BBM 25 Push Mower Model: BB25-Kawasaki. Manual - part 3

ASSEMBLY - SETUP

Taking the following precautions will lessen the risk of
injury and property damage.
Use extreme care in handling gasoline. Gasoline is ex-
tremely fl ammable and the vapors are explosive.

- Extinguish all cigarettes, cigars, pipes, and other
sources of ignition.
- Use only approved gasoline containers.
- Never remove gas cap or add fuel with the engine
running.
- Allow engine to cool a minimum of 3 minutes before
refueling.
- Never fuel the machine indoors.
- Never store the machine or fuel container where there
is an open fl ame, spark, or pilot light such as on a water
heater or other appliances.
- Never fi ll 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 when fi lling.
- Remove the mower from the truck or trailer and refuel
it on the ground. If this is not possible, then refuel the
equipment with a portable container, rather than from a
gasoline dispenser nozzle.
- Keep the nozzle in contact with the rim of the fuel tank
or container opening at all times until fueling is com-
plete. Do not use a nozzle lock-open device.
- If fuel is spilled on clothing, change clothing
immediately.
- Never overfi ll fuel tank. Always wipe off any spilled fuel
or oil. Replace fuel cap and tighten.

WARNING

MAXIMUM

FUEL LEVEL

FUEL FILLER

NECK

FUEL FILLER CAP

APPROVED FUEL
CONTAINER

STEP 9
Before fi lling the engine with gasoline - follow all instructions in
this manual as well as all instructions provided in the
Kawasaki

Owner’s Manual.

Maximum fi ll volume:
Kawasaki: 1.9 Qt (1.8 Liter) - 87 octane or higher

The engine will not operate on gasoline marketed as
E-85 (85% ethanol)

CONTROLS & OPERATION

Before operating the mower for the fi rst time, please review
and understand the entire manual including all Warnings and
Cautions.
Even if you have operated other mowers in the past please
take time to become familiar with how this mower works and
practice all operations to build up your skills.

BEFORE ANY OPERATION ALWAYS:

- Inspect the mower for any visible damage or broken parts
- Check the oil level in the engine
- Make sure that when you release the upper control bar

that the blade will disengage and stop. If it does not stop

immediately do not use the lawn mower until the problem has

been corrected. Contact

Bad Boy Mowers for advice.

- Never operate the mower with obvious damage or

malfunction until the problems have been corrected.

WARNING

ever make any adjustments or repairs with the

engine running. Disconnect the spark plug wire,
and keep the wire away from the spark plug to
prevent accidental starting.

STARTING THE ENGINE
To start a cold engine it is important to use the “Choke”
position. To start a warm engine it is not necessary to use the
choke.

For best performance use the “Full Throttle” position for all
mowing. To verify that the engine is running at full throttle
please follow the steps outlined under the set up instructions
-

Step 7 on Page 8 or 9.

Bad Boy Mower dealer can typically also verify the correct

full

throttle adjustment. The engine speed should be

approximate-ly 3600 RPM without the blade engaged (no
load).

BLADE CONTROL - BBC (Blade Brake Clutch)
It is a multi step process to engage the blade. Do not start the
engine and the blade on an uncut lawn. If the blade is blocked
by tall grass or debris it can damage the belt drive between the
engine and the blade during the engagement.

1. Start the engine and let it warm up for 10 to 30 seconds.
2. Set the throttle control to the “Full Throttle” position.
3. Push the lock (1) for the upper control bar to the side.
4. Push down on the upper control bar until it rests on the
handlebar (2). You will distinctly hear the blade operating -
making a fan like noise.
5. When the upper control bar is released the blade should
stop within 3 seconds.

Additional maintenance instructions are found on Page 14.

WARNING

NEVER insert a hand or any other object in the grass
discharge chute to verify that the blade has stopped.

If the blade continues to run (no change in the noise
or size of the grass bag) after releasing the upper
control bar it is an indication of a malfunction of the
BBC system.

If the blade did not stop during the BBC Function Test
procedure or if you are unsure - Immediately stop the
engine by using the throttle control on the left side of
the control panel. The BBC system will require a repair
before further use. Immediately contact

Bad Boy

Mowers for advice. Do not under any circumstances
defeat the function of the BBC system. This can cause
serious injury or death.

CHOKE

FULL THROTTLE

IDLE THROTTLE STOP

BBC Function Test - Before each use
A simple test to verify the BBC function is to install an empty
grass collection bag. The mulch plug should not be installed.

1. Start the engine.
2. Engage the blade per above procedure. Notice how the
noise changes and that the bag becomes “infl ated”.
3. Release the upper control bar. If the bag does not “defl ate”
immediately, it indicates that the blade is still engaged and
rotating.
4. IF the bag defl ated - verify that the blade has stopped
rotating by removing the grass bag and look at the stopped
blade through the grass discharge chute.

CONTROLS & OPERATION

Drive Adjustment

When operating the lower control
bar (1) typical movement on the
red adjustment knob (3) should be
between 1/4” to 3/8” (6 to 10 mm)

DRIVE CONTROL

The drive system consists of a two speed transmission and an
adjustable belt drive from the engine to the transmission.

The transmission speed can be set to LO - N - HI.
HI speed is approximately 4mph - a fast walking speed.
LO speed is approximately 3mph - an average walking speed.

The shifter arm is intentionally made fl exible. When the arm is
locked in the LO or the HI position the transmission will
automatically mesh into the gears as soon as the drive is
engaged by operating the lower control bar.

ENGAGING THE DRIVE

To engage and disengage the drive system pull up on the
lower control bar (1). Typically the drive will engage when the
lower control bar is approximately 1 to 1.5 inches from the
handle (2).

Notice
Due to wear, the drive engagement position of the lower
control bar can change. If the distance between the lower
bar and the handle (2) is less than a 1/4 inch when the mower
starts to drive make an adjustment on the red knob located
below the engine fuel tank (3).
If needed turn the red knob 2 turns clockwise. Verify the drive
position of the control bar by operating the mower. If needed
repeat the adjustment.

HEIGHT ADJUSTMENT

Each wheel can be adjusted individually to a specifi c cutting
height from 1 inch to 4.5 inch. Notice: It is only possible to
move the adjustment on one side 2 - 3 steps each time.

Moving the front wheel height adjusters forward raises the
cutting height. Moving the rear wheel height adjusters towards
the rear of the mower raises the rear cutting height.

Always adjust the height adjusters to the same position both in
the front and the rear for best cutting results.

WARNING

Never readjust the cutting height while the engine
is running. STOP the engine. Never lift the
mower by placing your hand or fi ngers under the
edge of the mower deck.

MODES OF OPERATION

This mower is approved to be used in two different operational
modes:

1 With a grass catcher in place
An original equipment

Bad Boy Mower catcher has been

tested to be used with this mower. It is important to always
inspect the catcher for deterioration. If the material is ripped or
worn the bag shall not be used.

2. With the mulch plug installed
If the mulch plug is installed ensure that the rear door can
close completely.

WARNING

Do not operate the lawn mower without the mulch
plug or the

Bad Boy Mower grass catcher in

place. Never attempt to operate the mower with
the rear door removed, damaged or propped
open.

Low 1” (25mm)

High 4.5” (114mm)

7 steps - 1/2” (13mm)

the engine before

making any height adjustment

MAINTENANCE

In addition to this schedule follow the Maintenance Schedule in the Kawasaki Owner’s Manual.

This maintenance schedule assumes daily use by a landscape company.
One Month of use is assumed to be 15 to 20 days of operation.

Maintenance -

Service Interval

Procedures

Before each use

Check the engine oil level.
Check the operation and integrity of the BBC control system (see page 10).
Inspect the mower blade for wear or damage.
Inspect the cables for any wear or damage.
Inspect the grass catcher for any damage.
Check for any loose or missing screws or damaged parts.
Clean under the lawn mower deck (after usage).

First 20 Hours or
Within 4 weeks

Change the engine oil (see page 13).
Check the throttle cable adjustment (see pages 8-9).

Every 50 Hours or
every 2 months

Lubricate the pivot arms on the control panel with oil.
Check the function and adjustment of the Blade Brake Clutch cable (see page 14)
Check and clean the engine air fi lter (see the engine Owner’s Manual)

Every 100 Hours or
every 4 months

Change the engine oil (more often in dusty conditions).
Check the spark plug.
Clean the engine with compressed air.

Every 200 Hours or
every 8 months

Replace the paper air fi lter (more frequently in dusty conditions).
Replace the spark plug.
Adjust the valve clearance.

NOTICE

Several of the operations described in this
Maintenance section involves placing the mower
on its right side.
To avoid spills of oil and gasoline always:
- Place the mower on a hard surface such as a

concrete driveway or a garage fl oor.

- Never place the mower on its side when there is

gasoline in the tank - do the service of the mower
when you have run out of gasoline during normal
operation.

- Always make sure that the Oil Filler Cap is

tightened.

Any spillage of oil or gasoline can be extremely
fl ammable and explosive and under certain
conditions can cause serious personal injury and
property damage.

CLEANING THE MOWER

We do not recommend using a garden hose to clean the
mower. The buildup of moist grass, fertilizer and water can
cause extreme corrosion damage to many parts of the mower
and the engine.
Never use a Pressure Washer:
The use of a pressure washer can force water and moisture
into ball bearings and engine parts and cause substantial dam-
age.

- Clean the underside of the mower by scraping any build-up

of grass and trash.

- Clean off the outside of the engine and the top of the mower

with compressed air. Any accumulation of debris under the
belt cover can typically also be removed with compressed air
without removing the protective belt cover.

- Wash the Grass Bag with a garden hose frequently. The
holes that allows the grass bag to breathe will eventually clog
with dirt. A clogged bag will not collect the grass clippings
effectively. Do not install and use a wet grass catcher. It will
plug prematurely.

Content .. 1 2 3 4 ..