model 1500g owner’s & parts...

Ride With An Attitude

MODEL 1500GOWNER’S & PARTS MANUAL

For additional information, please see us at

www.badboymowers.com Bad Boy, Inc.102 Industrial DriveBatesville, Arkansas 72501(870) 698-0090

UTV OWNER’S MANUAL GAS-POWERED

Table of Contents General Safety ..................................................................................................................... 3 Specifications ..................................................................................................................4–5 Important Identification Numbers ....................................................................................... 5 Starting/Operating Procedure ............................................................................................. 6 Periodical Maintenance Schedule ...................................................................................6–9 Basic Safety Rules ..............................................................................................................10 Service Record ...................................................................................................................11 PARTS LIST .................................................................................13 OWNER’S REGISTRATION & TRAINING CERTIFICATE ................................33

Dear Customer:Our Bad Boy Mower UTV is manufactured under strict quality control systems. The Warranty document sent to dealers guarantees all written items. Given that you follow the maintenance procedure by using original parts and riding normally, we will repair or replace any components found to be defective.

This warranty is not valid if the following occurs:

•UsingunspecifiedEngineOil. •Impropermaintenanceorrepairs. •Usingnon-originalormodifiedaccessoriesandparts. •ImproperOperationorevidenceofabuse. •Normalwearandtearitemsarenotcovered—Seat,SparkPlug,Bulbs,Filters,Brakes,Belt,Chain, Tires, etc.

This manual is a simple introduction of operation and basic maintenance. If you have additional questions, contact your dealer for assistance.

owner memo Name: ___________________________________________________________ Purchasing Date: ___________________________________________________________ Type: ___________________________________________________________ Pin Number: ___________________________________________________________ Special Note: ___________________________________________________________

IgnItIon KeyYourkeyisaseriestypekey,ofwhichthereareahighrangeofnumbers.Itishighlyrecommendedthatyouobtainadditionalcopiesofyourkey.Ifallkeysarelost,areplacementignitionswitchmustbeinstalled.

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general safety

Carbon MonoxideWhen running your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an exhaust fan.

CautionExhaustcontainstoxicgaswhichmaycauseonetoloseconsciousnessandevenresultindeath.

GasolineGasolinehasalowignitionpointandisanexplosivematerial.Workinawell-ventilatedplace,noflameorsparkshouldbeallowedintheworkplaceorwheregasolineisbeingstored.

Used Engine OilProlongedcontactwithusedengineoil(ortransmissionoil)maycauseskincanceralthoughitmaynotbeverified.We recommend that you wash your hands with soap and water right after coming in contact with used oil. Keep used oil beyond reach of children.

Hot ComponentsComponentsoftheengineandexhaustsystemcanbecomeextremelyhotafterenginerunning.Theyremainveryhotevenaftertheenginehasbeenstoppedforsometime.Whenperformingserviceworkontheseparts,wearinsulatedglovesandwait until cooling off. BatteryTheBatteryemitsexplosivegases;flameisstrictlyprohibited.Keepyourworkareawellventilatedwhenchargingthebattery.TheBatterycontainssulfuricacid(electrolyte)whichcancauseseriousburns,sobecarefulnottomakecontactwithyoureyesorskin.Ifyougetbatteryacidonyourskin,washitoffimmediatelywithwater.Ifyougetbatteryacidinyoureyes,flushit out immediately with water and then see a doctor.

Keep electrolyte beyond reach of children.

Brake DustDonotuseanairhoseoradrybrushtocleancomponentsofthebrakesystem:useavacuumcleanerorequivalenttoavoiddustflying.Inhalingbrakedusthasbeenknowntocausebreathingdisordersorcancer.

Brake FluidBrakefluidishygroscopicwhichmeansitabsorbsmoisture.Moistureinsidebrakecomponentscancausepartdeterioration.Spillingbrakefluidonpainted,plasticorrubberpartsmaycausedamagetotheparts.PlaceaCleantowelontheabove-mentionedpartsforprotectionwhenservicingthebrakesystem.Keepbrakefluidbeyondreachofchildren.

OWNER’S REGISTRATION AND TRAINING CERTIFICATE

PRINTEDON3,MUSTBEFILLEDOUTANDSIGNEDBYPURCHASERAND

DEALER.

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Before DrIvIng: Fuel: Check that you have sufficient fuel for your journey.Brakes: Check the brakes for operation.Tires: Check for proper inflation. Check tires for physical damage.Lighting System: Check lights and signaling devices.Engine Oil: Check oil level.

sPeCIfICatIons Dimensions OverallLength................................................ 103 inches Overall Width ................................................. 53 inches OverallHeight ................................................ 75 inches Wheel Base .................................................... 71.5 inchesweight CurbWeight ................................................... 1,125 lbs Passengers/Weight ....................................... Two / 500 lbs CargoWeight ................................................. 400 lbs Total Weight ................................................... 2,025 lbs Type ...............................................................S.O.H.C

Performance Max Speed ..................................................... 35 to 50 mph depending upon vehicle

suspension system Front...............................................................DoubleA-Arm Rear ................................................................4-Link tire specifications Front...............................................................25x8-12 Rear ................................................................25x10-12

Brake system Front..............................................................Disk(0200mm) Rear ................................................................Disk(0220mm) transmission Devices Transfer ......................................................... Shaft drive ShiftLever ......................................................L,H,N,R Shift ............................................................... Manual lever Clutchtype .....................................................Wetmulti-plate Transmission .................................................Continuouslyvariablecentrifugaltype

engine FuelUsed ....................................................... 87 octane or higher having less than an E15ethanolrating Cycle/cooling ................................................4-stroke/watercooled Bore ............................................................... 86 mm CylinderStroke .............................................. 69.4 mm Number/Arrangement ....................................SingleCylinder Displacement ................................................. 403.1 cc CompressionRatio ........................................ 9.2:1 Ignition ...........................................................C.D.I. Starting System .............................................Electrical/Recoilstarter AirFiltration ................................................... PaperPAGE 4

lubrication LubricationSystem ........................................PumpForcedCirculation EngineOil.......................................................BadBoyMowerUTVEngine LubricantSAE10w40 Lubrication .....................................................SG/CC EngineOilcapacity ........................................3.5Lgear lubrication Differential/FinalReductiondevice ..............Spec.90#,Capacity350c.c.

exhaust Concentration ................................................ Solid Particulate CO ..................................................................Below7.0g/km HC ..................................................................Below1.5g/km Nox ................................................................Below0.4g/km

FuelCapacity ................................................. 5.0 gal SparkPlug ..................................................... NGKCR7E Battery............................................................ 12V18AH

lamps FrontLamps ................................................... 12V 55WX2

ImPortant IDentIfICatIon numBers

PIN NumberRecord PIN number for future reference. The PIN Number is located on passenger side under seat and on driver’s side under hood.

Warning Labels:Before driving, read these labels thoroughly.Do not tear off decals. In case of wear or damage, contact your dealer for replacements.

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startIng/oPeratIng ProCeDuresChoke •ChokeLeverisforuseinlowtemperaturestartingsituations.DonotdrivetheUTVwiththechokeactivated. •Thisvehicleisequippedwithasafetyprotectionsystem—tostarttheenginebrakemustbeapplied. •TheUTVwillstartinanygearwhenbrakeisapplied.Keepthisinmindwhenstartingtopreventinjuryfrom movement of the vehicle. •TheUTVfuelsystemissensitiveandwillnotallowthevehicletostartifmorethan1/8ththrottleisapplied whencranking. •Forcoldweatherstarting,itisbesttostartthemachineinneutral,withnothrottleappliedandchokefullyengaged.

Brake Pedal •Beforeeachtrip,checkthefunctionofthebrakepedal.Alsocheckforsufficientbrakefluidinthereservoir. •Attention:Irregularitiesofthebrakessuchasleaksandpoorperformanceshouldonlybedealtwithbyan authorizeddealer.ThebrakefluidlevelmustbeabovetheMINmark.AlwaysuseDOT#4brakefluid.

Shift Lever L:Hightorqueuse(advancegear) H:Normaluse(drivinggear) N:Parkinguse(neutral) R: Reverse use

Shift Lever Instructions: •EngagethebrakeandmovetheshiftleverfromNtoH,LorR(Lshiftisusedforroughsurfaces) *WhenShiftingHtoLoranygear/directionthevehiclemustbeatacompletestop. notice: Operating the shift lever when vehicle is moving can be hazardous and can cause damage to the vehicles transmission. This is strictly prohibited. Always wait until the vehicle comes to a complete stop. Do not operate the UTV at high speed in reverse under any circumstances.

2WD/4WD Select Lever •The2WD/4WDselectleverisusedforchangingtheenginepowersuppliedtothewheels.Youcanselect2WDor 4WD for your preference according to different surface conditions. •2WD:Engagestheenginepowertotherearwheelsonly.Thisismainlyusedfornormalriding. •4WD:Engagestheenginepowertobothfrontandrearwheelswithdifferentialfunction.Thereisalimitedslipgear assembly inside the front differential that can engage the right and left front wheels at different speeds. This provides much more traction than 2WD and should be used when riding on wet, slippery, or loose surfaces.

general maIntenanCeRecoil StarterIn case the vehicle does not start with the electric starter, the emergency recoil starter can be used to start the engine. To use therecoilstartermakesuretheheadlightsareswitchedoff,shifttoneutral(N),settheparkbrakeandgripthestarterrope-handle, which is on the engine magneto cover. Pull the rope until you feel the starter engage. Pull the rope forcefully to start the engine. At the moment the engine starts, be sure to return the starter rope to its prior normal position.

TiresThe vehicle is equipped with tubeless tires. Tubeless tires should never be repaired. Damaged tires must be replaced.Yourauthorizeddealershouldonlyreplacetubelesstires.Sincethetirepressureinfluencesthedrivingability,themandatorytire pressure should always be maintained. You should determine outer damages of tires. The suggested minimum profile depth is 3mm; replace the tire immediately if below 3mm. tire pressure: 12 PsI

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Check Coolant Reserve TankYourUTVcomesfilledwithExtendedLifeAntifreezethatisredincolor.Useonlythistypewhenaddingcoolant.Donotmixantifreezecolorsortypes.Addcoolanttoproperlevelifbelowthe“LOW”markonthereservetank.Caution: Thereservecoolanttanklevelshouldnotbeoverfilledtoallowthermalexpansion.

Maintenance ScheduleThe below maintenance schedule is established by months and hours and are dependent on whichever comes first.Haveyourvehiclechecked,adjustedandrecordedmaintenancedatabyUTVdealertomaintaintheUTVattheoptimumcondition.Usethechartbelowfornecessaryserviceworktokeepthevehicleoperatingatpeakperformanceandeconomy.

Periodical Maintenance ScheduleKey to tableL:LubricateC:CleanR:ReplaceT:TightenI:Inspection,cleaningandadjustment

HaveyourUTVservicedandcheckedayanauthorizedUTVdealer.Ensuretheservicebookisstampedandsigned.Failuretodosocouldinvalidateyourwarranty.Themaintenancescheduleisestablishedbytakingthemonthly/hourlyasareferencewhichever comes first.

Interval Hours 25 100 500 1000Item montHs 1 3 6 12MufflerBolts&ExhaustPipeNuts T T T T

ValveClearance I I I

AirCleaner I R R R

EngineIdleRPM I I I I

SparkPlug R R

EngineOil R R R R

FrontDifferentialSetOil R R R R

FinalGearOil R R R

C.V.T.Belt I R

FuelTube I I I

ThrottleCablePlay I I I I

Brakes I I I I

BrakeHose I I

BrakeFluid I I I

Tires I I I

Suspensions I I

Steering System I I I I

ChassisBolts&Nuts T T T T

GeneralLubrications L L L

GreaseNipple(UniversalJointAssembly L L

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Additional maintenance suggestions:CleanorreplacetheaircleanerelementmoreoftenwhentheUTVisoperatedindustyconditionsorinaheavilypollutedenvironment. Maintenance should be performed more often if the UTV is frequently operated in high speed and after the UTV has accumulated a higher mileage.

Preventive maintenance: Ignition system-performmaintenanceandcheckwhencontinuousabnormalmisfire,after-burnoroverheatingoccurs.Carbon deposit removal – remove carbon deposits in cylinder head, piston and exhaust system when power is obviously lower than normal.

Spark PlugRecommendedsparkplug:CR7E.Installation instructions: •Removesparkplugcap. •Cleandirtaroundthesparkplughole. •Removesparkplug. •Measuresparkpluggap.Sparkpluggap:0.7-0.8mm. •Carefullybendgroundelectrodeoftheplugtoadjustthegapifnecessary. •Holdsparkplugwasherandinstallthesparkplug. •Tightentheplugbyturning½turnmorewithplugsocketafterinstalled.

Air CleanerInstallation Instructions: •Loosen2hooksfromtheaircleanercoverandthenremovethecoverandthenremovetheaircleaner. •Donotclean.Replaceasnecessary.

Carburetor Idle Speed Adjustment •Settheparkingbrake. •Shiftthetransmissiontoneutral. •Warmuptheengine. •Turnthethrottlevalvestopperscrewtospecifiedidlespeed.(Specifiedidlespeed:1500+-100rpm)

Engine Oil •PulltheUTVontoaflatsurface,turnofftheengineandengagetheparkingbrake. •Checktheoillevelwithoildipstick. •Donotscrewthedipstickintotheenginewhenchecking.Ifoillevelislow,fillwithrecommendedoiltoupperlevel.

Instructions for changing: •PlaceanoilpanundertheUTVandremoveoildrainplug. •Afterdrained,makesurewashercanbere-used. •Installoildrainplug.

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Instructions for changing engine oil filter: •Drainengineoilout. •Installoilfilter. •Addoiltocrankcase(UTVbyBadBoyEngineLubricantSAE10w40:partnumber785-1030-00) •Engineoilcapacity:3500/3860c.cc •Installdipstick,runtheengineforseveralminutes. •Turnofftheengineandcheckoillevelagain. •Checkforanyengineoilleaks.

Differential OilInstructions for changing: •Removeoilfillerbolt. •Removedrainpluganddraingearoil. •Installthedrainplug. •Makesurethatthedrainboltwashercanbereusedorreplaced. •Addoiltospecifiedquantity.(oilviscositySAE80-90#) •GearOilQuantity:300-350ml.

Fuse and BatteryIn order to access the battery or to replace the fuse, you first remove the seat. Under the seat on the driver’s side, you will find the fuses.note: Only install the correct fuse for replacement. If the fuse should fail several times, you should immediately consult your authorized dealer.Instructions for installation: •Lifttheseat.Youcanseethebattery.Thebatteryisasealedtype.Youcantakeittoyoudealertocheckthebattery’s charge condition periodically. In order to remove the battery, loosen the bolts from the battery clamp then remove the battery.Whenthebatteryneedstoberecharged,use1.8Acurrentfor5-10hours.Maximumchargingrate:9Ax1hr.Reversing the battery lead wires can harm your UTV, the battery and\or the charging system. •Whenconnectingthebattery,connecttheredwirewiththemark(+)andtheblackwirewiththemark(-)ofthebattery, note:connecttheredwire(+)first,thentheblackwire(-).

Disconnect the battery when not in use for long periods of time.attention: The maximum power consumption must not exceed 5a.

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BasIC safety rules •WhoeverridestheUTV,mustcarefullyobservetheinstructionsgivenbelow. •Approvedsafetyhelmet,boots,goggles,glovesandprotectiveclothingarehighlyrecommended. •Beforegettinginthevehicle,makesuretheparkingbrakeisontoavoidanyinjuryordamagetothevehicle. •Afterstartingtheengine,removeparkingbrake,selectagearposition,andgraduallyopenthethrottle.Makesurethat the throttle opens and closes smoothly and the steering wheel steers smoothly in both directions. •Thebrakescouldgetdampwhentheroadiswet.Makesurethebrakesfunctionproperlybeforeriding. •Ifyoumustrideyourvehicleinrainyweather,oronloosesurfaces,rememberthattractionisgreatlyreduced.Under theseconditions,avoidsuddenbrakingwhichmaycausethevehicletoskid. •Whenyoufirstreceiveyourvehicle,ensureyouhavebasicdrivingskillssuchasgoingforward,makingturnsand stopping. Do no attempt any high performance operation until you are very comfortable with your vehicle and your abilities.Starttheengineandletitidleforseveralminutes,releaseparkingbrake,selectagearposition,andopenthe throttle.Alwayslookstraightaheadanddrivewithbothhandsonthesteeringwheel. •Whenbackingupuseextremecaution.Besurethepathisclearandapplythethrottleslowly.Donotsteerabruptly whenbackingupbecauseitcouldleadtoloseofcontrolorrollover.

Dear UTV Rider:

ByfollowingtheinstructionsoutlinesinthismanualyouwillknowhowtooperateyourUTV.Alsoyouarebeingprovidedinstructions on how to maintain your UTV, so you can ride safely. Be aware of the Safety Instructions.

Haveasafeandenjoyableride.

•ShouldanypartsofcomponentsoftheUTVbechanged,itmaycausethewarrantytobecomeinvalid.Consult yourauthorizeddealerbeforemakinganymodification. •Damagecausedbyusingnon-genuinepartscouldinvalidatethewarranty. •Failuretofollowtheinstructionsoutlinedinthismanualcouldinvalidatewarrantyclaims. •GenuineaccessoriesfortheUTVaremadeaccordingtothecontractbetweenthedealerandthemanufacturer. •Themanufacturerreservestherighttointroduceanymodificationwithoutpriornotice.

safe rIDIng tIPs: •Beforeembarkingonanyjourney,makesureyourUTVisingoodandsafeworkingorder. •Alwayswearanapprovedhelmet.Helmetsareyourbestdefenseagainstseriousheadinjuries. •Inadditiontoyourhelmet,weareyeandfaceprotection.Longpants,gloves,bootsandadurablelong-sleeved jacketarerecommended. •Beseen!Wearbrightlycoloredclothing. •NeverdrinkalcoholortakedrugsbeforeoperationofanUTV. •Alwaysindicatewhenyouareturningleftorright. •Beawareofotherroadusers’intentions. •Leaveplentyofroombetweenyouandthevehicleinfront. •Slowdownbeforeenteringblindturnsandbewatchfulatjunctionsandintersections. •Watchforhazardsontheroadortrailway. •Don’tspeed–50percentofdriversinvolvedinseriousaccidentswerespeeding.

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servICe reCorD

PDI

Date: ________________________________

HourMeterReading: _____________________

Dealer Stamp: __________________________

1st Service

Date: ________________________________


Dealer Stamp: __________________________

2nd Service

Date: ________________________________


Dealer Stamp: __________________________

3rd Service

Date: ________________________________


Dealer Stamp: __________________________

4th Service

Date: ________________________________


Dealer Stamp: __________________________

5th Service

Date: ________________________________


Dealer Stamp: __________________________

6th Service

Date: ________________________________


Dealer Stamp: __________________________

7th Service

Date: ________________________________


Dealer Stamp: __________________________

8th Service

Date: ________________________________


Dealer Stamp: __________________________

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UTV PARTS MANUAL 1500G Gas

Table of Contents

Dump Bed Assembly ..........................................................17

Hood, Dash & Bumper Assembly ..................................18-19

Roll Cage Assembly .......................................................... 20

Front Gas Tank & Steering Assembly ................................ 21

Seat Frame Assembly .................................................. 22-23

Brake Pedal & Battery Compartment Assembly ........... 24-25

Front Axle Assembly .................................................... 26-27

Brake Cylinder and Lines ................................................... 28

Exhaust Assembly ............................................................. 29

Engine .......................................................................... 30-31

Rear Axle Assembly ..................................................... 32-33

Engine Assembly ............................................................... 34

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2012 BaD Boy InC all gasolIne utv moDels

lImIteD warrantyLimited, 6 Month WarrantyBad Boy, Inc. will, at its option, repair or replace, without charge, any part covered by the warranty which is found to be defectiveinmaterialand/orworkmanshipwithin6monthsafterdateofsaletotheoriginalretailpurchaserofanewBadBoy4X4,GasolineUTV.Thislimitedwarrantywillbesubjecttocertainlimitations.Also,BadBoy,Inc.willnotberesponsiblefordefects attributed to abuse, accidents, nature or vandalism.

Additional 6 Month Internal Rotating Engine Assembly Part Only WarrantyBad Boy, Inc. will, at its option, replace, without charge (excluding labor), any part within the internal rotating engine assembly for an additional 6 months or for one total year after the date of sale to the original retail purchaser. The additional six month partonlywarrantyexcludes,butisnotlimitedtoexcluding,thefollowingcomponents:CarburetionAssemblies,theCDI,Starter,ExhaustSystem,FuelPump,ChargingSystem,U-Joints/DriveShafts,etc…

Warranty PeriodBad Boy UTV 4X4 gasoline vehicles shall carry a warranty of 6 months after the specific date of purchase for both private and commercial users. This 6 month warranty will only be valid for the original purchaser of the vehicle, and the warranty will not be transferrable to succeeding purchasers.

Replacement PartsBad Boy UTV dealers will repair or replace, at Bad Boy Inc’s option, any defective part during the six month warranty period. Theparts,tobewarranted,mustbedefectiveinmaterialand/orworkmanship.AllreplacementpartsmustbeobtainedfromBad Boy, Inc.

Battery WarrantyThe batteries used to power the Bad Boy UTV will carry a 6 month, free replacement warranty. These warranty claims will be handled by the manufacturer, Interstate Battery.

ExclusionsThis warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper maintenance, improper use or abuse of the product, or failure to follow the instructions contained in any owner’s manual for operationandmaintenance.Somespecificexclusionsincludebutarenotlimitedto:lightbulbs,wheels,tires,brakes,cvbootsor upholstery.

Responsibility of the CustomerIt is the responsibility of the customer to register his/her machine for warranty by promptly returning a completed warranty registration card within 30 days from the date of purchase. Also, the customer must operate and maintain his/her machine within the proper guidelines of the owner’s manual.

This warranty gives you specific legal rights, and you may also have other rights, which may vary from state to state.

AnywarrantyissuesthatarisecanbehandledbyyourBadBoyUTV/LSVdealerorat:BadBoy,Inc---102IndustrialDrive---Batesville,AR72501---(866)622-3269

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BaD Boy mowers utIlIty veHICleowners regIstratIon & traInIng CertIfICate(Keep original copy on file at your dealership)

VIN/PIN____________________________________

MODEL_____________________

DATEOFPURCHASE_______________________ DEALER_______________________________

PURCHASERLASTNAME____________________ FIRSTNAME____________________________

ADDRESS____________________________________________________________________

CITY__________________________________ STATE____________POSTALCODE__________

DAYPHONE_____________________ EVENINGPHONE_________________________

Safety Check ListPurchaser: By initialing each line, I understand and give my word of Honor_____This Utility Vehicle must not be operated by anyone under the age indicated in the Operator’s manual. I will not

allowanyoneundertheageindicatedintheOperator’smanualtooperatethisvehicle.Everyoperatormustreadand

understand the Operator’s manual before riding this Utility Vehicle.

_____This Utility Vehicle must not be operated by anyone who does not have a valid driver’s license.

_____Never ride an Utility Vehicle after consuming alcohol or drugs.

_____OverlyaggressiveuseoninclinesmaycausetheUtilityVehicletoflipover.

_____Always ride within your abilities.

_____Neverattemptjumpsorotherstunts.

_____Always be extra careful when riding on unfamiliar terrain, steep slopes, or when encountering obstacles.

_____Ihavereadtheabovewarnings,andIunderstandthatSEVEREINJURYORDEATHcanresultfromignoringthese

warnings or from improper use.

_____I will watch the safety/training video provided by Bad Boy Mowers before operating this vehicle.

_______________________________ __________ Purchaser’s Signature Date

I have reviewed the safety features and Operator’s Manual with this purchaser and to all appropriate immediate family memberspriortotheirtakingdeliveryofthisUTVandqualifyingthemforwarranty.TheUTVdescribedabovehasbeenservicedandapprovedfordeliverybymeoranemployeeonmybehalf.IwillmaintainthisOwnerRegistrationFormfromthecustomerandmeinapaperformalongwithotherbooksandrecordsofthedealership.

_______________________________ __________ Authorized Dealership Signature Date

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notes: ______________________________________________________________________________

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Bad Boy, Inc.102 Industrial Drive

Batesville, Arkansas 72501(870) 698-0090

BaD Boy, InC.102INDUSTRIALDRIVEBATESVILLE,AR72501

1.866.622.3269www.badboymowers.com

Technical Support:David WattsRandel Davis [email protected] [email protected]

Warranty:DustinTissiere [email protected] Ext6613BillHurst [email protected] Ext6617Nathan Simmons

Parts:JakeReed [email protected]

model 1500g owner’s & parts...

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