Bad Boy 1500 Manual de usuario
All information contained within this publication is based on the
latest product information at the time of publication. Due to
constant improvements in the design and quality of production
components, some minor discrep ancies may result between the
actual vehicle and the information presented in this publi cation.
Model 1500
(Gas Powered)
Multi-Terrain Vehicle
(MTV)
Service Manual
PAGE 2
SERVICE MANUAL
This service manual contains the technical data of each component inspection and repair for the MTV
(Multi-Terrain Vehicle) by Bad Boy Mowers. The manual is shown with illustrations and focused on “Service
Procedures,” “Operation Key Points,” and “Inspection Adjustment” which provides technician with service
guidelines.
All information contained within this publication is based on the latest product information at the time of
publication. Due to constant improvements in the design and quality of production components, some minor
discrep ancies may result between the actual vehicle and the information presented in this publi cation.
Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted
for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within,
whether whole or in part, is expressly prohibited.
Bad Boy, Inc.
102 Industrial Drive
Batesville, Arkansas 72501
United States of America
PAGE 3
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and system
inspection & service for the Bad Boy MTV.
In addition, please refer to the manual contents for details on servicing, inspecting and adjusting
the Bad Boy MTV.
Chapter 1 Page 4 covers general information and troubleshooting diagnosis.
Chapter 2 Page 24 covers the service maintenance information and special tools manual.
Chapters 3 - 11 Page 36 cover engine and driving systems.
Chapter 12 Page 100 covers the cooling system.
Chapters 13 -14 Page 107 covers the frame and body assembly.
Chapter 15 Page 122 covers the electrical equipment and the wiring diagram.
PAGE 4
SERVICE MANUAL
Chapter CONTENTS
1 GENERAL INFORMATION
2 SERVICE MAINTENANCE INFORMATION
3 LUBRICATION SYSTEM
4 FUEL SYSTEM
5 ENGINE REMOVAL
6 CYLINDER HEAD/VALVE
7 CYLINDER/PISTON
8 “V” TYPE BELT DRIVING SYSTEM
9 FINAL DRIVING MECHANISM
10 ALTERNATOR / STARTING CLUTCH
11 CRANKSHAFT / CRANKCASE
12 COOLING SYSTEM
13 FRONT BRAKE AND FRONT WHEEL
14 STEERING / FRONT SUSPENSION
15 REAR BRAKE/REAR WHEEL / REAR CUSHION
16 ELECTRICAL EQUIPMENT
17 ELECTRICAL DIAGRAM
PAGE 5
Serial Number on MTV
PIN Number:
Located under seat on passenger side.
PAGE 6
SERVICE MANUAL
CHAPTER 1 GENERAL INFORMATION/TROUBLESHOOTING
General Safety .........................................................pages 6–7
Service Precautions ...................................................page 8–11
Specifications ..........................................................pages 12–13
Torque Values ..........................................................pages 14 –15
Troubleshooting/Diagnosis ..........................................page 16 – 23
General Safety
Carbon Monoxide Warning
If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area.
CAUTION
Exhaust contains toxic gas which may cause unconsciousness and even result in death.
Gasoline
Gasoline has a low ignition point and is an explosive material. Work in a well-ventilated area, no flame or spark
should be allowed in the work place or anywhere near where gasoline is being stored.
CAUTION
Gasoline is highly flammable, and may explode under some conditions, keep it away from children.
CAUTION
Used Engine Oil - Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although
it might not be verified. We recommend that you wash your hands with soap and water right after contacting.
Keep used oil beyond reach of children.
PAGE 7
CAUTION
Hot Components - Components of the engine and exhaust system can become extremely hot after engine
running. They remain very hot even after the engine has been stopped for some time. When performing service
work on these parts, wear insulated gloves and wait until cooling off.
CAUTION
Battery - Battery emits explosive gases; flame is strictly prohibited. Keep the work area well ventilated when
charging the battery. The battery contains sulfuric acid (electrolyte) which can cause serious burns, so be
careful. Avoid contact with your eyes and skin. If you get battery acid on your skin, wash immediately with
water. If you get battery acid in your eyes, wash immediately with water and then see a doctor.
Brake shoe quick tip:
Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum cleaner or
equivalent to avoid flying dust.
CAUTION
Brake Shoe Caution - Inhaling brake shoe or pad ash or dust may cause disorders or cancer.
CAUTION
Brake Fluid Caution - Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts.
Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the out
of reach of children. Brake fluid is hygroscopic which means it absorbs moisture from the surrounding air. For
this reason, we recommend that the reservoir cap is always secured. When filling the reservoir, leave the cap off
only long enough to fill the reservoir to the appropriate level then re-secure the cap.
PAGE 8
SERVICE MANUAL
Service Precautions
Always use with Bad Boy genuine parts and recommended oils. Using non-recommended parts for the Bad Boy
MTV may damage the Vehicle.
Special tools are designed for removal and installation of engine components without damage. Using the wrong
tools may result in damage to the parts.
When servicing this MTV, be sure to select appropriate tools. This machine uses both Metric and English
system bolts, screws, nuts, etc. Using improper tools can damage components.
Clean the outside of the parts or the cover before removing it from the MTV. Otherwise, dirt and deposits
accumulated on the part’s surface may fall into the engine, chassis, or brake system and cause damage.
Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay special attention
to O-rings or oil seals because most cleaning agents have an adverse effect on them.
Never bend or twist a control cable to prevent cable damage or premature wear.
Old rubber parts may become deteriorated and prone to damage by solvent and oil. Check these parts before
installation to make sure that they are in good condition, replace if necessary.
When loosening a component which has different sized fasteners, work with a diagonal pattern and from inside
out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much
stress.
Store complex components such as transmission parts in the proper assembled order and tie them together
with wire for ease of installation later.
Note the position of components before disassembling them to ensure they will be reassembled in correct
order. (depth, distance or position).
Components not to be reused should be replaced when disassembled including gaskets metal seal rings,
O-rings, oil seals, snap rings, and split pins.
PAGE 9
General Information
If the length of
bolts and screws
for assemblies,
cover plates or
boxes is different
from one another,
be sure they
are correctly
installed. In case
of confusion,
Insert the bolt into the hole to compare its length with
other bolts, if its length out side the hole is the same
with other bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
Tighten assemblies with different dimension fasteners
as follows: Tighten all the fasteners with fingers,
then work diagonally
from inside toward
outside, important
components should
be tightened 2 to 3
times with appropriate
increments to avoid
warp unless otherwise
indicated. Bolts and
fasteners should be kept clean and dry. Do not apply
oil to the threads.
When oil seal is installed, fill the groove with grease,
install the oil seal
with the name of
the manufacturer
facing outside, and
check the shaft on
which the oil seal is
to be installed for
smoothness and for burrs that may damage the oil
seal.
Remove residues
of the old gasket
or sealant before
reinstallation,
grind with a
grindstone if the
contact surface
has any damage.
The ends of
rubber hoses for
fuel, vacuum, or
coolant should
be pushed as far
as they can go to
their connections
so that there is enough room below the enlarged ends
for tightening the clamps.
Rubber and plastic
boots should be
properly reinstalled
to the original correct
positions as designed.
The tool should be
pressed against two (inner and outer) bearing races
when removing a ball bearing. Damage may result if
the tool is pressed against only one race (either inner
race or outer race). In this case, the bearing should be
replaced. To avoid damaging the bearing, use equal
force on both races.
Both of these examples can result in bearing damage.
PAGE 10
SERVICE MANUAL
General Information
Lubricate the
rotation faces
with specified
lubricant on
the lubrication
points before
assembling.
Check the
positions and
operation of
installed parts
is in correct
and properly.
Before battery removal make sure to remove the
battery negative (-) cable first. Note - make sure
tools like open-ended
wrenches do not make
contact with the body.
This prevents the
circuit from shorting
and creating spark.
After service is
completed, make sure
all connection points
are secured. Battery
positive (+) cable
should be connected
first. The two
battery posts have
to be greased after
connected the cables.
Make sure that the battery
post caps are placed in
their proper position after
the battery posts have
been serviced.
When separating a
connector, its locker
needs to be unlocked first.
Then, conduct the service
operation.
Do not pull the wires when disconnecting a connector
or wires. Hold the connector body.
Check to see if
the connector
pins are bent or
loose.
Insert the connectors completely. If there are two
locks on two connector sides, make sure the locks are
locked in properly.
Check to see if any
wires are loose.
If the connector is
covered by a
twin connector
boot, then
secure it
properly.
Before
terminal
connection,
check to see
if the boot is cracked or the terminal is loose.
Insert the
terminal
completely.
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