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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.
Summary of Contents for 1500
Page 5: ...PAGE 5 Serial Number on MTV PIN Number Located under seat on passenger side...
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