Bobcat Utility Vehicle 2200 2200S 2300 Service Manual-21416B320181.pdf -Bookmark created by https://wimanual.com TOC Section 1 - Safety General Warning Section 2a - Vehicle Specifications: Honda Gas & Kubota Diesel Powered 2200 and 2200S Specifications 2300 Specifications Section 2b - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered 2200 and 2200S Specifications 2300 Specifications Section 3 - General Information General Information Model Identification Storage Preparing the Vehicle for Extended Storage Returning the Stored Vehicle to Service Using A Booster Battery (Jump Starting) Section 4 - Body and Trim Cleaning the Vehicle Seat Cleaning Front Body Repair Light Scratches Abrasions and Haze Large Scratches and Abrasions Front Body Components Instrument Panel Removal Instrument Panel Installation Front Fascia Removal Front Fascia Installation Hood Removal Hood Installation Center Cowl Panel Removal Center Cowl Panel Installation Side Cowl Panel (Fender) Removal Side Cowl Panel (Fender) Installation Front Fender Flare Removal Front Fender Flare Installation Roll-Over Protective Structure (ROPS) ROPS Removal ROPS Installation Seat Seat Removal Seat Adjustment Seat Installation Seat Support Removal Seat Support Installation Safety Belts Safety Belt Removal Safety Belt Installation Cargo Bed - Electric Lift Testing the Bed Lift Motor Bed Lift Motor Removal Bed Lift Motor Installation Cargo Bed Removal Cargo Bed Installation Cargo Bed - Manual Lift Cargo Bed Removal Cargo Bed Installation Rear Fender Rear Fender Removal Rear Fender Installation Floor Mat Floor Mat Removal Floor Mat Installation Section 5 - Accelerator and Brake Pedal Assemblies Accelerator Pedal Accelerator Pedal Removal Accelerator Pedal Installation Accelerator Pedal and RPM Adjustment Brake Pedal Brake Pedal Removal Brake Pedal Installation Brake Pedal Adjustment Park Brake Pedal Park Brake Pedal Assembly Removal Park Brake Pedal Assembly Installation Section 6 - Hydraulic and Park Brake Systems Brake System Inspection Brake System Troubleshooting Brake Pads and Caliper Front Brake Pad and Caliper Removal Front Brake Pad and Caliper Installation Rear Brake Pad and Caliper Removal Rear Brake Pad and Caliper Installation Brake Disc and Hub Front Wheel Disc and Hub Removal Front Wheel Disc and Hub Installation Rear Wheel Disc Removal Rear Wheel Disc Installation Hydraulic Line Replacement Front Brake Line Removal Front Brake Line Installation Rear Brake Line Removal Rear Brake Line Installation Master Cylinder and Reservoir Filling the Hydraulic System Reservoir Removal Reservoir Installation Master Cylinder Removal Master Cylinder Installation Bleeding the Hydraulic Brake System Purging the Hydraulic System Park Brake System Park Brake Adjustment Park Brake Cable Adjustment Park Brake Wheel Cables Front Park Brake Cable Removal Front Park Brake Cable Installation Park Brake Equalizer Removal Park Brake Equalizer Installation Section 7 - Steering and Front Suspension Steering Wheel Steering Wheel Removal Steering Wheel Installation Steering Column Steering Column Removal Steering Column Installation Rack and Pinion Rack and Pinion Removal Rack and Pinion Installation Rack and Pinion Disassembly Rack and Pinion Assembly Front Suspension Wheel Alignment Front Suspension Components Steering Upright Removal Upper A-Arm Removal Upper A-Arm Installation Lower A-Arm Removal Lower A-Arm Installation Front Coil-Over Shock Absorber Removal Front Coil-Over Shock Absorber Installation Steering Upright Installation Section 8 - Wheels and Tires General Information Wheels Wheel Removal Wheel Installation Tires Tire Removal Tire Installation Section 9 - Rear Suspension Rear Coil-Over Shock Absorber Swing Arms Swing Arm Removal Swing Arm Installation Section 10a - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles Periodic Service Schedule Periodic Lubrication Schedule Lubricating The Attachment Arm And Interface Brake Fluid Reservoir Brake Fluid Engine Oil Oil Pressure - Gasoline Engine Engine Oil Level Check Engine Oil and Filter Change Oil Viscosity Gearcase Lubrication Lubrication Level Check for Front Differential, Transmission, and Rear Differential Lubrication Change for Front Differential, Transmission, and Rear Differential Hydraulic System - 2300 Vehicle Engine Coolant - Diesel Vehicles Engine Coolant Level Check Fueling Instructions Draining Water from Fuel Filter Battery Section 10b - Periodic Maintenance: Kawasaki Gasoline & Kubota Diesel Powered Vehicles Periodic Service Schedule Periodic Lubrication Schedule Lubricating The Attachment Arm And Interface Brake Fluid Reservoir Brake Fluid Engine Oil Oil Pressure - Gasoline Engine Engine Oil Level Check Engine Oil and Filter Change Oil Viscosity Spark Plugs Spark Plug Cleaning And Inspection Spark Plug Gap Inspection Gearcase Lubrication Lubrication Level Check for Front Differential, Transmission, and Rear Differential Lubrication Change for Front Differential, Transmission, and Rear Differential Hydraulic System - 2300 Vehicle Engine Coolant - Diesel Vehicles Engine Coolant Level Check Fueling Instructions Draining Water from Fuel Filter Battery Section 11a - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles Troubleshooting Guide Wiring Diagram Test Procedures Index of Test Procedures Section 11b - Troubleshooting and Electrical System: Honda Powered Gasoline Vehicles Troubleshooting Guide Wiring Diagram Test Procedures Index of Test Procedures Section 11c - Troubleshooting and Electrical System: Diesel Vehicles Troubleshooting Guide Wiring Diagram Test Procedures Index of Test Procedures Section 12a - Electrical Components: Kawasaki Powered Gasoline Vehicles Starter and Starter Solenoid Relays Neutral Switch Carburetor Solenoid Carburetor Heater Voltage Regulator Warning Lights Fuel Gauge Key Switch 12-Volt Accessory Receptacle Bed Lift Switch Bed Lift Circuit Breaker Light Switch Fuse Reverse Warning Buzzer (If Equipped) Reverse Warning Buzzer Limit Switch (If Equipped) Front Differential Switch Fuel Level Sending Unit Ignition Coil and Charge Coil Oil Pressure Sensor Headlights Wire Harness Diodes Battery General Information Section 12b - Electrical Components: Honda Powered Gasoline Vehicles Starter and Starter Solenoid Relays Neutral Switch Carburetor Solenoid Voltage Regulator Warning Lights Fuel Gauge Key Switch 12-Volt Accessory Receptacle Bed Lift Switch Bed Lift Circuit Breaker Light Switch Fuse Reverse Warning Buzzer Reverse Warning Buzzer Limit Switch Fuel Level Sending Unit Ignition Coil and Charge Coil Charge Coil Oil Pressure Sensor Headlights Wire Harness Diodes Battery General Information Section 12c - Electrical Components: Diesel Vehicles Starter and Starter Solenoid Relays Neutral Switch Fuel Solenoid 60-Amp Fusible Link Warning Lights Fuel Gauge Key Switch 12-Volt Accessory Receptacle Bed Lift Switch Bed Lift Circuit Breaker Light Switch Fuse Reverse Warning Buzzer (If Equipped) Reverse Warning Buzzer Limit Switch (If Equipped) Electric Fuel Pump Fuel Level Sending Unit Alternator Oil Pressure Sensor Headlights Thermostat Switch Fan Wire Harness Diodes Battery General Information Section 13a - Kawasaki Gasoline Engine, Muffler, Fuel System, and Clutches Gasoline Engine Engine Removal Engine Installation Oil Filter Hoses Exhaust System Muffler Removal Intermediate Pipe Removal Intermediate Pipe Installation Muffler Installation Fuel System Fuel Lines Fuel Filter Fuel Pump Carburetor Fuel Level Sending Unit Fuel Tank Fuel Shut-Off Valve Engine Control Linkages Accelerator Cable Choke Cable Engine Governor Arm Engine RPM Adjustment Air Intake System Air Filter Replacement Air Canister Removal Air Canister Installation Air Filter Intake Hose Removal Air Filter Intake Hose Installation Air Filter Outlet Hose Removal Air Filter Outlet Hose Installation Clutches Clutch Troubleshooting Drive Belt Drive Clutch Driven Clutch Clutch Cover Section 13b - Honda Gasoline Engine, Muffler, Fuel System, and Clutches Gasoline Engine Engine Removal Engine Installation Exhaust System Muffler Removal Intermediate Pipe Removal Intermediate Pipe Installation Muffler Installation Fuel System Fuel Lines Fuel Filter Fuel Pump Carburetor Fuel Level Sending Unit Fuel Tank Fuel Shut-Off Valve Oil Filter Hoses Engine Control Linkages Accelerator Cable Governor Guard Governor Cable Accelerator Cable Retention Clip Adjustment Ground Speed (Transmission) Governor Arm Adjustment Engine Governor Arm Engine RPM Adjustment Choke and Air Intake System Air Filter Replacement Choke Cable Removal Choke Cable Installation Air Canister Removal Air Canister Installation Air Filter Intake Hose Removal Air Filter Intake Hose Installation Air Filter Outlet Hose Removal Air Filter Outlet Hose Installation Clutches Clutch Troubleshooting Drive Belt Drive Clutch Driven Clutch Clutch Cover Section 13c - Diesel Engine, Muffler, Fuel System, and Clutches Diesel Engine Engine Removal Engine Installation Exhaust System Muffler Removal Intermediate Pipe Removal Manifold Pipe Removal Manifold Pipe Installation Intermediate Pipe Installation Muffler Installation Fuel System Fuel Lines Fuel Filter Replacement Draining Water from the Secondary Fuel Filter Electric Fuel Pump Fuel Level Sending Unit Fuel Tank Engine Control Linkages Accelerator Cable Engine RPM Adjustment Air Intake System Air Filter Replacement Air Canister Removal Air Canister Installation Air Filter Intake Hose Removal Air Filter Intake Hose Installation Air Filter Outlet Hose Removal Air Filter Outlet Hose Installation Clutches Clutch Troubleshooting Drive Belt Drive Clutch Driven Clutch Clutch Cover Section 14 - Drivetrain Components Half Shafts Half Shaft Removal Half Shaft Installation Front Differential Front Differential Removal Front Differential Installation Front Driveshaft Front Driveshaft Removal Front Driveshaft Installation Rear Receiver Hitch Rear Receiver Hitch Removal Rear Receiver Hitch Installation Rear Axle Rear Axle Removal Rear Axle Installation Rear Driveshaft Rear Driveshaft Removal Rear Driveshaft Installation Transmission Transmission Removal Transmission Installation Forward Forward Rear Differential and Axle Shafts Rear Differential and Axle Shaft Removal Rear Differential and Axle Shaft Installation Rear Wheel Bearings Section 15 - Radiator and Coolant System (Diesel) General Information Engine Coolant Level Check Engine Coolant Change Coolant Reservoir Coolant Reservoir Removal Coolant Reservoir Installation Radiator Radiator Removal Radiator Installation Coolant Pipe Weldment Coolant Pipe Weldment Removal Coolant Pipe Weldment Installation Fan Fan Removal Fan Installation Section 16 - Transmission Models 421274 and 421275 General Information Model Identification Service Fixture Transmission Removal Transmission Disassembly Input Shaft Disassembly Input Shaft Assembly Intermediate Shaft Disassembly Output Shaft Disassembly Shifter Shaft Removal Shifter Shaft Installation Case Inspection Shaft Seal Removal Shaft Seal Installation Output Shaft Assembly Intermediate Shaft Assembly Intermediate and Output Shaft Assembly Transmission Assembly Transmission Installation Section 17 - Front Differential Models 6203-01-139-S and 6203-01-189-S General Information Axle Half Shaft Removal Front Differential Removal Tools Required For This Section Front Differential Coil And Output Cover Coil and Output Cover Removal Coil and Output Cover Installation Front Differential Front Differential Disassembly Front Differential Assembly Front Differential Installation Axle Half Shaft Installation Section 18 - Rear Differential Models 420366 and 420851 General Information Axle Shafts and Differential Removal Rear Differential Disassembly Pinion Gear Removal Ring Gear Removal Clutch Carrier Assembly Ring Gear Installation Pinion Gear Installation Rear Differential Assembly Axle Shafts and Differential Installation Section 19 - Kubota D722 Diesel Engine Manual Section 20a - Kawasaki FH680D Gasoline Engine Manual FH601D M&S.pdf Top Page General Information Before Servicing Model Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent Special Tools Fuel System Exploded View Specifications Governor Link Mechanism Carburetor Intake manifold Fuel Pump,Fuel Filter Air Cleaner Cooling System Exploded View Cooling Fan Engine Top End Exploded View Specifications Cylinder Head Valves Cylinder,Piston Muffler Lubrication System Exploded View Engine Oil Flow Chart Specifications Engine Oil and Oil Filter Pressurized Lubrication System Oil Pump,Relief Valve Oil Screen Camshaft Exploded View Specifications Crankcase Breather Camshaft,Tappet Crankshaft,Connecting Rod Electrical System Exploded View Specifications Wiring Diagram Precautions Charging,Ignition Sydtem Starter System Troubleshooting Engine Troubleshooting Guide Starter Motor Troubleshooting Guide Section 20b - Honda GX 620 Gasoline Engine Manual GX620K1_(GCAD-2000001-FORWARD).pdf NAVIGATION QUICKTIPS SPECIFICATIONS SPECIFICATIONS DIMENSIONS AND WEIGHTS PERFORMANCE CURVES DIMENSIONAL DRAWINGS SNORKEL AIR CLEANER EQUIPPED TYPE P.T.O. DIMENSIONAL DRAWINGS WIRING DIAGRAMS SERVICE INFORMATION GENERAL SAFETY SERIAL NUMBER LOCATION SERVICE RULES MAINTENANCE STANDARDS ENGINE ELECTRICAL VALVES CONNECTING ROD CYLINDER TORQUE VALUES SPECIAL TOOLS TROUBLESHOOTING GENERAL SYMPTOMS AND POSSIBLE CAUSES HARD STARTING OIL ALERT SYSTEM IGNITION SYSTEM STARTER MOTOR HARNESS ROUTING MAINTENANCE MAINTENANCE SCHEDULE ENGINE OIL OIL FILTER AIR CLEANER SNORKEL TYPE VALVE CLEARANCE SPARK PLUG CARBURETOR GOVERNOR FUEL FILTER SPARK ARRESTER DISASSEMBLY AIR CLEANER RECOIL STARTER REMOVAL RECOIL STARTER ASSEMBLY FAN COVER REMOVAL INSTALLATION CONTROL BOX DISASSEMBLY INSPECTION GOVERNOR ARM DISASSEMBLY INSTALLATION FUEL PUMP CARBURETOR REMOVAL DISASSEMBLY INSPECTION ADJUSTMENT STARTER MOTOR REMOVAL DISASSEMBLY INSPECTION INSTALLATION COOLING FAN DISASSEMBLY INSPECTION ADJUSTMENT CYLINDER HEAD REMOVAL DISASSEMBLY INSPECTION VALVE GUIDE REPLACEMENT VALVE SEAT RECONDITIONING INSTALLATION CRANKCASE COVER REMOVAL DISASSEMBLY INSPECTION CRANKSHAFT DISASSEMBLY INSPECTION PISTON DISASSEMBLY INSPECTION PISTON ASSEMBLY VALVE LIFTER ASSEMBLY DISASSEMBLY INSPECTION INSTALLATION HIGH MOUNT MUFFLER A Section 21 - Hydraulic Attachment System Model Identification Relieving Hydraulic System Pressure To Relieve Hydraulic Fluid Pressure Attachment Interface Inspection Removing and Installing the Attachment Arm Mechanism Electrical Joystick Joystick ON Attachment Arm Float Switch Auxiliary Hydraulic Switch Relays Solenoid Circuit Breaker Control Valves Hoses Hose Routing Hose Removal Hose Installation Quick Connect Fittings (Auxiliary Hydraulic Circuit only) Quick Connect Removal Quick Connect Installation Cylinders Vehicle Mounted Cylinders Auxiliary Cylinder (Optional) Cylinder Disassembly Cylinder Assembly Cylinder Bushings (If Equipped) Angle Frame Bushings Snow Blade Angle Frame Whisk Broom Angle Frame Front Mount Front Mount Removal Front Mount installation Hydraulic Pump Assembly Fluid Level Inspection Fluid Change Pump Assembly Reservoir Motor Pump Priming the Pump Index A a-arm, lower a-arm, upper accelerator air canister (diesel vehicles) air canister (gasoline vehicles) air filter (diesel vehicles) air filter (gasoline vehicles) alternator (diesel vehicles) antifreeze attachment arm attachment interface (hydraulic attachment vehicles) axle half shaft axle shaft and differential axle, rear B ball joint, lower ball joint, upper battery (diesel vehicles) 12c-19 battery (gasoline vehicles) 12a-17, 12b-15 bed lift circuit breaker (diesel vehicles) bed lift circuit breaker (gasoline vehicles) bed lift motor bed lift motor (diesel vehicles) bed lift motor (gasoline vehicles) bed lift switch (diesel vehicles) bed lift switch (gasoline vehicles) bed, cargo belt, drive belt, seat body, front box bed brakes bushings C cable, accelerator cable, forward cable, governor camber carburetor (diesel vehicles) carburetor (gasoline vehicles) carburetor heater (gasoline vehicles) carburetor heater relay (gasoline vehicles) carburetor solenoid (gasoline vehicles) cargo bed CAUTION charge coil (gasoline vehicles) 12a-15, 12b-12 choke cable (gasoline vehicles) circuit breaker, bed lift (diesel vehicles) circuit breaker, bed lift (gasoline vehicles) circuit breaker, hydraulic attachment cleaning clutch and ring gear clutch carrier clutch inner cover (diesel vehicles) clutch inner cover (gasoline vehicles) clutch outer cover (diesel vehicles) clutch outer cover (gasoline vehicles) clutch, drive clutch, driven coil and output cover coil, charge (gasoline vehicles) 12a-15, 12b-12 coil, ignition (gasoline vehicles) 12a-15, 12b-12 column, steering coolant reservoir (diesel vehicles) coolant temperature warning light circuit (diesel vehicles) coolant, engine (diesel vehicles) cylinder, auxiliary cylinder, hydraulic cylinder, vehicle mounted D DANGER differential relay (diesel vehicles) differential relay (gasoline vehicles) differential, front differential, rear diode, wire harness (diesel vehicles) diode, wire harness (gasoline vehicles) drive belt (diesel vehicles) drive belt (gasoline vehicles) drive clutch (diesel vehicles) 13c-27 drive clutch (gasoline vehicles) 13a-27, 13b-29 driven clutch (diesel vehicles) 13c-27 driven clutch (gasoline vehicles) 13a-27, 13b-29 driveshaft, front driveshaft, rear E engine (diesel vehicles) engine (gasoline vehicles) engine governor arm engine oil exhaust system (diesel vehicles) exhaust system (gasoline vehicles) F fan motor (diesel vehicles) fan relay (diesel vehicles) fender, front fender, rear floor mat fluid fluid, brake 10a-7, 10b-7 forward forward front differential front drive gearcase coil (diesel vehicles) front drive gearcase coil (gasoline vehicles) front driveshaft front mount fuel filter (gasoline vehicles) 13a-10, 13b-8 fuel filter, primary (diesel vehicles) fuel filter, secondary (diesel vehicles) fuel gauge fuel gauge fuel level sending unit (diesel vehicles) fuel level sending unit (gasoline vehicles) fuel pump (diesel vehicles) fuel pump (gasoline vehicles) 13a-10, 13b-8 fuel shut-off valve (gasoline vehicles) 13a-17, 13b-15 fuel solenoid (diesel vehicles) fuel system (diesel vehicles) 13c-8 fuel system (gasoline vehicles) 13a-9, 13b-7 fuel tank (diesel vehicles) fuel tank (gasoline vehicles) fueling instructions 10a-16, 10b-16 fuse (diesel vehicles) fuse (gasoline vehicles) fusible link (diesel vehicles) G gearcase gearcase coil glow plug circuit (diesel vehicles) governor arm, engine (gasoline vehicles) governor arm, transmission (gasoline vehicles) governor cable (gasoline vehicles) governor guard (gasoline vehicles) ground cables (diesel vehicles) ground cables (gasoline vehicles) H half shaft handle, forward headlight (diesel vehicles) headlight (gasoline vehicles) hitch, receiver hoses, hydraulic hydrometer test (diesel vehicles) 11c-11 hydrometer test (gasoline vehicles) 11a-9, 11b-9 I ignition (gasoline vehicles) ignition coil (gasoline vehicles) 12a-15, 12b-12 input shaft input shaft seal inspection instrument panel intake hose, air (diesel vehicles) intake hose, air (gasoline vehicles) intermediate and output shaft intermediate shaft J jetting, carburetor (gasoline vehicles) 13a-10, 13b-8 joystick (hydraulic attachment vehicles) K key switch (diesel vehicles) key switch (gasoline vehicles) kill circuit, engine (gasoline vehicles) kill wire, engine (gasoline vehicles) L lubrication M maintenance manifold (diesel vehicles) motor, hydraulic pump muffler muffler (diesel vehicles) muffler (gasoline vehicles) N neutral switch (diesel vehicles) neutral switch (gasoline vehicles) O oil filter oil warning light, low (diesel vehicles) oil warning light, low (gasoline vehicles) oil, engine 10a-7, 10b-7 outlet hose, air (diesel vehicles) outlet hose, air (gasoline vehicles) output shaft P panel, instrument park brake pedal, accelerator pedal, brake periodic lubrication schedule 10a-4, 10b-4 periodic service schedule 10a-1, 10b-1 pinion gear pump assembly, hydraulic pump, fuel (diesel vehicles) pump, fuel (gasoline vehicles) 13a-10, 13b-8 pump, hydraulic Q quick connect fitting R rack and pinion radiator (diesel vehicles) rear axle rear differential rear driveshaft rear wheel bearing receiver hitch relay, accessory (diesel vehicles) relay, accessory (gasoline vehicles) relay, differential (diesel vehicles) relay, differential (gasoline vehicles) relay, float relay, start (diesel vehicles) relay, start (gasoline vehicles) reservoir, coolant reservoir, hydraulic fluid reverse buzzer (diesel vehicles) reverse buzzer (gasoline vehicles) ring gear ROPS (roll-over protective structure) RPM adjustment (diesel vehicles) RPM adjustment (gasoline vehicles) S safety safety belt seat seat belt seat frame serial number, vehicle 3-1 service schedule service tools shaft seal shifter shaft shock absorber solenoid, fuel (diesel vehicles) solenoid, hydraulic attachment spark plug (gasoline vehicles) specifications start relay (diesel vehicles) start relay (gasoline vehicles) starter control circuit (diesel vehicles) starter control circuit (gasoline vehicles) steering steering column steering upright steering wheel storage suspension, front suspension, rear switch, auxiliary switch, bed lift (diesel vehicles) switch, bed lift (gasoline vehicles) switch, float switch, joystick ON switch, neutral (diesel vehicles) switch, neutral (gasoline vehicles) T 12-volt accessory receptacle (diesel vehicles) 12-volt accessory receptacle (gasoline vehicles) test procedures (diesel vehicles) test procedures (hydraulic attachment vehicles) test procedures (gasoline vehicles) test procedures, index of (diesel vehicles) 11c-10 test procedures, index of (gasoline vehicles) 11a-8, 11b-8 thermostat switch (diesel vehicles) throttle tire tools torque converter (diesel vehicles) 13c-27 torque converter (gasoline vehicles) 13a-27, 13b-29 transmission transmission governor arm troubleshooting V v-belt (diesel vehicles) voltage regulator (gasoline vehicles) W WARNING wheel wheel bearing wheel, steering wire continuity (diesel vehicles) wire continuity (gasoline vehicles) wire harness diode (diesel vehicles) wire harness diode (gasoline vehicles) wiring diagram (diesel vehicles) 11c-6 wiring diagram (gasoline vehicles) 11a-6, 11b-6 wiring diagram (hydraulic attachment) 21-8 . 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