Bobcat Utility Vehicle 2100 2100S Service Manual 6901987

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 MC012CAS00 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
– AArm Removal
– AArm 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
MultiLeaf Springs
– MultiLeaf Spring Removal
– MultiLeaf 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
StarterGenerator
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 GaugeHour 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 ElevationSize 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 ShutOff Valve
Section 15 Exhaust System
Muffler
– Muffler Removal
– Muffler Installation
Section 16 MC012CAS00 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
ForwardReverse Shifter Cable
– ForwardReverse Shifter Cable Removal
– ForwardReverse Shifter Cable Installation
– ForwardReverse 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