NG A LI GHT DUTY COMMERCI AL MOWER WI TH A
SEALED TRANSAXLE UNI T, START BY REMOVI NG THE FI LTER
SKI D PLATE ON THE BOTTOM OF EACH UNI T. THE SKI D I S HELD
ON BY THREE 10MM BOLTS. NEXT, REMOVE THE FI LTER. THE
FI LTER ALSO SERVES AS THE OI L DRAI N. EACH TRANSAXLE
HOLDS ABOUT 2 QUARTS OF HYDRO OI L. REI NSTALL NEW
FI LTERS AND SKI D PLATES. USE ONLY HYDRO-GEAR OR BAD
BOY HYDRO FI LTERS. USE OF ANY OTHER TYPE OF FI LTER
WI LL RESULT I N DAMAGE TO THE HYDRO SYSTEM AND VOI D
THE WARRANTY.




THE FI LL PLUG I S LOCATED AT THE TOP CENTER OF THE
I NSI DE CASE OF EACH TRANSAXLE. USE ONLY 20W50 MOTOR
OI L I N THE HYDRO SYSTEM.




ONCE THE SYSTEM I S FI LLED WI TH OI L, LI FT REAR OF MOWER
UNTI L REAR TI RES ARE OFF THE GROUND. START ENGI NE,
RELEASE PARKI NG BRAKE, PUSH DRI VE HANDLES FORWARD,
STAY CLEAR OF MOVI NG REAR TI RES. NEXT, PULL THE
NEUTRAL BYPASS LEVERS (LOCATED AT THE REAR OF THE
FRAME, ON EI THER SI DE OF THE MUFFLER) I N AND OUT 6-10
TI MES TO PURGE THE SYSTEM OF ANY AI R. I T MAY BE
NECESSARY TO ADD MORE OI L TO THE OVERFLOW TANK AFTER
10-15 MI NUTES OF RUNNI NG. THESE BYPASS LEVERS ALSO
SERVE AS A NEUTRAL FOR MOVI NG THE MOWER WI THOUT THE
ENGI NE RUNNI NG.




THE HYDRO OVERFLOW TANK ON A ZT MODEL I S LOCATED
BEHI ND THE SEAT. NOTI CE THE FULL COLD LI NE AT THE
BOTTOM OF THE TANK. USE ONLY 20W50 MOTOR OI L I N THI S
TANK.

















SECTI ON 2: DRI VE BELT

SHOWN ABOVE I S THE AOS/DI ESEL PUMP BELT TENSI ONER.
TI GHTENI NG THE TWO J AM NUTS ON THE LEFT SI DE WI LL
I NCREASE THE BELT TENSI ON ON ALL MODELS. FACTORY
SETTI NG I S ABOUT .030 (ABOUT THE THI CKNESS OF A CREDI T
CARD) BETWEEN COI LS AS SHOWN BELOW.










SHOWN ABOVE I S A TYPI CAL PUMP BELT TESI ONER FOR PUP


AND LI GHTENI NG MODELS.


SHOWN ABOVE I S A TYPI CAL PUMP BELT LAYOUT FOR MOST
COMMERCI AL MODELS.

























SECTI ON 3: ENGI NE


SHOWN ABOVE I S A KAWASAKI ENGI NE WI TH THE QUI CK
DRAI N OI L DRAI N LOCATED ON THE LEFT SI DE OF THE ENGI NE.
USE A FLAT SCREW DRI VER AS SHOWN TO LOOSEN THE DRAI N.




MOST MODELS HAVE A DRAI N HOSE I NSTALLED ON THE ENGI NE
FOR EASI ER OI L CHANGES. ALL GAS ENGI NES USED BY BAD
BOY HAVE AN OI L CAPACI TY OF 2 QUARTS. BAD BOY
RECOMMENDS THAT THE OI L AND FI LTER BE CHANGED EVERY
50-60 HOURS OF USAGE.




THE FUEL FI LTER I S LOCATED I N THE FUEL LI NE ABOUT 12
FROM THE CARBURATOR ON THE SI DE OF THE ENGI NE. NOTE
THE DI RECTI ON OF FLOW ON THE SI DE OF THE FI LTER.
REPLACE ONCE A YEAR.




MOST ALL MODELS HAVE A VACUUM OPERATED FUEL PUMP
BOLTED TO THE SI DE OR TOP OF THE ENGI NE. THE PUMP HAS
A FUEL I N , A FUEL OUT , AND A VACUUM LI NE COMI NG FROM
THE ENGI NE BLOCK. FUEL FLOW CAN BE CHECKED HERE I F
THE PUMP I S SUSPECTED TO BE DEFECTI VE.





WHEN SERVI CI NG THE FUEL SYSTEM ON THE CAT DI ESEL, I T I S
NECESSARY TO PURGE THE AI R FROM THE SYSTEM BY
LOOSENI NG THE 9/16 BOLT ON TOP OF THE FUEL FI LTER AND
PUMPI NG THE FUEL BULB UNTI L AI R BUBBLES ARE NO LONGER
VI SI BLE.





REMOVE AND I NSPECT AI R CLEANER WEEKLY. (MORE OFTEN I N
DUSTY CONDI TI ONS). DO NOT BLOW FI LTER OUT WI TH AI R
PRESSURE, THI S WI LL CAUSE THE FI LTER TO BE FI LLED WI TH
TI NY HOLES THAT WI LL ALLOW DI RT TO ENTER. I NSTEAD, TAP
FI LTER ON SI DE TO REMOVE ANY DEBRI S. REPLACE AT LEAST
ONCE A YEAR, MORE OFTEN I N DUSTY CONDI TI ONS.





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





KEEP RADI ATOR SCREEN CLEAN AND FREE OF DEBRI S ON
LI QUI D COOLED MODELS. CHECK SCREEN HOURLY DURI NG
DRY CONDI TI ONS. SLI DE RADI ATOR SCREEN UP TO REMOVE.


















SECTI ON 4: ELECTRI CAL SYSTEM

ON MOST LARGER COMMERCI AL ENGI NES (27 HP AND UP). THE
25 AMP MAI N FUSE I S LOCATED ABOUT 3 FROM THE STARTER
ON THE ENGI NE.




ON SMALLER COMMERCI AL AND LI GHT DUTY COMMERCI AL
MOWERS, THE 25 AMP MAI N FUSE I S LOCATED J UST BEHI ND
THE BATTERY CONNECTED TO THE STARTER SOLI NOI D.




ALWAYS CHECK THE CONDI TI ON OF THE WI RI NG HARNESS
GROUND CABLE. THE GROUND I S LOCATED J UST I NSI DE OF
THE RI GHT SI DE FUEL TANK ON MOST MODELS. ENSURE THAT
THE GROUND I S CONNECTED, CLEAN, AND TI GHT. ON SOME
MODELS, THI S WI RE MAY BE CONNECTED TO THE NEGATI VE
SI DE OF THE BATTERY.




CHECK THE CONDI TI ON AND CONNECTI ON OF THE RELAYS
LOCATED UNDER THE SEAT. ENSURE THAT THEY ARE CLEAN
AND CONNECTED. MAKE SURE THAT WI RE TERMI NAL ENDS
HAVE NOT BEEN PUSHED OUT OF THE RELAY BLOCK.




ON MOST MODELS, THE RED WI RE COMI NG OUT OF THE ENGI NE
I S THE CHARGI NG WI RE FROM THE ALTERNATOR. CHECK FOR
13.6 - 14.2 VOLTS DC AT THI S WI RE WI TH ENGI NE AT FULL
THROTTLE.

















SECTI ON 5: FRAME


TORQUE FRONT FORK CASTLE NUT TO 40 FT.LBS. BE SURE TO
SPI N THE FORK WHI LE TORQUI NG THE NUT TO ENSURE THAT
NO BEARI NG DAMAGE I S DONE.




BE SURE TO REI NSTALL THE COTTER PI N I NTO THE CASTLE
NUT. ALWAYS TRY TO GO TI GHTER ON THE NUT TO FI ND A
CASTLATI ON FOR THE PI N TO FI T I N. NEVER BACK THE
BEARI NG TENSI ON OFF AFTER TORQUI NG THE NUT, THI S WI LL
SPRI NG THE BEARI NG CAGE.




TORQUE REAR WHEEL LUGS TO 65-75 FT.LBS. RETORQUE AT
EVERY OI L CHANGE.




THERE I S ONE GREASE FI TTI NG I N EACH FRONT WHEEL AND
ONE I N EACH FRONT CASTER BEARI NG HOUSI NG. GREASE AT
EVERY ENGI NE OI L CHANGE.




THERE I S ONE GREASE FI TTI NG ON EACH OF THE ACTUATOR
BAR PI LLOW BLOCKS LOCATED UNDER THE FUEL TANKS.
GREASE TWI CE A SEASON.





THE PUMP BELT TENSI ONER I S LOCATED UNDER THE ENGI NE
AND HAS A GREASE FI TTI NG AT I TS PI VOT POI NT. GREASE AT
EVERY ENGI NE OI L CHANGE.





THE DECK BELT TENSI ONER I S LOCATED AT THE REAR OF THE
DECK AND HAS A GREASE FI TTI NG ON I TS PI VOT POI NT.
GREASE AT EVERY ENGI NE OI L CHANGE.




THE CONTROL ARM BLOCKS HAVE GREASE FI TTI NGS LOCATED
ON THE TOP AND BOTTOM OF EACH BLOCK. GREASE ONE TI ME
A YEAR.








WHEN ADJ USTI NG THE TRACKI NG ON THE MOWER, THE
LENGTH OF THE PUSHRODS CAN BE CHANGED BY SCREWI NG
THE SWI VEL J OI NT I N OR OUT ON THE ENDS OF THE RODS.
SHORTENI NG THE OVERALL LENGTH OF THE ROD SLOWS THE
PUMP DOWN. LENGTHENI NG THE ROD WI LL I NCREASE THE
SPEED OF THE PUMP.




ON COMMERCI AL MODELS, THE REACTI ON OF THE HYDRO
PUMPS AND THE RESI STANCE FELT I N THE CONTROL ARMS
CAN BE ADJ USTED BY MOVI NG THE PUSHRODS OR THE
DAMPENERS UP OR DOWN I N THE MOUNTI NG HOLES.
MOVI NG DAMPENERS UP, LESS RESI STANCE.
DAMPENERS DOWN, MORE RESI STANCE.
MOVI NG PUSHRODS UP, SLOWER REACTI ON.
PUSHRODS DOWN, FASTER REACTI ON.










TO SERVI CE THE PARKI NG BRAKE SYSTEM, THE REAR BRAKE
ASSEMBLY REQUI RES A HUB PULLER TO REMOVE THE BRAKE
DRUM AS SHOWN ABOVE. THE AXLE NUT MUST BE REPLACED
AND TORQUED TO 200 FT.LBS. BE SURE TO REI NSTALL THE
COTTER PI N.
















SECTI ON 6: CUTTI NG DECK



TO REMOVE THE DECK BELT, LI FT UP ON THE BELT WHI LE
ROTATI NG THE PULLEY TO ROLL THE BELT UP AND OFF OF THE
PULLEY. (BE SURE NOT TO GET YOUR FI NGERS BETWEEN BELT
AND PULLEY).




TO CHECK THE LEVEL OF THE DECK, START ON A FLAT
SURFACE AND SET THE AI R PRESSURE I N ALL FOUR TI RES.
RAI SE THE DECK UP, AND MEASURE ALL FOUR CORNERS OF
THE DECK TO SEE I F I T I S LEVEL FROM LEFT TO RI GHT AND
FRONT TO BACK. ALL DECKS SHOULD BE LEVEL FROM LEFT TO
RI GHT AND HAVE A PI TCH DOWN I N THE FRONT.




I F DECK ADJ USTMENTS ARE NECESSARY, START WI TH THE
CHAI N LENGTH ADJ USTERS. THESE ADJ USTERS AFFECT THE
OVERALL HI EGHT OF THE DECK AND THE LEVEL FROM LEFT TO
RI GHT.




THE LARGE TURN BUCKLES ON THE FRONT OF THE DECK ONLY
AFFECT THE PI TCH OF THE DECK OR THE LEVEL FROM FRONT
TO BACK.




THE DECK SPRI NG TENSI ON I S CRI TI CAL. I F THE TENSI ON I S
TOO MUCH, I T WI LL CAUSE THE SPRI NG TO BREAK. I F TOO
LOOSE, THE BELT CAN J UMP OFF OR SLI P ON THE PULLEYS
AND CAUSE A CUT QUALI TY I SSUE. WI TH THE DECK UP, THE
SPRI NG COI L GAP SHOULD BE ABOUT .025 - .030 (ABOUT THE
THI CKNESS OF A BUSI NESS CARD). SPRI NG TENSI ON
ADJ USTMENTS CAN BE MADE BY SLI DI NG THE BOLT SHOWN
ABOVE FORWARD OR BACKWARD I N THE SLOT OF THE DECK.




ON AN AOS/DI ESEL MODEL, DECK BELT ADJ USTMENTS CAN BE
MADE BY SLI DI NG THE REAR V I DLER PULLEYS UP OR DOWN
I N THEI R SLOTS.




THE CONDI TI ON OF THE BLADES CAN DRASTI CLY AFFECT THE
CUT QUALI TY OF THE MOWER DECK. REPLACE AS NECESSARY.
THESE BLADES WERE USED CONSI DERABLY TOO LONG.
RESHARPENI NG I S RECOMMENDED BY PROFESSI ONALS ONLY
TO DETERMI NE WHEN THE BLADE NEEDS TO BE REPLACED AND
BECAUSE OF THE NEED FOR REBALANCI NG.




TO CHANGE BLADES, I T MAY BE EASI ER TO USE A PI ECE OF
WOOD TO KEEP THE BLADE FROM TURNI NG SO THAT THE BOLT
CAN BE LOOSENED. RETORQUE THE BLADE BOLTS TO 90 - 110
FT.LBS.




THE BLADE SPI NDLES CONTAI N A SEALED BALL BEARI NG I N
THE TOP AND BOTTOM OF THE SPI NDLE. THE BEARI NGS ARE
REPLACEABLE FOR A MORE COST EFFECTI VE REPAI R.