Bobcat 2100, 2100S Utility Vehicle Workshop Repair Service Manual - 6901987

(S/N: 522711001 & ABOVE - S/N: 524411001 & ABOVE) 
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This workshop repair service manual PDF download for the Bobcat 1200 & Bobcat 1200S 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 2100 / 2100S 
S/N: 522711001 & ABOVE
S/N: 524411001 & ABOVE


TABLE OF CONTENTS :

Section 1 - Safety
Section 2 - Vehicle Specifications
Section 3 - General Information
Section 4 - Body and Trim
Section 5 - Accelerator and Brake Pedal Assemblies
Section 6 - MC012C-AS00 Transaxle: Hydraulic and Park Brake Systems
Section 7 - Steering and Front Suspension
Section 8 - Wheels and Tires
Section 9 - Rear Suspension
Section 10 - Periodic Maintenance
Section 11 - Troubleshooting and Electrical System: FE400 Engine
Section 12 - Electrical Components: FE400 Engine
Section 13 - FE400 Engine
Section 14 - Fuel System
Section 15 - Exhaust System
Section 16 - MC012C-AS00 Unitized Transaxle with Differential Lock
Section 17 - Torque Converter
Section 18 - Reconditioning the FE400 Engine
Section 19 - Reconditioning the MC012C- AS00 Unitized Transaxle with Differential Lock


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901987 (5-09)
Total Pages : 382


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 !!!! 

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Bobcat 2100 2100S Workmate Utility Vehicle

Section 1 - Safety
General Warning

Section 2 - Vehicle Specifications

Section 3 - General Information
General Information
Serial Number Identification
Storage
    Preparing the Vehicle for Extended Storage
    To Return Vehicle to Service
    
Section 4 - Body and Trim
Cleaning the Vehicle
Front Body Repair
    Abrasions and Haze
    Light Scratches
    Large Scratches and Abrasions
Front Body Components
    Dashboard Removal
    Dashboard Installation
    Front Body Removal
    Front Fender Removal
    Front Fender Installation
    Front Body Installation
Seat
    Seat Adjustment
Front Seat Support
    Front Seat Support Removal
    Front Seat Support Installation
Rear Seat Support
    Rear Seat Support Removal
    Rear Seat Support Installation
Cargo Bed
    Cargo Bed Removal
    Cargo Bed Installation
    Bed Stop Bumper Adjustment
Rear Fender
    Rear Fender Removal
    Rear Fender Installation
Tailskirt
    Tailskirt Removal
    Tailskirt Installation
Receiver Hitch
    Receiver Hitch Removal
    Receiver Hitch Installation
Floor Mat
    Floor Mat Removal
    Floor Mat Installation
    
Section 5 - Accelerator and Brake Pedal Assemblies
Brake Pedal
    Brake Pedal Removal
    Brake Pedal Installation
Brake Pedal Adjustment
Accelerator Pedal
    Accelerator Pedal Removal
    Accelerator Pedal Installation
Accelerator Pedal Adjustment

Section 6 - MC012C-AS00 Transaxle: Hydraulic and Park Brake Systems
Brake System Inspection
Brake System Troubleshooting
Brake Drum Removal
    Front Wheel Brake Drum Removal
    Rear Wheel Brake Drum Removal
Brake Shoe Removal
    Front Brake Shoe Removal
    Rear Brake Shoe Removal
Brake Cluster Inspection and Cleaning
Brake Shoe Installation
    Front Brake Shoe Installation
    Rear Brake Shoe Installation
Brake Drum Installation
    Front Wheel Brake Drum Installation
    Rear Wheel Brake Drum Installation
Brake Cluster Assembly Replacement
    Front Brake Cluster Assembly Removal
    Front Brake Cluster Assembly Installation
    Rear Brake Cluster Assembly Removal
    Rear Brake Cluster Assembly Installation
Wheel Cylinder Replacement
    Front Wheel Cylinder Removal
    Front Wheel Cylinder Installation
    Rear Wheel Cylinder Removal
    Rear Wheel Cylinder Installation
Brake Shoe Adjuster Replacement
    Front Brake Shoe Adjuster Removal
    Front Brake Shoe Adjuster Installation
    Rear Brake Shoe Adjuster Removal
    Rear Brake Shoe Adjuster Installation
Hydraulic Line and Hose Replacement
    Front Brake Line Removal
    Front Brake Line Installation
    Front Brake Hose Assembly Removal
    Front Brake Hose Assembly Installation
    Rear Brake Line Removal
    Rear Brake Line Installation
    Rear Brake Hose Removal
    Rear Brake Hose Installation
Master Cylinder And Bell Crank Replacement
    Bell Crank Removal
    Bell Crank Installation
    Master Cylinder Removal
    Master Cylinder Installation
Bleeding the Hydraulic Brake System
    Purging the Hydraulic System
    Filling the Hydraulic System
Park Brake System
    Park Brake Cable Removal
    Park Brake Cable Installation
    Park Brake Handle Removal
    Park Brake Handle Installation
    Park Brake Adjustment
    
Section 7 - Steering and Front Suspension
Steering Wheel
    Steering Wheel Removal
    Steering Wheel Installation
Steering Column
    Steering Column Removal
    Steering Column Disassembly
    Steering Column Assembly
    Steering Column Installation
Rack and Pinion
    Rack and Pinion Removal
    Rack and Pinion Disassembly
    Rack and Pinion Assembly
    Rack and Pinion Installation
Front Suspension
    Lubrication
    Wheel Alignment
Front Suspension Components
    Kingpin and Steering Spindle Removal
    Kingpin and Steering Spindle Installation
    A-Arm Removal
    A-Arm Installation
    Shock Absorber Removal
    Shock Absorber Installation
Front Wheel Bearings and Hubs
    Front Wheel Free Play Inspection
    Front Wheel Bearings and Hub Removal
    Front Wheel Bearings and Hub Installation
    
Section 8 - Wheels and Tires
General Information

Section 9 - Rear Suspension
Shock Absorbers
    Shock Absorber Removal and Inspection
    Shock Absorber Installation
Multi-Leaf Springs
    Multi-Leaf Spring Removal
    Multi-Leaf Spring Installation
Snubber
    Snubber Removal
    Snubber Installation
    
Section 10 - Periodic Maintenance
Periodic Service Schedule
Periodic Lubrication Schedule
Master Cylinder
    Brake Fluid
Engine Oil
    Engine Oil Level Check
    Engine Oil and Filter Change
    Oil Viscosity
Fueling Instructions
Battery

Section 11 - Troubleshooting and Electrical System: FE400 Engine
Troubleshooting Guide
Electrical System
Wiring Diagram
Electrical Circuits
    Starter Circuit
    Generator Circuit
    Engine Ignition Circuit
    Engine Kill Circuit
    Reverse Buzzer Circuit
    Low Oil Warning Circuit
    Lockout Cam Circuit
    Fuel Gauge and Sending Unit Circuit
    Hour Meter Circuit
    Lighting Circuit
Circuit Testing
    Testing the Starter Circuit and Generator Circuit
    Testing the Engine Ignition Circuit
    Testing the Engine Kill Circuit
    Testing the Reverse Buzzer Circuit
    Testing the Low Oil Warning Circuit
    Testing the Lockout Cam Circuit
    Testing the Fuel Gauge and Sending Unit Circuit
    Testing the Lighting Circuit
Test Procedures
    Index of Test Procedures
    
Section 12 - Electrical Components: FE400 Engine
Starter/Generator
Voltage Regulator
Diode
Key Switch
Solenoid
Fuse
Lockout Cam Limit Switch
Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Low Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
RPM Limiter
Ignition Coil
Oil Level Sensor
Headlights
Headlight Diode
Light Switch
    Testing the Light Switch
Battery
    General Information
Ground Straps

Section 13 - FE400 Engine
General Information
    Before Servicing
    Lubrication System
    Spark Plug
Cylinder
    Breather Valve (Reed Valve)
    Valve Clearance Check and Adjustment
Crankcase
    Engine Removal
    Crankcase Cover Removal
    Oil Level Sensor
Ignition Coil and Flywheel
    Crankcase Cover Installation
Flywheel Installation
Engine Installation
    Torque Specifications
    Adjustment and Settings
    
Section 14 - Fuel System
General Information
Carburetor
    Main Jet Elevation/Size Chart
    Changing the Main Jet
Engine Control Linkage
    General Information
    Accelerator Rod
    Governor Cable
    Accelerator Cable
    Closed Throttle or Idle Adjustment
    Engine RPM Adjustment
Choke and Air Intake System
    Choke Cable Removal
    Choke Cable Installation
    Air Box Removal
    Air Box Installation
    Intake Duct Repair
    Intake Duct Removal
    Intake Duct Installation
    Air Filter
Fuel Filters
    Fuel Filter Removal
    Fuel Filter Installation
Fuel Pump
    General Information
    Fuel Pump Removal
    Fuel Pump Disassembly
    Fuel Pump Cleaning and Inspection
    Fuel Pump Assembly
    Fuel Pump Installation
Fuel Tank
    Fuel Tank Removal
    Fuel Tank Storage or Disposal
    Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve

Section 15 - Exhaust System
Muffler
    Muffler Removal
    Muffler Installation
    
Section 16 - MC012C-AS00 Unitized Transaxle with Differential Lock
General Information
    Lubrication
Axle Shaft
    Axle Shaft, Bearing, and Oil Seal Removal
    Axle Bearing Removal
    Axle Shaft, Bearing, and Oil Seal Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
    Forward/Reverse Shifter Cable Removal
    Forward/Reverse Shifter Cable Installation
    Forward/Reverse Shifter Cable Adjustment
Differential Lock System
    Differential Lock System Inspection
    Differential Lock Cable Removal
    Differential Lock Cable Installation
    
Section 17 - Torque Converter
General Information
Troubleshooting
Drive Belt
    Drive Belt Removal
    Drive Belt Installation
Drive Clutch
    Drive Clutch Removal
    Drive Clutch Cleaning and Inspection
    Drive Clutch Disassembly
    Inspection of Drive Clutch Parts
    Drive Clutch Assembly
    Drive Clutch Installation
Driven Clutch
    Driven Clutch Removal
    Driven Clutch Disassembly
    Driven Clutch Inspection
    Driven Clutch Assembly
    Driven Clutch Installation
    
Section 18 - Reconditioning the FE400 Engine
General Information
Special Engine Service Tools Available
    Recommended Replacement Parts For Engine Teardown
    Before Servicing
    Mechanical Systems
Cylinder Components
    Cylinder Head
    General Information
    Cylinder Shroud Removal
    Rocker Arm and Push Rod Removal
    Cylinder Head Removal
    Valve Removal
    Breather Valve (Reed Valve)
    Cylinder Head Cleaning and Inspection
    Valve Guides
    Valve Seats
    Valves
    Rocker Arm and Rocker Shaft inspection
    Push Rod Inspection
    Cylinder Head Installation
    Valve Clearance Check and Adjustment
    Breather Valve (Reed Valve)
    Installation of Remaining Engine Components
Crankcase Components
    Crankcase Cover Removal
    Camshaft and Hydraulic Lifters
Piston and Connecting Rod
Cylinder Block
Ignition Coil and Flywheel
Oil Pump
    Oil Pressure Relief Valve
Crankshaft and Counterbalance
    Counterbalance Weight
    Oil Screen
    Ball Bearing
    Oil Seals
Crankshaft Axial Play Adjustment
    Crankcase Cover Installation
Engine Assembly
Engine Installation
Service Specifications
    Specifications for Resizing Cylinder Bore
    Torque Specifications
    Adjustment and Settings
    
Section 19 - Reconditioning the MC012C- AS00 Unitized Transaxle with Differential Lock
General Information
Transaxle Model and Identification
    Lubrication
Axle Shaft
Unitized Transaxle Removal
Unitized Transaxle Disassembly
Component Disassembly
    Differential Gear Lock Housing Disassembly
    Governor Gear Disassembly
    Differential Gear Case Disassembly
    Shifter Fork Disassembly
    Synchronizer Gear Disassembly
    Intermediate Gear Disassembly
    Idler Shaft Disassembly
Unitized Transaxle Component Inspection
Component Assembly
    Idler Shaft Assembly
    Intermediate Gear Assembly
    Synchronizer Gear Assembly
    Shifter Fork Assembly
    Differential Gear Case Assembly
    Governor Gear Assembly
    Differential Gear Lock Housing Assembly
Unitized Transaxle Assembly
Unitized Transaxle Installation
    A
        accelerator
        air box
        air filter 14-1
        armature
        axle
    B
        ball bearing
        battery 12-28
        bed, cargo
        belt, drive
        body, front
        brakes
        breather valve (reed valve) 18-9
    C
        camshaft
        camshaft and hydraulic lifter
        carburetor
        cargo bed
        CAUTION
        choke 14-1
        cleaning
        clutch (torque converter) troubleshooting 17-3
        clutch, drive
        clutch, driven
        column, steering
        commutator
        connecting rod
        counterbalance
        counterbalance guide shaft
        counterbalance weight
        crankcase 18-20
        crankshaft
        cylinder block 18-26
        cylinder head 18-4
        cylinder shroud
    D
        DANGER
        dashboard
        differential gear case
        differential lock
        differential lock housing
        diode
        diode, headlight
        drive belt
        drive clutch
        driven clutch
    E
        electrical system
        engine
        engine oil 10-4
        exhaust system 14-1
    F
        fender, front
        fender, rear
        field coil
        fluid, brake 10-4
        flywheel
        forward/reverse
        front body
        fuel filter 14-1
        fuel gauge
        fuel gauge sending unit circuit
        fuel gauge/hour meter
        fuel level sending unit 12-22
        fuel lines 14-1
        fuel pump 14-1, 14-17
        fuel shut-off valve 14-28
        fuel tank
        fueling instructions 10-7
        fuse
    G
        generator circuit
        governor cable
        governor gear
        governor system 16-3, 19-3
        ground straps
    H
        headlight bulb
        headlight diode
        headlight switch
        headlights
        hour meter
        hydraulic lifter
        hydrometer test 11-21
    I
        idler shaft
        ignition
        ignition coil
        inspection
        intake duct
        intermediate gear
    K
        key switch
        kill circuit, engine
        kill wire, engine
    L
        leaf springs, multi 9-1
        lighting circuit
        link rod
        lockout cam
        lockout cam circuit
        low oil warning circuit
        low oil warning light
        lubrication
    M
        maintenance
        master cylinder
        muffler
    N
        neutral lockout 16-3
    O
        oil level sensor
        oil light
        oil pressure relief valve
        oil pump
        oil screen
        oil seal
        oil viscosity 10-7
        oil, engine 10-4
    P
        park brake
        pedal, accelerator
        pedal, brake
        periodic lubrication schedule 10-2
        periodic service schedule 10-1
        piston
        piston and connecting rod
        piston pin
        piston ring
        push rod
    R
        rack and pinion
        receiver hitch
        reed valve
        reverse buzzer
        reverse buzzer circuit
        rocker arm
        rocker arm and push rod
        rocker shaft
        RPM adjustment 14-10
        RPM limiter
    S
        safety
        seat
        serial number, vehicle 3-1
        service schedule
        shifter fork
        shock absorber
        snubber
        solenoid
        spark plug 13-1, 14-1
        specifications
        starter/generator
        starter/generator circuit
        steering
        steering column
        steering wheel
        storage
        suspension, front
        suspension, rear
        synchronizer gear
    T
        test procedure
        test procedures, index of 11-19
        testing
        tire
        torque converter
        torque specifications 18-48
        trailer hitch
        transaxle
        troubleshooting
    U
        unitized transaxle 19-1
    V
        valve (cylinder)
        valve guide
        valve seat
        valves (engine)
        voltage limiter
        voltage regulator
    W
        WARNING
        wheel
        wheel cylinder
        wire continuity testing 11-29
        wiring diagram 11-5
        
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