Bad Boy 640690-G, Owner'S Manual

Page 1: ...OWNER S MANUAL 640689 G RECOIL iS REVISED FEBRUARY 2016 ISSUED JULY 2014...

Page 2: ...may not be representative of all models Most service procedures can be accomplished using common tools Perform service procedures at intervals shown in the Periodic Service Schedule located elsewhere...

Page 3: ...TIAL DAMAGES resulting from the use of the information and materials in this manual These are the original instructions as defined by 2006 42 EC CONTACT US Bad Boy Buggies 1451 Marvin Griffin Rd Augus...

Page 4: ...eck the charge on the battery pack This will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner As with all electric vehicles the batteries...

Page 5: ...TION FEATURES 11 General Information 11 Key Switch Direction Selector 11 State of Charge Meter 11 Park Brake Light 11 Light Switch 11 Max Speed Range Switch 12 Auxiliary Switch Positions 12 12 Volt Po...

Page 6: ...ion 21 Seat Belt Operation 21 COMMON SENSE OPERATION 22 ENVIRONMENTAL CONCERNS 22 STARTING AND DRIVING 22 Starting the Vehicle on a Hill 23 COASTING 23 TOWING A TRAILER 23 TERRAIN 23 TRUCK BED 24 REAR...

Page 7: ...cant Level 36 BATTERY CHARGING AND MAINTENANCE 37 Battery Safety 37 Battery Disposal 37 Battery 38 Battery Maintenance 38 At Each Charging Cycle 38 Monthly 38 Temperature Affects Battery Capacity 39 E...

Page 8: ...B vi TABLE OF CONTENTS Owner s Manual...

Page 9: ...on which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided will result in death or serious injury This manual has been designed to assist in m...

Page 10: ...ehicle contact your BAD BOY BUGGIES dealer or write to the address on the back cover of this publication Attention Customer Care Department E Z GO reserves the right to make design changes without obl...

Page 11: ...er in which each component may fail A vehicle requiring repair is no longer functioning as designed and therefore could be potentially hazardous Therefore use extreme care when working on any vehicle...

Page 12: ...smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance in a safe area that is free of...

Page 13: ...EMAIN SEATED KEEP ARMS LEGS WITHIN VEHICLE WARNING USE CAUTION IN INCLEMENT WEATHER OPERATE FROM DRIVERS SIDE ONLY OCCUPANT MUST WEAR SEAT BELTS NO UNATTENDED CHILDREN NO MORE THAN TWO OCCUPANTS PER S...

Page 14: ...EHICLE IN THREAT OF LIGHTNING DRIVE IN ACCORDANCE WITH LOCAL RULES AND REGULATIONS OPERATOR MUST BE MIN 150 CM REMAIN SEATED KEEP ARMS LEGS WITHIN VEHICLE WARNING USE CAUTION IN INCLEMENT WEATHER OPER...

Page 15: ...rance Frame in cm Gross Axle Weight Rating R lb kg Gnd Clearance Differential in cm Outside Clearance Circle ft m Vehicle Power Speed Low Level Ground mph kph Power Source 72 Volts DC Speed High Level...

Page 16: ...any procedure Pay particular attention to Notices Cautions Warnings and Dangers VEHICLE DIMENSIONS AND INCLINE INFORMATION Maximum Recommended Side Tilt 25 or 14 Max Maximum Recommended Ramp Grade 25...

Page 17: ...9 Owner s Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS...

Page 18: ...10 Owner s Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 19: ...ction of travel It allows the operator to turn the electrical system off completely by mov ing the key to the OFF position or select Reverse Neutral or Forward by rotating key to the right 2 State of...

Page 20: ...r additional equipment equipped with a 12 volt plug 8 Cupholder A cupholder is provided for convenience of vehicle occupants 9 Accelerator Pedal The accelerator pedal is located on the floorboard to t...

Page 21: ...at the rear of the truck below the truck bed 16 Head Protection Rubber pads provide head protection while driving over rough terrain They are a standard safety feature on the vehicle and should not be...

Page 22: ...d The OPS and top provide some protection from smaller falling objects but will not protect against large falling objects such as trees or heavy limbs The windshield deflects oncoming wind from occupa...

Page 23: ...vehicle could result in severe injury or death The buggy is a light duty utility vehicle NOT an All Terrain Vehicle ATV When driving vehicle consider the terrain traffic conditions and the environment...

Page 24: ...ce Individual keys can only be replaced if the key number is known Without a key number the entire ignition switch will have to be replaced if keys are lost Make a note of the key number in the event...

Page 25: ...erials away from batteries Provide adequate ventilation during charging Never charge a frozen battery Study all battery manufacturers specific precautions such as recommended rates of charge and remov...

Page 26: ...trical device may become a physical hazard that could result in an electrical shock or electrocution Using the Charger Before use read the charger manufacturer s operation manual that is supplied with...

Page 27: ...brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of con trol Slow down before and during turns All turns should be made at reduced speed N...

Page 28: ...ch to select the Max Range setting This setting limits top speed to 16 MPH which conserves battery power in order to extend the range of distance the vehicle is capable of traveling before the bat ter...

Page 29: ...seat belts in proper working condition do the following Inspect the seat belt webbing and hardware periodically Check for cuts frays or loose parts Replace components if excessive wear or damage is n...

Page 30: ...oad When operating vehicle in wet weather conditions remem ber that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit If wet the brakes lose much of t...

Page 31: ...er speeds than possible on a flat surface To reduce possible loss of vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on level ground se...

Page 32: ...backwards Always ensure that no one is behind or close to the bed while the electric dump mechanism is being operated REAR FACING SEAT LOAD DECK Do not allow passengers to ride on load deck Severe inj...

Page 33: ...t the vehicle will stop With the differential locked power is distributed to both drive wheels at all times If both drive wheels lose traction as a result of vehicle becoming hung up on an object the...

Page 34: ...ight and inspect all winching connec tions Check winch attachment hook attachment nylon sling if required and load attachment Do not pull at an angle This will cause the wire cable to pile up on one e...

Page 35: ...27 Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers OPERATING PROCEDURES Owner s Manual...

Page 36: ...28 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Manual...

Page 37: ...nyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the...

Page 38: ...at the areas indicated Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting Lift Entire Vehicle 1 Place wheel chocks in front and behind each front wheel...

Page 39: ...er the jack and test the stability of the vehicle on the two jack stands 5 The jack may be left under rear axle tube while the rear end of the vehicle is on the jackstands Lower Vehicle Lower the vehi...

Page 40: ...for steel rims 1 Impact Socket 3 4 for steel rims 1 Lug Wrench 17mm for aluminum rims 1 Impact Socket 17mm for aluminum rims 1 Impact Wrench 1 Torque Wrench ft lbs 1 Generally the most cost effective...

Page 41: ...to position the wheel on the hub cor rectly with the arrow indicating the direction of rotation when moving forward WHEEL ALIGNMENT Driving over rough terrain may cause misalignment of the wheels Wit...

Page 42: ...be bled to remove air from the brake lines Refer to Bleeding Brakes on page 34 for procedure Master Cylinder The master cylinder is located behind the driver side front wheel mounted to the frame Bef...

Page 43: ...olds pressure on the brake pedal as the pedal slowly goes through the full stroke c Close the bleeder valve and have the assistant slowly release the brake pedal d Repeat the process until no bubbles...

Page 44: ...contacting battery terminals which could result in an explosion It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual Pr...

Page 45: ...rolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when adding water or charging batterie...

Page 46: ...d reduce the factors that can reduce the life of the battery Battery Maintenance Tool List Qty Tool List Qty Insulated Wrench 9 16 1 Battery Carrier 1 Hydrometer 1 Battery Maintenance Kit P N 25587 G0...

Page 47: ...s exposed to air will be ruined beyond repair Also avoid filling with too much water which will result in electrolyte being forced out of the battery due to gassing and a decrease in volume of the ele...

Page 48: ...within the battery cells The watering device should only be used if the electrolyte level is less than 1 2 13 mm above top of plates Electrolyte in a storage battery is an acid solution which can cau...

Page 49: ...ess cover in the cowl and lift the cover The batteries under the seat can be accessed by raising and removing the seat bottom and battery cover Clean batteries 1 Use a plastic spray bottle to spray th...

Page 50: ...ned to prevent discharge In winter conditions the batteries must be fully charged to prevent the possibility of freezing A fully charged battery will not freeze in temperatures above 75 F 60 C Althoug...

Page 51: ...troubleshooting will be done for two distinct reasons A battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of th...

Page 52: ...Examine the color of the electrolyte A brown or gray coloration indicates a prob lem with the battery and is a sign that the battery is near ing the end of its life 2 Draw the minimum quantity of ele...

Page 53: ...marks on the head metric hardware is marked on the head with 8 8 or 10 9 Unmarked hardware is Grade 2 CAPACITIES AND REPLACEMENT PARTS CAPACITIES REPLACEMENT PARTS Front Axle Oil 13 8 oz 90 wt Gear O...

Page 54: ...46 MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Manual...

Page 55: ...g C A C A C A C A Brakes Check fluid level in master cylinder CH CH CH CH 3000 miles 5000 kms Brakes smooth operation of pedal stopping distance CH CH CH CH CH Park Brake ability to hold on a hill C A...

Page 56: ...48 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Manual...

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Page 59: ...prop erly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible component failures or the manner in which they may fail A vehicle requiring repair indicat...

Page 60: ...0 E mail info badboybuggies com For parts and repair contact local dealer Dealers can be located at www BADBOYBUGGIES com Copyrighted Material This manual may not be reproduced in whole or in part wit...