Description
Repair Manual For Bobcat 2100, 2100S Utility Vehicle. Illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, maintenance, inspection, repair, troubleshooting, tune-up.
Format: PDF
Language: English
Pages: 382
Issued: may 2009
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Models:
Bobcat Utility Vehicle
2100
S/N 522711001 & Above
2100S
S/N 524411001 & Above
Contents
SAFETY
-GENERAL WARNING
Vehicle Specifications
GENERAL INFORMATION
SERIAL NUMBER IDENTIFICATION
-STORAGE
Preparing the Vehicle for Extended Storage
To Return Vehicle to Service
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
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
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
-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
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
WHEELS AND TIRES
GENERAL INFORMATION
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
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
-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
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
-FE400 ENGINE
-GENERAL INFORMATION
Before Servicing
Lubrication System
Sparkplug
-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
FUEL SYSTEM
GENERAL INFORMATION
-CARBURETOR
Main Jet Elevation/Size Chart
Changing the Main Jet sQ
-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
-EXHAUST SYSTEM
Muffler
MUFFLER REMOVAL
MUFFLER INSTALLATION
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
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
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
RECONDITIONING THE MC012C- ASOO 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
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