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Bad Boy
Offroad Vehicle
1500
Bad Boy 1500 User Manual
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All in
forma
tion con
t
aine
d wi
thin this public
at
ion is ba
sed o
n the
lat
est pr
oduc
t inform
ation a
t the t
ime of public
at
ion. Due to
cons
t
ant improvem
ent
s in the de
sign and qua
lit
y of produc
tion
componen
ts
, some minor discr
ep
ancie
s may r
esult be
t
we
en the
ac
tual vehi
cle and t
he infor
mat
ion pres
ente
d in this publi
c
ation.
Mod
el 1
50
0
(Gas Powered)
Mu
lti-
T
e
rr
ain V
ehic
le
(MT
V
)
Ser
vice Manual
2
Table of Contents
Table of Contents
4
General Information
9
Lubrication System
13
Chapter 2 Maintenance Information
24
Specifications
25
Periodical Maintenance Schedule
26
Shift Cable
28
Acceleration Operation
29
Air Cleaner
29
Fuel Lines
29
Spark Plug
30
Valve Clearance
30
Carburetor Idle Speed Adjustment
31
Cylinder Compression Pressure
32
Ignition System
32
Brake System (Disk Brake)
33
Drive Belt
33
Brake Light Switch/Starting Inhibitor
34
Brake Lining Wear
34
Clutch Shoe Wear
34
Nuts, Bolts Tightness
35
Wheel/Tire
35
Differential Oil Change: Front/Rear
36
Chapter 3 Lubrication System
38
Mechanism Diagram
38
Troubleshooting
39
Engine Oil
40
Engine Oil Strainer Clean
40
Oil Pump
41
Chapter 4 Fuel System
43
Precautions In Operation
43
Fuel System
44
Troubleshooting
44
Air Cut-Off Valve
45
Carburetor Removal / Installation
45
Throttle Valve
46
Float Chamber
47
Adjustment Of Idle Speed
48
Fuel Tank
49
Fuel Valve Operation
49
Precautions In Operation
50
Engine Removal
52
Chapter 6 Cylinder Head/Valve
58
Mechanism Diagram
58
Precautions In Operation
59
Cylinder Head/Valve
60
Troubleshooting
60
Cylinder Head Removal
61
Cylinder Head Inspection
63
Valve Stem Replacement
64
Valve Seat Inspection And Service
65
Cylinder Head Installation
67
Cylinder Head Reassembly
67
Valve Clearance Inspection
68
Chapter 7 Cylinder/Piston
70
Mechanism Diagram
70
Precautions In Operation
71
Troubleshooting
71
Cylinder & Piston Removal
72
Cylinder/Piston
72
Piston Installation
74
Piston Ring Installation
74
Cylinder Installation
75
Final Driving Mechanism
83
Chapter 10 Alternator/Starting Clutch
88
Mechanism Diagram
88
Precautions In Operation
89
A.C.g. Set Removal
90
Alternator/Starting Clutch
90
Flywheel Removal
90
Left Crankcase Cover Removal
90
Lift Cover Bearing
90
A.C.g. Set Installation
92
Right Crankcase Cover Installation
92
Mechanism Diagram
93
Crankshaft/Crankcase
94
Cooling System
104
Chapter 13 Front Brakes and Front Wheels
109
Mechanism Diagram
109
Front Brake and Front Wheel
110
Maintenance Description
110
Troubleshooting
111
Front Wheel
112
Front Wheel Hub
112
Disk Brake System Inspection
112
Brake Fluid Replacement/Air Bleed
113
Front Brake Caliper
114
Steering/Front Suspension
116
Chapter 15 Rear Brake & Rear Wheel & Rear Cushion
118
Mechanism Diagram
118
Maintenance Description
119
Rear Brake/Rear Wheel / Rear Cushion
120
Troubleshooting
120
Disk Brake System Inspection
121
Rear Wheel
121
Adding Brake Fluid
122
Rear Wheel Axle
122
Rear Brake Master Cylinder
123
Rear Cushion
123
Maintenance Data
124
Technical Specifications
124
Troubleshooting
125
Battery
126
Charging System
127
Ignition System
128
Starting System
129
Cooling Fan Thermo Switch
129
4
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Bad Boy 1500 Specifications
General
Brand
Bad Boy
Model
1500
Category
Offroad Vehicle
Language
English
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