Bobcat 3200 Utility Vehicle Workshop Repair Service Manual - 6989598

(S/N: AJNS11001 & Above) 
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This workshop repair service manual PDF download for the 3200 Bobcat Utility Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Utility Vehicle 3200 
S/N: AJNS11001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE 
DRIVE SYSTEM 
MAINFRAME 
ELECTRICAL SYSTEM & ANALYSIS 
ENGINE SERVICE 
SPECIFICATIONS 
ALPHABETICAL INDEX 
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6989598 (9-10)
Total Pages : 423


This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Utility Vehicle Serial Number
        Engine Serial Number
    DELIVERY REPORT
    UTILITY VEHICLE IDENTIFICATION (3200)
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE UTILITY VEHICLE
        Procedure
    ROLLOVER PROTECTIVE STRUCTURE (ROPS)
        Description
    TRANSPORTING THE UTILITY VEHICLE ON A TRAILER
        Loading And Unloading
        Fastening
    TOWING THE UTILITY VEHICLE
        Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Pre-Filter Element
        Replacing Filter Element
        Engine Breather Filter
    ENGINE COOLING SYSTEM
        Checking Level
        Cleaning
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Replacing The Fuel Filter
        Filling The Fuel Tank
        Filling A Portable Fuel Container
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil
        Engine Oil
        Removing And Replacing Oil And Filter
        Oil Pump Priming Procedure
    CONTINUOUS VARIABLE TRANSMISSION (CVT)
        CVT Drying
        CVT Filter
    GEARCASE
        Checking Transmission Fluid
        Transmission Fluid
        Adding Transmission Fluid
        Removing And Replacing Transmission Fluid
    TIRE MAINTENANCE
        Tires
        Tire Tread Depth
        Axle And Wheel Nut Torque
        Wheel Removal And Installation
        Mounting
        Tire Pressure
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
        Storage
        Return To Service
    STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
        Procedure
        
DRIVE SYSTEM
    BRAKE
        General Specifications
        Torque Specifications
        System Service Notes
        Noise Troubleshooting
        System Troubleshooting
        Hydraulic Brake System Operation
        System Parts Identification
        Master Cylinder Removal And Installation
        Foot Brake Pedal Removal And Installation
        Bleeding / Fluid Removal And Installation
        Brake Inspection
        Brake Pad Inspection
        Burnishing
    BRAKE (FRONT)
        Pad Removal
        Pad Installation
        Caliper Removal
        Caliper Parts Identification
        Caliper Disassembly
        Caliper Inspection
        Caliper Assembly
        Caliper Installation
        Disc Inspection
        Disc Removal And Installation
    BRAKE (REAR)
        Pad Removal
        Pad Installation
        Caliper Removal
        Caliper Parts Identification
        Caliper Disassembly
        Caliper Inspection
        Caliper Assembly
        Caliper Installation
        Disc Inspection
        Disc Removal And Installation
    BRAKE (PARK)
        Inspection And Maintenance
        Parts Identification
        Lever Removal And Installation
        Cable Tension Inspection
        Cable Adjustment
        Caliper Removal
        Caliper Parts Identification
        Caliper Disassembly
        Caliper Inspection
        Pad Installation
        Caliper Assembly
        Disc Inspection
        Disc Removal And Installation
        Caliper Installation
    GEARCASE (TRANSMISSION)
        General Operation
        System Troubleshooting
        Shift Lever Removal And Installation
        Shift Cable Inspecting
        Shift Cable Adjustment
        Removal And Installation
        Parts Identification
        Disassembly
        Gear Cluster Disassembly
        Assembly
    DRIVE BELT
        Removal
        Installation
        Belt Inspection
    CONTINUOUS VARIABLE TRANSMISSION (CVT)
        CVT System Overview
        Drive Clutch Operation
        Driven Clutch Operation
        CVT Break-In (Drive Belt / Clutches)
        Maintenance And Inspection
        Overheating Troubleshooting
        System Troubleshooting
        CVT Sealing, Guard And Ducting Components Parts Identification
        CVT (Outer) Cover Removal And Installation
        CVT (Inner) Cover Removal And Installation
        Clutch Alignment
        Clutch Offset
        Clutch Center Distance
    CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)
        Removal And Installation
        Spring Specifications
        Shift Weights
        Parts Identification
        Inspection
        Button To Tower Clearance Inspection
        Disassembly
        Moveable Sheave Bushing Removal And Installation
        Clutch Cover Bushing Removal And Installation
        Assembly
    CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)
        Removal And Installation
        Parts Identification
        Disassembly
        Bushing Removal
        Bushing Installation
        Assembly
    FINAL DRIVE
        Description
        Front Hub And Spindle Removal
        Front Hub And Spindle Installation
        Rear Bearing Carrier Inspection
        Rear Bearing Carrier Removal
        Rear Bearing Carrier Disassembly And Assembly
        Rear Bearing Carrier Installation
        Rear Drive Shaft Removal And Installation
        Outer CV Joint And Boot Removal And Installation
        Inner Plunging Joint And Boot Removal And Installation
        
MAINFRAME
    ROLL OVER PROTECTIVE STRUCTURE (ROPS)
        Removal And Installation
    OPERATOR SEAT
        Seat Back Removal And Installation
        Seat Base Removal And Installation
        Seat Belt Removal And Installation
    DASH
        Front Access Cover Removal And Installation
        Left Dash Removal And Installation
        Right Dash Removal And Installation
        Center Dash Removal And Installation
    BUMPER COVER
        Removal And Installation
    STRUT
        Strut Cartridge Removal And Installation
    STEERING COLUMN
        Removal And Installation
    STEERING BOX
        Removal And Installation
    FUEL TANK
        Removal And Installation
    SHOCKS
        Removal And Installation
        Shock Spring Removal And Installation
    CONTROL ARMS
        Removal And Installation (Rear Lower Arm)
        Removal And Installation (Upper Arm)
        Removal And Installation (Front Arm)
        Inspection
        Ball Joint Removal And Installation
    TIE ROD
        Description
        Removal And Installation
        Toe Adjustment Procedure
    TAILGATE
        Removal And Installation
        Latch Removal And Installation
    CARGO BOX
        Removal And Installation
    FENDER
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Flare Removal And Installation
    REAR STABILIZER BAR / LINKAGE
        Removal And Installation
        Inspection
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATIC
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Description
        Troubleshooting
        Fuse And Relay Location - Cab Panel
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    CHARGING SYSTEM
        Current Draw - Key OFF
        Break Even Test
        Stator Testing
        Stator Plate Assembly Removal
        Stator Plate Assembly Installation
        Testing Flow Chart
    STARTER SYSTEM
        Testing
        Removal And Installation
        Parts Identification
        Starting Testing Flow Chart
    REGULATOR / RECTIFIER
        Location
        Removal And Installation
        Testing
    LIGHTS
        Headlight Removal And Installation
        Headlight Adjustment
        Tail Light / Brake Light Removal And Installation
        Indicator Lamp Removal And Installation
    VEHICLE CONTROL MODULE
        Description
        Removal And Installation
    DC / CDI IGNITION SYSTEM
        Description
        CDI Module Removal And Installation
        Testing
        Ignition System Troubleshooting
        Ignition System Testing Flow Chart
    HEADLIGHT SWITCH
        Removal And Installation
        Testing
    BRAKE LIGHT SWITCH
        Removal And Installation
        Testing
    PARKING BRAKE SWITCH
        Description
        Removal And Installation
        Testing
    SWITCH (2WD / TURF)
        Removal And Installation
        Testing
    IGNITION SWITCH
        Removal And Installation
    GEAR SELECTOR SWITCH
        Removal And Installation
    TEMPERATURE SENSOR
        Removal And Installation
        Testing
    DIFFERENTIAL SOLENOID
        Description
        Removal And Installation
    DIFFERENTIAL SOLENOID (REAR RELAY)
        Description
        Removal And Installation
    AIR SOLENOID
        Description
        Removal And Installation
    HOURMETER
        Removal And Installation
    BACK-UP ALARM SYSTEM (IF EQUIPPED)
        Description
        Inspecting
        Removal And Installation
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Specifications (Engine Model EH460PLE040)
        Torque Values
        Troubleshooting
        Accessible Engine Components
        Engine Removal And Installation
        Engine Installation Notes
        Engine Mount Replacement
        Compression - Checking
    THROTTLE SYSTEM
        Throttle Pedal Removal And Installation
        Throttle Cable Removal And Installation
        Throttle Freeplay
        Inspection And Maintenance
        Throttle Freeplay Adjustment
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    ENGINE COOLING SYSTEM
        Cooling System Pressure Test
        Radiator Cap Pressure Test
        Radiator Removal And Installation
        Cooling Fan Removal And Installation
        Shroud Removal And Installation
        Water Pump Housing Cover Removal And Installation
        Water Pump Disassembly And Assembly
        Water Pump Mechanical Seal Removal (Engine Installed)
        Thermostat Housing Removal And Installation
        Thermostat Removal And Installation
    LUBRICATION SYSTEM
        Oil Tank Removal And Installation
        Engine Oil Pressure - Testing
        Oil Flow Diagram
        Oil Flow Chart
    FUEL SYSTEM (CARBURETOR)
        Fuel Pump Removal And Installation
        Carburetor Jetting
        Jetting Guidelines
        Carburetor Parts Identification
        System Function - Mikuni CV Carb
        Vent Systems - Mikuni CV Carb
        Operation - Mikuni CV Carb
        Pilot System (Idle And Slow Speed)
        Starter System (Choke Or Enrichment)
        Float System
        Main System
        Pilot Screw
        Pilot Screw Adjustment
        Idle Speed Adjustment
        Choke Cable Adjustment
        Choke Cable Removal And Installation
        Removal And Installation
        Disassembly
        Cleaning
        Inspection
        Float Height Adjustment
        Fuel Level
        Assembly
    ENGINE DISASSEMBLY AND ASSEMBLY
        Cam Chain Tensioner / Rocker Arm / Camshaft Removal
        Cam Chain Tensioner Inspection
        Rocker Shaft / Rocker Arm Assembly Removal
        Rocker Arm / Shaft Inspection
        Rocker Shaft / Rocker Arm Assembly Installation
        Valve Clearance Adjustment (Intake And Exhaust)
        Camshaft Removal
        Automatic Compression Release Removal / Inspection
        Automatic Compression Release Installation
        Camshaft Inspection
        Cam Chain / Camshaft Installation
        Camshaft Timing
        Engine Parts Illustration
        Cylinder Head Removal
        Cylinder Head Warpage
        Cylinder Head Disassembly
        Valve Inspection
        Combustion Chamber
        Valve Seat Reconditioning
        Cylinder Head Assembly
        Valve Sealing Test
        Cylinder Head Installation
        Cylinder Removal
        Cylinder Inspection
        Cylinder Hone Selection / Honing Procedure
        Cleaning The Cylinder After Honing
        Cylinder Installation
        Piston Removal
        Piston - To - Cylinder Clearance
        Piston / Rod Inspection
        Piston Ring Installed Gap
        Piston Ring Installation
        Piston Installation
        Crankcase Disassembly
        Starter Drive Removal And Installation
        Flywheel Removal And Installation
        Stator Removal / Inspection
        Stator Installation
        Cam Chain / Tensioner Blade
        Cam Chain Drive Sprocket Removal And Installation
        One Way Valve Removal And Installation
        Crankcase Separation
        Crankcase Inspection
        Crankcase Assembly
        Oil Pump Removal / Inspection
        Oil Pump Assembly
        Counter Balancer Shaft Removal / Inspection
        Crankshaft Removal / Inspection
        Crankshaft Straightening
        Crankcase Bearing Inspection
        Oil Seal / Mechanical Seal Removal (Engine Disassembled)
        Pump Shaft Oil Seal Installation
        Water Pump Mechanical Seal Installation
        Bearing Installation
        End Play Inspection / Adjustment
        Crankshaft End Play Adjustment
        Counter Balancer Shaft End Play Adjustment
        Oil Pump Shaft End Play Adjustment
        Crankshaft / Counter Balance / Oil Pump Installation
        Oil Pump Priming Procedure
        
SPECIFICATIONS
    (3200) UTILITY VEHICLE SPECIFICATIONS
        Utility Vehicle Dimensions
        Performance
        Controls
        Engine
        Electrical
        Drive System
        Fluid And Capacities
        Tires
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    CONVERSIONS
        Decimal And Millimeter Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

SERVICE MANUAL REVISION
    Revision No: 3200 - 1
    
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