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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