Another small repair job. Bad Boy mower.
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    flyweight's Avatar
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    Another small repair job. Bad Boy mower.

    Not long after I signed off from this fabulous site this morning, I got a call from a friend about his Zero Turn. It's a Bad Boy brand with a little over 700 hr. He told me it was making a chirping sound while the engine is running; and leaks oil onto the frame. He and his son replaced the right side head gasket at ~300 hr.
    He asked if I'd work on it and I told him, "no problem - load the wagon". So, I hook up my utility trailer and drove to his house to pick it up. After I got home, I unloaded it and parked it in my shop. I removed the right head and found the head gasket was blown.
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    When I was removing the head, the two lower head bolts were not very tight. I barely used any force while removing. The two upper bolts were tight as a frog's anus. Hope I can say that..... I have no idea why the gasket failed the first time, but I have a suspicion, on the second go 'round, they may not have torqued the bolts to specs.

    Anyway, the head doesn't seem to be bad. I cleaned the head surface and check for any warpness. In an area near the damaged gasket, it barely has .004 clearance under the straight-edge. I resurfaced the head with a flat file and that trued it up. I checked the cylinder head surface also and it was found to be true.
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    This thing must have been leaking for a while. Can you believe I didn't pressure wash this thing before working on it. Working on equipment on a job-site is one thing. I have no choice but to work on it as is(clean, or dirty). But, this thing was here in my shop. I should not have even posted this pic. I will however, give it a good bath before I return it.
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    I went to the local Bad Boy dealer who is 5 miles from me. They sell X-Mark, Bad Boy and Echo products. They had the gaskets I needed in stock. I'll be replacing the four head bolts, but they had none in stock. They ordered them and should arrive tomorrow.

    ---to be
    continued---
    Michael

    2019 JD Z540R, 54" cutting deck w/MulchControl™
    1984 JD 750 Tractor
    1971 JD 15 Chainsaw, ← hasn't run since ~1975

    Also have a bunch of other useless stuff.










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    coaltrain's Avatar
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    What for engine Michael?

    I always wondered about Bad Boy. I think there are 2 versions - a commercial and consumer.

    I remember some time back on the lawnsite forum they seemed to be quite popular. Even had a CAT diesel option in one. But then I see them lined up in front of Tractor Supply with a $xx99 price tag. I never looked that close at any but wasn’t impressed with a couple glances.

    Was wondering your overall opinion on the machine since you have one apart in your shop.
    rydplrs, JKR, flyweight and 1 others like this.
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    flyweight's Avatar
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    Quote Originally Posted by coaltrain View Post
    What engine Michael?
    This version(23 Pro) has the 23 hp. B&S engine. The engine looks very crude, cheaply made.

    Quote Originally Posted by coaltrain View Post
    I always wondered about Bad Boy. I think there are 2 versions - a commercial and consumer.


    I remember some time back on the lawnsite forum they seemed to be quite popular. Even had a CAT diesel option in one. But then I see them lined up in front of Tractor Supply with a $xx99 price tag. I never looked that close at any but wasn’t impressed with a couple glances.

    Was wondering your overall opinion on the machine since you have one apart in your shop.
    This one must be a Consumer/Residential.
    I don't know that much about Bad Boy mowers, but I can't see this one being a Professional mower.

    Cons:


    • Seat is mounted too high.
    • Seat uncomfortable.
    • No armrest.
    • Travel levers have no resistance(floppy).
    • Insufficient leg-room.
    • Narrow stance(width).
    • 48" deck too narrow for my use.
    • Wheel base too short.


    Pros:

    • I haven't found any features that comes close to my residential JD Z445




    The owner's son runs a Commercial Lawn and Landscape company. They use X-mark exclusively. I have no Idea why he bought this Bad Boy. He told me he regrets it. He said he'd buy a John Deere, but doesn't like the dealer. He's had problems in the past, but the general manager has long been gone. I do know the attitude and atmosphere of the dealership had changed for the better.

    Mrs.FW was a Parts Manager there when we first moved here(1994). That was when the other manager ran it. She didn't stay a year, she had enough of promises gone by the wind. But, that's another story.

    I'm trying to get him to buy JD, but he may go X-Mark. If JD would lower the quality of the residential mowers, I'd be looking hard at x-Mark.
    Michael

    2019 JD Z540R, 54" cutting deck w/MulchControl™
    1984 JD 750 Tractor
    1971 JD 15 Chainsaw, ← hasn't run since ~1975

    Also have a bunch of other useless stuff.










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    With that much crud in the fins it may be simply a thermal failure.

    I would probably go with a torque, run, cool, retorque method for insurance if everything was flat before and you trust they torqued it the first time.
    etcallhome, Gizmo2, pcabe5 and 3 others like this.

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    coaltrain's Avatar
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    Thanks Michael!

    When thinking of possibly getting myself a dedicated mower, I am in such a quandary not having a Deere dealer. I’ve been mowing for 45 some years now - a lot of that commercially - and have had nothing but Deere equipment. It has become partially just creature of habit to buy Deere.

    That’s why I asked about the Bad Boy. As time goes on I may need to find a machine - and having a servicing dealer relatively close by is an important factor. But the oniy brands with that criterea are consumer type models like the one you are working on.

    OK - enough of that - back to your repair thread!
    ~Stan~
    It is what it is
    Knowledge is power, ignorance is bliss
    2520 w/200CX w/62D2

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    Old Pa-pa Old Cajun's Avatar
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    Man, air had a fight on it's hands to get to the cooling fins on that one cylinder.
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    Neil

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    He may have torqued them properly the first time but failed to follow up on the re-torque them after running it a bit. Or may have had dirt under the gasket when he installed it.
    flyweight and Old Cajun like this.
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    Keeper of the GTT Cookies dieselshadow's Avatar
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    Any updates on this?
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    flyweight's Avatar
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    Quote Originally Posted by rydplrs View Post
    With that much crud in the fins it may be simply a thermal failure. I would probably go with a torque, run, cool, retorque method for insurance if everything was flat before and you trust they torqued it the first time.
    Done.



    Quote Originally Posted by Old Cajun View Post
    Man, air had a fight on it's hands to get to the cooling fins on that one cylinder.
    Yes, some of the cooling fins were plugged solid. I didn't see any signs of damage to the cylinder walls. In fact, I was surprised to see it in very good condition. Cleaned out the cooling fins as best I could. Wish I had a glass-bead cabinet. I could have done a better job.



    Quote Originally Posted by BillieS View Post
    He may have torqued them properly the first time but failed to follow up on the re-torque them after running it a bit. Or may have had dirt under the gasket when he installed it.
    Anything is Possible.
    pcabe5, rydplrs, JKR and 1 others like this.
    Michael

    2019 JD Z540R, 54" cutting deck w/MulchControl™
    1984 JD 750 Tractor
    1971 JD 15 Chainsaw, ← hasn't run since ~1975

    Also have a bunch of other useless stuff.










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    flyweight's Avatar
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    Quote Originally Posted by dieselshadow View Post
    Any updates on this?
    Yes.
    As for why all the oil had collected over time, I found the tab(see photo) on the exhaust gasket had somehow inadvertently gotten caught between the valve cover gasket and the gasket mating surface. I think this led to a very slow oil leak which had wicked over time to the cooling fins.
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    Also, in the photo of the engine below, the two small bolts retaining the crank-case vent(top of valve cover/black hose) were loose, leading to another oil leak.

    I retoured the head bolts and installed the engine guard this morning. I called my buddy and told him it was complete; and said I'd be delivering it to him today. He said his trailer was hitched to his truck and was on his way to get it. That meant I didn't have to unload my trailer to do so.

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    The work bay in my shop is now empty.
    Michael

    2019 JD Z540R, 54" cutting deck w/MulchControl™
    1984 JD 750 Tractor
    1971 JD 15 Chainsaw, ← hasn't run since ~1975

    Also have a bunch of other useless stuff.










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