Taylor-Dunn G0-010-00 Service And Replacement Parts Manual

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T h e B e s t W a y

T o G o

A b o u t Y o u r

B u s i n e s s

WARNING

READ THE OPERATOR'S MANUAL BEFORE OPERATING

THIS VEHICLE.

The operator's manual contains important information

regarding the safe operation of this vehicle.

Service Manual

MANUAL #:

2019 G-100

Model Numbers:

G0-010-00

Originally Published [10/23/2018]

Revision

[

10/23/2018

], contents subject to change

without notice Taylor-Dunn

Mfg.

2114 W. Ball Rd.

Anaheim, CA 92804

(800)-688-8680

(714) 956-4040

(FAX) (714) 956-0504

Visit our Web site: www.taylor-dunn.com

9929758

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Taylor-Dunn G0-010-00

Page 1 Mfg. READ THE OPERATOR’S MANUAL BEFORE OPERATING 2114 W. Ball Rd. THIS VEHICLE. Anaheim, CA 92804 The operator’s manual contains important information (800)-688-8680 regarding the safe operation of this vehicle. (714) 956-4040 (FAX) (714) 956-0504 Visit our Web site: www.taylor-dunn.com...
Page 2 INTRODUCTION This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn® vehicles and is not intended as a training guide. Taylor-Dunn® has made every effort to include as much information as possible about the operation and maintenance of this vehicle. Taylor-Dunn is not to be held liable for errors in this manual or any consequential damage that results from the use of this manual.
Page 3 Service Manual © Copyright 2018 TAYLOR-DUNN All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 4 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
Page 5 2019 TAYLOR-DUNN G-100 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: CVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION...
Page 6 TRADEMARKS TAYLOR-DUNN ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron...
Page 8: Vehicle Information
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017 VIN / ENGINE NUMBER LOCATION Whenever corresponding about a TAYLOR-DUNN utility vehicle, be sure to refer to the Vehicle Identification Number (VIN) and the engine model and serial number.
Page 9: Reference Information
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141. SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 10: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. TAYLOR-DUNN recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 11: Master Special Tools Table
Engine Stand Sleeve Adapter (Use With 2” Bore Stand) (Use With 2.375” Bore Stand) PA-49316 PU-50625 PW-47054 Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool PA-49317 PV-1253 PU-50869 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 12 ENGINE / COOLING SYSTEM GENERAL Crankshaft Removal / Installation Oil Filter Wrench Oil Pressure Gauge Tool Kit PU-50105 PV-43531 PU-50784 Oil Pressure Gauge Adapter Valve Spring Compressor Adapter PU-50569 PV-43513-A 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 13 *Digital Wrench® PC Interface Cable *Digital Wrench® Vehicle *Digital Wrench® SmartLink Module PU-47470 Interface Cable PU-47468 PU-47469 Digital Wrench® Wireless Fuel Pressure Gauge Kit Fuel Pressure Gauge Adapter Vehicle Link PU-43506-A PV-48656 PU-51435 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 14 (Fluke 77: PV-43568) PS-48762 2201519-A (Includes: 547927, PU-47466) Laptop or Desktop Computer USB/ Serial Adaptor: Saelig RS-232 Commercially Available (refer to diagnostic software user manual or HELP section for minimum requirements) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 15 Piston Pin Puller Roller Pin Tool Drive Clutch Spider Removal and Install Tool 2870386 2870910-A 2870341 Universal Clutch Compressor Tool Standard Clutch Alignment Tool Clutch Center Distance Tool PU-50518-A 2870654 PU-50658-A 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 16 CV Boot Clamp Pliers 2870772 8700226 or PU-48951 2872608 STEERING / SUSPENSION Ball Joint Removal / Installation Tool Strut Compression Tools Shock Absorber Spring 2870871 2871573, 2871574 Compression Tool 2870623 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.10 © Copyright TAYLOR-DUNN...
Page 17 Battery Hydrometer Fluke® 77 Digital Multimeter PU-50296 PU-50338 PV-43568 Timing Light Hall Sensor Probe Harness Static Timing Light Harness 2460761 2871745 2870630 Relay Bypass Connector Test Kit PU-49466 PV-43526 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.11 © Copyright TAYLOR-DUNN...
Page 18: General Specifications
1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.12 © Copyright TAYLOR-DUNN...
Page 19: Clutching Chart
Transmission Type Automatic CVT Shift Type In Line Shift - P/ H / L / N / R Transmission Lubricant Full Synthetic AGL Requirement 33.8 oz. (1000 ml) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.13 © Copyright TAYLOR-DUNN...
Page 20: Misc. Specifications And Charts
π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.14 © Copyright TAYLOR-DUNN...
Page 21: Sae Tap / Drill Sizes
1 25/32 5/16–18 2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.15 © Copyright TAYLOR-DUNN...
Page 22: Metric Tap / Drill Sizes
5/16 10 x 1.25 11/32 0.3437 11/32 10 x 1.50 0.339 11/32 11 x 1.50 0.375 12 x 1.50 13/32 0.406 13/32 12 x 1.75 13/32 0.406 13/32 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.16 © Copyright TAYLOR-DUNN...
Page 23: Decimal Equivalents
13 mm = 0.5118″ 33/64 0.5156″ 17/32 0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.17 © Copyright TAYLOR-DUNN...
Page 24 0.875″ 0.8906″ 23 mm = 0.9055″ 57/64 29/32 0.9063″ 59/64 0.9219″ 15/16 0.9375″ 24 mm = 0.9449″ 61/64 0.9531″ 31/32 0.9688″ 25 mm = 0.9843″ 63/64 0.9844″ 1.000″ 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 1.18 © Copyright TAYLOR-DUNN...
Page 27: Maintenance
Do not operate at full throttle or high speeds during the first three hours of use. Use of any oils other than those recommended by TAYLOR-DUNN may cause serious engine damage. We recommend the use of POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil for your 4-cycle engine.
Page 28: Brake System Break-In
WARNING Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or death. Have an authorized TAYLOR-DUNN dealer perform these services. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 29: Periodic Maintenance Chart
12 M ▶ Engine mounts Inspect 100 H 12 M Exhaust muffler /pipe Inspect 100 H 12 M Spark plug 1000 (1600) inspect; replace as needed 100 H 12 M 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 30 ▶ = Perform these procedures more often for vehicles subjected to severe use. E= Emission Control System Service (California) D = Have an authorized TAYLOR-DUNN dealer perform these services. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 31: Grease Lubrication Points
** Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 32: Component Quick Reference
DOT 4 Brake Fluid “MIN” lines on the every two years master cylinder reservoir * More often under severe use, such as operated in water or under severe loads. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 33: Storage Tips
Periodic Maintenance Chart. • Rear gearcase • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 34: Lubricants / Service Products
Battery Tender™ Charger 2859044 NOTE Each item can be purchased separately at your local TAYLOR-DUNN dealer. NOTE The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
Page 35: Engine
1. Set machine on a level surface. 2. Clean the area around the dip stick. 3. Remove dipstick and wipe dry with a clean cloth. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.11 © Copyright TAYLOR-DUNN...
Page 36: Breather Hose
12. Using a clean dry cloth, clean filter sealing surface on the crankcase. 13. Lubricate the o-ring on new filter with a thin film of engine oil. Check to make sure the O-ring is in good condition. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.12 © Copyright TAYLOR-DUNN...
Page 37: Breather Valve Inspection
7. Reinstall all components that were removed. gasket. NOTE It may be necessary to tap the cover lightly with a soft- faced hammer to loosen it from the cylinder head. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.13 © Copyright TAYLOR-DUNN...
Page 38: Cooling System
8. Reinstall the recovery bottle cap. With the engine at operating temperature, the coolant level should be between the “MAX” and “MIN” marks on the recovery bottle. If not, perform the following: 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.14 © Copyright TAYLOR-DUNN...
Page 39 MAINTENANCE 9. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.15 © Copyright TAYLOR-DUNN...
Page 40: 50/50 Extended-Life Engine Antifreeze
DESCRIPTION 2880514 1 US Quart (0.9 L) / 12 per case 2880513 1 US Gallon (3.8 L) / 6 per case 2880512 55 US Gallon Drum (208 L) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.16 © Copyright TAYLOR-DUNN...
Page 41: Coolant Strength / Type
2. Place a suitable drain pan underneath the right hand Bolt side of the radiator. 1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.17 © Copyright TAYLOR-DUNN...
Page 42 9. Carefully lift the radiator straight up and out of the vehicle. Take care not to damage the cooling fins. 10. Remove the four bolts that retain the fan motor and shroud to the radiator. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.18 © Copyright TAYLOR-DUNN...
Page 43 14. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant. 15. Refer to the cooling system bleeding procedure in Chapter 3, under “Engine Installation Notes”. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.19 © Copyright TAYLOR-DUNN...
Page 44: Fuel System And Air Intake
Replace every two years. 2. Be sure vent line is routed properly and secured with cable ties. CAUTION Make sure line is not obstructed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.20 © Copyright TAYLOR-DUNN...
Page 45: Engine Air Intake Inspection
5. Reinstall the air filter into the airbox container. Be sure the filter fits tightly in the air box and engage the (2) clips. 2. Verify there is no debris obstructing the airway. 3. Reinstall the cover. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.21 © Copyright TAYLOR-DUNN...
Page 46: Transmission And Gearcase
5. Remove the fill plug (refer to “Transmission Lubricant Level Check”). 6. Place a drain pan under the transmission drain plug. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.22 © Copyright TAYLOR-DUNN...
Page 47 10. Reinstall fill plug with a new O-ring and torque to specification. TORQUE Transmission Drain / Fill Plug: 14 ft-lbs (19 Nm) 11. Check for leaks. Dispose of used lubricant properly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.23 © Copyright TAYLOR-DUNN...
Page 48: Final Drive / Wheel / Tire
• The use of non-standard size or type tires may affect vehicle handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.24 © Copyright TAYLOR-DUNN...
Page 49: Tire Pressure
MAINTENANCE WARNING Operating a TAYLOR-DUNN Vehicle with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/ 8", (.3 cm) or less.
Page 50: Steering
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). • Refer to the Steering/Suspension or Final Drive chapter for more information. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.26 © Copyright TAYLOR-DUNN...
Page 51: Wheel Toe Alignment Inspection
Position chalk marks facing rearward, even with the hub/axle center line. 1. Hold tie rod end to keep it from rotating 2. Loosen jam nuts at both end of the tie rod 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.27 © Copyright TAYLOR-DUNN...
Page 52: Camber And Caster
4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) CAMBER AND CASTER The camber and caster are non-adjustable. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.28 © Copyright TAYLOR-DUNN...
Page 53: Suspension
Always adjust both left and right sides equally. Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench to adjust pre-load as necessary to avoid bottoming of the shocks. Shock Spanner Wrench 2871095 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.29 © Copyright TAYLOR-DUNN...
Page 54: Suspension Pivot Point Lubrication
A-Arm pivot points . See the maintenance chart for service intervals or grease as needed. NOTICE Wheels removed for clarification only. Procedure can be done with wheels installed on unit. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.30 © Copyright TAYLOR-DUNN...
Page 55: Brake System
Tighten any loose fittings and replace any worn or damaged parts. BRAKE PAD INSPECTION 1. Check the brake pads for wear, damage, or looseness. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.31 © Copyright TAYLOR-DUNN...
Page 56 Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.32 © Copyright TAYLOR-DUNN...
Page 57: Electrical And Ignition System
CAUTION To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, install the negative cable last. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.33 © Copyright TAYLOR-DUNN...
Page 58: Battery Installation
1.270 or greater. CAUTION 3. Reinstall the battery. A wire brush or coated abrasive should not be used. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.34 © Copyright TAYLOR-DUNN...
Page 59: Main Frame/Engine Ground
7. Install spark plugs and torque to specification. Recommended Spark Plug: Autolite 5924 TORQUE Spark Plug: 9 ft-lbs (12 Nm) Do Not Apply Anti-seize 8. Install spark plug wire into spark plug / engine. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 2.35 © Copyright TAYLOR-DUNN...
Page 62 ENGINE ASSEMBLY - LOWER END ............... .3.84 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual...
Page 64: General Information
10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) Oil Pressure Gauge Adapter: PU-50569 Oil Pressure Gauge: PV-43531 2. Remove the seats and engine service panel. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 65: Engine Oil Flow Chart
6. Upon assembly, torque the crankcase gallery plug to specification. TORQUE Oil Gallery Plug: 11 ft-lbs (15 Nm) 4. Remove the plug and insert the oil pressure adapter. ENGINE OIL FLOW CHART 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 66: Engine Specifications
3.8976" ± 0.0003" (99.0 mm ± 0.008 mm) Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 67 1.6137" (40.990 mm) Crankshaft Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm) Balance Shaft 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 68: Engine Service
Failing to do so may lead to possible injury or death. 1. If vehicle was recently operated, allow it to cool down before attempting to perform any work. 2. Thoroughly clean the engine and chassis. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 69 10. Remove the CPS sensor from the stator cover on the right-hand side of the engine. Plug CPS hole with clean shop towel. Inspect CPS O-ring and replace if needed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 70 20. Place a support between the main frame and 27. Select the proper engine stand sleeve adapter and transmission case. Do not pinch any lines. install it onto the engine stand adapter. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.10 © Copyright TAYLOR-DUNN...
Page 71: Engine Installation
5. Install the four engine to transmission coupler plates and instal the eight bolts and washers . Do not tighten fasteners at this time. IMPORTANT DO NOT torque fasteners at this time. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.11 © Copyright TAYLOR-DUNN...
Page 72 40 ft-lbs (54 Nm) 11. Remove the lifting straps and overhead or portable engine hoist and remove the support previously installed under the transmission case during the engine removal process. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.12 © Copyright TAYLOR-DUNN...
Page 73: Engine Break-In Period
Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.13 © Copyright TAYLOR-DUNN...
Page 74: Engine Mounting And Torque Values
NOTES Bolt Torque to 55 ft-lbs (75 Nm) Bolt Torque to 40 ft-lbs (54 Nm) Torque to 25 ft-lbs (34 Nm) Bolt Torque to 18 ft-lbs (25 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.14 © Copyright TAYLOR-DUNN...
Page 75: Setting Tdc (Top-Dead-Center)
3. With the stator cover and flywheel removed, rotate the engine and position the piston at TDC by aligning the timing hole in crank case with a timing hole in the crankshaft. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.15 © Copyright TAYLOR-DUNN...
Page 76: Cooling System
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM REF. DESCRIPTION NOTES Radiator Fan Shroud Cooling Fan Recovery Bottle Radiator Drain Plug Upper Radiator Hose Lower Radiator Hose Bypass Hose Water Pump Hose 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.16 © Copyright TAYLOR-DUNN...
Page 77: Cooling System Specifications
(commercially available). pre-mixed, ready to use. 3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.17 © Copyright TAYLOR-DUNN...
Page 78: Radiator
9. Remove the two upper radiator retaining bolts 3. Place a suitable drain pan underneath the drain valve on the front left side of the vehicle. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.18 © Copyright TAYLOR-DUNN...
Page 79: Thermostat Replacement
TORQUE Thermostat Cover Bolts: 8 ft-lbs (10 Nm) 8. Be sure to properly fill and bleed cooling system as outlined in this chapter. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.19 © Copyright TAYLOR-DUNN...
Page 80: Cooling System Bleeding Procedure
Premium Antifreeze to the radiator filler neck. 5. Remove the cargo box access cover to gain access to the coolant bleed screw that is on top of the thermostat housing. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.20 © Copyright TAYLOR-DUNN...
Page 81: Water Pump Cover And Impeller Service (Stator Cover Remains On Engine)
10. Using an 8mm socket, remove the water pump impeller NOTICE The water pump impeller uses reverse (left) threads. 11. Inspect the water pump cover and impeller for damage. Replace as necessary. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.21 © Copyright TAYLOR-DUNN...
Page 82: Water Pump Mechanical Seal / Oil Seal Replacement
11. Remove the water pump cover and water pump cover gasket . Discard the water pump gasket. 12. Remove the water pump impeller NOTE The water pump impeller uses reverse (left) threads. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.22 © Copyright TAYLOR-DUNN...
Page 83 Be sure engine coolant does not contaminate the engine oil during stator cover service. 17. Bring the stator cover assembly to a clean work bench. Water Pump Assembly 21. Thoroughly clean the stator cover. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.23 © Copyright TAYLOR-DUNN...
Page 84 23. Clean and de-grease the water pump drive shaft. 24. Press in the water pump drive shaft into the bearing using PU-50869. 26. Lubricate the new water pump oil seal with clean engine oil. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.24 © Copyright TAYLOR-DUNN...
Page 85 PU-50869 to fully install the new water pump mechanical seal until it is fully seated in the cover. 29. Install a new stator cover gasket onto the engine. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.25 © Copyright TAYLOR-DUNN...
Page 86 PA-49317 to the water cover bolt holes to aid in stator cover installation. TORQUE Stator Cover and Water Pump Cover: 9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt threads) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.26 © Copyright TAYLOR-DUNN...
Page 87 48. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 49. Check for leaks. 38. Install a new water pump cover gasket. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.27 © Copyright TAYLOR-DUNN...
Page 88: Troubleshooting
Engine Idles But Will Not Accelerate • Worn valve guides or seals • Spark plug fouled/weak spark • Restricted breather • Obstruction in air intake • Air filter dirty or contaminated 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.28 © Copyright TAYLOR-DUNN...
Page 89 • Thermostat stuck open • Thermostat missing Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.29 © Copyright TAYLOR-DUNN...
Page 90: Engine
3.6614" ± 0.0003" (93.0 mm ± 0.008 mm) Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00138" - 0.00256" (.035 - .065 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.30 © Copyright TAYLOR-DUNN...
Page 91 (40.990 mm) Crankshaft Crankshaft Runout Limit See Service Procedure (PTO and MAG) Listed In This Chapter Bearing Journal O.D. 1.1798” - 1.1802" Balance Shaft (Standard) (29.969 - 29.979 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.31 © Copyright TAYLOR-DUNN...
Page 92: Engine Torque Sequences
ENGINE / COOLING SYSTEM ENGINE TORQUE SEQUENCES CAM CARRIER CYLINDER HEAD WATER PUMP COVER VALVE COVER 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.32 © Copyright TAYLOR-DUNN...
Page 93 ENGINE / COOLING SYSTEM STATOR COVER CRANKCASE 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.33 © Copyright TAYLOR-DUNN...
Page 94: Crankcase Sealant Path
Clean the case halves with ISOPROPYL ALCOHOL to remove all sealant before applying new sealant. Alignment Pins MUST be installed prior to assembly CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.34 © Copyright TAYLOR-DUNN...
Page 95 Engine oil may be used to aid installation. Oil Pressure Regulator Assembly Torque: 20 ft-lbs (12 Nm) Piston Oil Jet Torque: 35–in-lbs (4 Nm) Oil Pump Cover Torque: 106 in-lbs (12 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.35 © Copyright TAYLOR-DUNN...
Page 96: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.36 © Copyright TAYLOR-DUNN...
Page 97 Gerotor Outer Gerotor dots must not be visible after assembly. Piston Assembly Apply ENGINE OIL to bottom 50 mm of cylinder bore and to piston rings before assembly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.37 © Copyright TAYLOR-DUNN...
Page 98: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.38 © Copyright TAYLOR-DUNN...
Page 99 Torque in Sequence shown in Torque Sequence topic. Replace if loosened of removed. Water Pump Impeller Impeller has left hand thread, tighten to finger tight. Screw Torque: 106 in-lbs (12 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.39 © Copyright TAYLOR-DUNN...
Page 100: Spark Plugs / Starter / Throttle Body / Valve Cover
ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.40 © Copyright TAYLOR-DUNN...
Page 101 Torque: (22.5 Nm) Screw Torque: 89 in-lbs (10 Nm) Screw Torque: 89 in-lbs (10 Nm) Starter Motor Apply grease to starter o-ring. Dipstick Apply engine oil to o-ring 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.41 © Copyright TAYLOR-DUNN...
Page 102: Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.42 © Copyright TAYLOR-DUNN...
Page 103 Bearings MUST rotate freely after assembly. Apply load to outer race only. Balance Shaft Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and/or bore. Align gears to gear timing marks. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.43 © Copyright TAYLOR-DUNN...
Page 104 Orient cir-clip as shown below. The gap should be located at the 6 o’clock or 12 o’clock locations. IMPORTANT Orient Piston as shown. Arrow should be pointing to the exhaust valve side. IMPORTANT Time balance shaft and crankshaft gears as shown. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.44 © Copyright TAYLOR-DUNN...
Page 105: Engine Disassembly / Inspection - Top End
3. Remove the camshaft sprocket bolt while holding engine from turning. Pull the camshaft sprocket of the camshaft and remove the timing chain from the sprocket. Carefully remove the camshaft from the engine. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.45 © Copyright TAYLOR-DUNN...
Page 106: Camshaft Sprocket Inspection
5. Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the engine. 6. Carefully remove the camshaft from the engine 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.46 © Copyright TAYLOR-DUNN...
Page 107: Engine / Cooling System
Intake: 2.0327" ± 0.0038" (51.63 ± 0.097 mm) spring, or shaft, the service kit 2207556 can be ordered Exhaust: 2.0657" ± 0.0038" (52.47 ± 0.097 mm) to replace the assembly. Decompression Kit Part Number 2207556. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.47 © Copyright TAYLOR-DUNN...
Page 108: Cam Chain And Guide Service
TORQUE Lower Cam Chain Guide Fasteners: 10 ft-lbs (12 Nm) Upper Cam Chain Guide Fasteners 7 ft-lbs (10 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.48 © Copyright TAYLOR-DUNN...
Page 109: Cylinder Head Disassembly
2. Compress the valve spring by hand using valve 7. Repeat the previous steps to remove the remaining spring compressor adapter. valve. 8. Clean the combustion chamber and head gasket surface. Valve Spring Compressor Adapter PV-43513-A 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.49 © Copyright TAYLOR-DUNN...
Page 110: Cylinder Head Inspection
5. Inspect split keeper groove for wear or flaring in the keeper seat area. NOTICE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.50 © Copyright TAYLOR-DUNN...
Page 111: Combustion Chamber Cleaning
Valve Guide I.D.: 0.2741" - 0.2747" (6.963 - 6.978 mm) 8. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.51 © Copyright TAYLOR-DUNN...
Page 112: Valve Seat Reconditioning
Renewing Valve Seats 1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.52 © Copyright TAYLOR-DUNN...
Page 113 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.53 © Copyright TAYLOR-DUNN...
Page 114: Cylinder Removal
6. Remove and discard cylinder base gasket. NOTICE Stuffing a clean rag around the connecting rod after cylinder is removed is helpful in keeping foreign objects from falling into the crankcase. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.54 © Copyright TAYLOR-DUNN...
Page 115: Piston Removal
4. Repeat procedure for second ring. 5. Remove oil control ring top rail first, then bottom rail. 6. Remove oil control ring expander. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.55 © Copyright TAYLOR-DUNN...
Page 116: Piston-To-Cylinder Clearance
Piston O.D.: 3.6592 - 3.6598″ (92.943 - 92.957 mm) Piston Pin O.D.: Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm) Service Limit: 0.8651″ (21.975 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.56 © Copyright TAYLOR-DUNN...
Page 117: Piston Ring Installed Gap
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring: Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.57 © Copyright TAYLOR-DUNN...
Page 118: Honing To Oversize
• Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check piston fit. NOTICE Do not allow cylinder to heat up during honing. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.58 © Copyright TAYLOR-DUNN...
Page 119: Engine Assembly - Top End
Second Ring Gap Position Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.59 © Copyright TAYLOR-DUNN...
Page 120: Piston / Connecting Rod Assembly
(12:00 position) or bottom (6:00 position). Push the piston pin in both directions to make sure the clips are properly seated in the groove. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.60 © Copyright TAYLOR-DUNN...
Page 121: Cylinder Installation
7. Remove support block and ring compressor. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.61 © Copyright TAYLOR-DUNN...
Page 122: Cylinder Head Installation
4. Install and finger tighten the four new cylinder head bolts evenly. 5. Install and finger tighten the two new outer M6 bolts evenly. 6. Torque the new cylinder head bolts in sequence to specification. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.62 © Copyright TAYLOR-DUNN...
Page 123: Valve Sealing Test
3. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out. 4. Carefully install the camshaft carrier onto the camshafts. 5. Install the four bolts that retain the camshaft carrier. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.63 © Copyright TAYLOR-DUNN...
Page 124 7 ft-lbs (10 Nm) 16. Measure and confirm that valve clearance is now within specification for each valve. 17. If valve clearance is not within specification, repeat this procedure. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.64 © Copyright TAYLOR-DUNN...
Page 125: Valve Lash - Tappet Selection Matrix
0.010 ± 0.002" (0.25 ± 0.05 mm) Valve Tappet Selection. PART NUMBER NUMBER PART NUMBER NUMBER THICKNESS THICKNESS 5139458–322 3.225 5139458–378 3.775 5139458–325 3.250 5139458–380 3.800 5139458–328 3.275 5139458–382 3.825 5139458–330 3.300 5139458–385 3.850 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.65 © Copyright TAYLOR-DUNN...
Page 126: Camshaft Installation / Timing
2. Lubricate all camshaft lobes and bearing journal surfaces with 5W-50 full synthetic engine oil prior to installation. 4. Wrap the cam chain around the camshaft in its current position. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.66 © Copyright TAYLOR-DUNN...
Page 127 • Remove the cam carrier bolt and cam carrier. • Correct the camshaft timing as needed. • Reinstall the cam carrier. • Re-check cam timing. 10. If needed, install the camshaft carrier and bolts. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.67 © Copyright TAYLOR-DUNN...
Page 128 14. Install the hydraulic cam chain tensioner into the cylinder and torque to specification. TORQUE Cam Chain Tensioner: 37 ft-lbs (50 Nm) 15. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.68 © Copyright TAYLOR-DUNN...
Page 129: Camshaft Timing - Quick Reference
Stator Cover/Flywheel Installed. “V” marked on the down and insert a 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole. the crankcase and into the crankshaft locating hole 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.69 © Copyright TAYLOR-DUNN...
Page 130: Valve Cover Installation
2. Install a new valve cover seal 3. Install the four valve cover bolts 4. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 9 ft-lbs (12 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.70 © Copyright TAYLOR-DUNN...
Page 131: Engine Disassembly / Inspection - Lower End
Inspect fit of shaft inside gear and replace gear assembly if clearance is excessive. Inspect shaft and shaft bearing surfaces in case and stator housing for wear. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.71 © Copyright TAYLOR-DUNN...
Page 132: Starter One-Way Clutch Inspection
5. Inspect crankshaft bearing surface for abnormal wear. 8. Remove clutch and inspect both sides of drive rollers and roller contact surface inside hub for wear, damage, or uneven surface. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.72 © Copyright TAYLOR-DUNN...
Page 133: Starter One-Way Clutch Installation
One Way Clutch Retaining Bolts: 9 ft-lbs (12 Nm)Apply Loctite® 272™ FLYWHEEL INSTALLATION 1. Clean the threads, taper and flat of crankshaft to remove all oil or grease. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.73 © Copyright TAYLOR-DUNN...
Page 134 TORQUE Flywheel Retaining Nut: 133 ft-lbs (180 Nm)Torque to specification, back of 180 degrees, retorque to specification. 11. Install starter idler gear and shaft 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.74 © Copyright TAYLOR-DUNN...
Page 135: Stator Removal
The flywheel contains powerful magnets. Use caution when installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.75 © Copyright TAYLOR-DUNN...
Page 136: Oil Pump Removal
Discard the bolts and replace with new for assembly. Remove the sprockets and chain from the engine. 6. Remove the three bolts securing the oil pump cover to the crankcase. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.76 © Copyright TAYLOR-DUNN...
Page 137 There is a spacer in between the inner oil pump gerotor and the oil pump cover. 9. Remove the oil pump gerotor that is in the engine case (if needed). 10. Clean the gerotors to remove oil. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.77 © Copyright TAYLOR-DUNN...
Page 138: Oil Pump Assembly
9. Install the upper oil pump sprocket spacer 5. Install the washer onto the drive shaft 6. Install the oil pump cover onto the shaft assembly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.78 © Copyright TAYLOR-DUNN...
Page 139 MAG crankcase mating surface. Crankcase 3 Bond Sealant: 2871557 14. Install the inter (mag) crankcase bolts finger tight in MAG side crankcase. 15. Tighten all bolts evenly until snug. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.79 © Copyright TAYLOR-DUNN...
Page 140: Crankcase Breather Valve / Hose
Operation of your vehicle without a breather valve can cause engine damage. Always reinstall the breather valve after removing it for service. 6. Install the left side panel 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.80 © Copyright TAYLOR-DUNN...
Page 141: Balance Shaft Removal / Inspection
MAG crankcase the crankcase. off PTO case. 3. Inspect drive gear for broken or damaged teeth. 4. Inspect bearing surfaces for scoring or signs of wear. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.81 © Copyright TAYLOR-DUNN...
Page 142: Crankshaft Removal
3. With the help of an assistant holding the crankshaft, slowly tighten the screw “C” until the crankcase is completely separated from the crankshaft. 4. Remove all special tools from the crankcase. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.82 © Copyright TAYLOR-DUNN...
Page 143: Crankshaft Inspection
MAG side bearing surface is not groved, pitted, damaged or excessively worn. Small End I.D. Standard: 0.8665” - 0.8670” (22.010 - 22.023 mm) Service Limit: 0.08682” (22.053 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.83 © Copyright TAYLOR-DUNN...
Page 144: Engine Assembly - Lower End
6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 7. Remove the crankshaft removal / installation tool from the crankcase. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.84 © Copyright TAYLOR-DUNN...
Page 145 12. Turn PTO crankcase over and support with crankshaft upright. • Place the nut and large washer onto the crankshaft installation screw. • Insert the crankshaft installation screw through the threaded portion of the adaptor. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.85 © Copyright TAYLOR-DUNN...
Page 146 4. Tap crankcase evenly until fully seated with a soft sided hammer. 5. Install the new crankcase bolts finger tight in MAG side crankcase. 6. Tighten all bolts evenly until snug. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.86 © Copyright TAYLOR-DUNN...
Page 147 Engine Stand Sleeve Adapter (2” Bore Stand): PU- 50625 Engine Stand Sleeve Adapter (2.375” Bore Stand): PW-47054 10. Place engine onto the engine stand for final assembly of the engine. Engine Stand: PU-50624-A 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.87 © Copyright TAYLOR-DUNN...
Page 148 ENGINE / COOLING SYSTEM NOTES 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 3.88 © Copyright TAYLOR-DUNN...
Page 151: General Information
Digital Wrench® Diagnostic Software • Temperature and Manifold Absolute Pressure Sensor (dealer only). (T-MAP) • Electronic Throttle Control (ETC) • Wire Harness Assembly • Check Engine Light 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 152: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. TAYLOR-DUNN recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 153: Fuel Pressure Gauge Kit - Pu-43506-A
Never drain the fuel when the engine is hot. Severe burns may result. Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 154: Digital Wrench® Diagnostic Softwarepu-47063-B
SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. NOTE For the most recent information on Digital Wrench® software and update downloads please visit the website: www.polaris.diagsys.com 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 155: Efi Component Locations
EFI COMPONENT LOCATIONS - LEFT VIEW REF. Component Instrument Cluster Ignition Switch Regulator / Rectifier Battery Fuse / Relay Box Starter Motor Solenoid Ignition Coil Starter Motor Engine Temperature Sensor (ECT) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 156: Efi Component Locations - Right View
FUEL SYSTEM EFI COMPONENT LOCATIONS - RIGHT VIEW REF. COMPONENT Fuel Pump / Sender High Tension Wire / Spark Plug Throttle Body (ETC) Speed Sensor (Mounted to Transmission) Stator (Magneto) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 157: Line / Hose Routing
The ears on the clip (arrows) will not hold the fitting and give it 5 pumps. The gauge should return properly once it is removed. to 0 immediately or there is an obstruction. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 158: Air Box / Intake System
FUEL SYSTEM AIR BOX / INTAKE SYSTEM AIR BOX / AIR FILTER ASSEMBLY VIEW 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.10 © Copyright TAYLOR-DUNN...
Page 159 Torque to 24 in-lbs (2.5 Nm) Pre-Filter Box, Intake Plug, Drain Screw Torque to 8 ft-lbs (11 Nm) Seal, Engine, Inlet Screw Torque to 18 ft-lbs (27 Nm) Hose - Breather 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.11 © Copyright TAYLOR-DUNN...
Page 160: Air Box Removal / Installation
4. Reinstall the breather hose spring clamp. Reposition the gear clamps to secure the intake hoses onto the air box. Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 24 in-lbs (2.7 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.12 © Copyright TAYLOR-DUNN...
Page 161: Electronic Control Unit (Ecu)
This process repeats it self in rapid succession, limiting operation to the preset maximum. RPM Limit: Max RPM Limit - Fuel / Spark Cutoff 7500 rpm (All Gears) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.13 © Copyright TAYLOR-DUNN...
Page 162: Ecu Replacement
Digital Wrench to ensure that all essential data contained within the original ECU is transferred to the replacement ECU. 2. Remove seat and ECU cover 3. Remove the 4 screws retaining the ECU. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.14 © Copyright TAYLOR-DUNN...
Page 163: Electronic Throttle Control
3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.15 © Copyright TAYLOR-DUNN...
Page 164: Pedal Position Sensor (Pps)
If the PPS fails, disconnect the battery power for 10 min. and retest. The Pedal Position Sensor is calibrated to the accelerator pedal. If the PPS is faulty, the accelerator pedal assembly must replaced (see "PPS Replacement"). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.16 © Copyright TAYLOR-DUNN...
Page 165: Fuel Tank / Pump / Sender
1. Lift the rear cargo box 2. Remove the seat from the vehicle. 3. Disconnect the negative (-), and then positive (+) battery cables from the battery. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.17 © Copyright TAYLOR-DUNN...
Page 166: Fuel Tank Installation
Empty: 90 ± 4.5 Ω 1. Hook up an ohm meter to the Fuel Pump Module connector terminal and terminal • Fuel Level Sender (+) • Fuel Level Sender (-) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.18 © Copyright TAYLOR-DUNN...
Page 167: Fuel Pump Test
Never drain the fuel when the engine is hot. Severe burns may result. Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.19 © Copyright TAYLOR-DUNN...
Page 168 “3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTICE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.20 © Copyright TAYLOR-DUNN...
Page 169: Fuel Pump Replacement
Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.21 © Copyright TAYLOR-DUNN...
Page 170 Pull on fuel line lightly to confirm connection. 13. Install new PFA gasket onto fuel pump assembly using care not to damage gasket or bend float arm. 21. Connect the fuel pump electrical harness. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.22 © Copyright TAYLOR-DUNN...
Page 171 24. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system and check for leaks. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.23 © Copyright TAYLOR-DUNN...
Page 172: Temperature / Manifold Absolute Pressure Sensor
The T-MAP sensor is a non-serviceable item. If it is faulty, it must be replaced. 7. Install the retaining bolt and torque to specification. TORQUE T-MAP Retaining Bolt: 24 in-lbs (2.8 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.24 © Copyright TAYLOR-DUNN...
Page 173: Crankshaft Position Sensor
Check both wires in this matter. engine will stop running. They should both read OL, indicating no shorts to ground. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.25 © Copyright TAYLOR-DUNN...
Page 174: Air Gap Test
6. Subtract the sensor length from the sensor mounting whether the flywheel is out of round, or if the crankshaft point to encoder flywheel measurement. Verify that is bent. the calculated air gap is within specification. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.26 © Copyright TAYLOR-DUNN...
Page 175: Cps Replacement
9. Install a NEW or known good CPS. (see CPS TORQUE Replacement). CPS Retaining Bolt: 10. Fill and bleed the coolant system (see Engine / 9 ft-lbs (12 Nm) Cooling System chapter) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.27 © Copyright TAYLOR-DUNN...
Page 176: Ignition Coil Overview
Secondary Coil Coil Pack – and 6.6kΩ +/- 10% Spark Plug Wire Terminal Spark Plug Wire Wire Connector 7.0kΩ +/- 10% Terminal and Spark Boot Terminal COIL PACK CONNECTIONS 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.28 © Copyright TAYLOR-DUNN...
Page 177: Fuel Injector
“injection duration” or “pulse width”. It may vary in length depending on the speed and load requirements of the engine. Fuel Injector Resistance Specification: 11.4 - 12.6 Ω 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.29 © Copyright TAYLOR-DUNN...
Page 178: Fuel Injector Replacement
/ injector assembly into the cylinder head. 14. Install the fuel rail mounting screws and torque to specification TORQUE Fuel Rail Mounting Screws: 7 ft-lbs (10 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.30 © Copyright TAYLOR-DUNN...
Page 179: Fuel Injector Troubleshooting
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.31 © Copyright TAYLOR-DUNN...
Page 180: Engine Coolant Temperature Sensor
4. Place a pot of water on a hot plate. 5. Place the sensor / tip of a thermometer in the water, ensure the display is legible as you will reference the thermometer throughout the test. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.32 © Copyright TAYLOR-DUNN...
Page 181: Efi Diagnostics
• Never disconnect battery while engine is running. • Always unplug ECU from the wire harness before performing any welding on the unit. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.33 © Copyright TAYLOR-DUNN...
Page 182 Valid But Above Normal C1057 C1704 Valid But Below Normal P0502 Vehicle Speed Signal Data Erratic or Intermittent (or P0503 missing) C1058 Voltage Above Normal P1507 Voltage Below Normal P1506 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.34 © Copyright TAYLOR-DUNN...
Page 183 (least severe) Temperature Too High P0217 Valid But Below Normal P0128 System Power Valid But Above Normal P1562 (Battery Potential / Power Valid But Below Normal P1563 Input) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.35 © Copyright TAYLOR-DUNN...
Page 184 Driver Circuit Short to B+ P1692 Rear Differential Output Driver Circuit Grounded P1693 Driver Circuit Open P1691 Driver Circuit Short to B+ P1482 Fan Relay Driver Circuit 1071 Driver Circuit Grounded P1483 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.36 © Copyright TAYLOR-DUNN...
Page 185 ECU Output Supply Voltage 3 3599 Valid But Above Normal P17AD (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified 65590 P0314 Misfire Detected Cylinder 1 65591 P0301 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.37 © Copyright TAYLOR-DUNN...
Page 186 Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D Throttle Body Control - Condition Exists 520284 P152E Position Deviation Fault 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.38 © Copyright TAYLOR-DUNN...
Page 187 Accelerator Sensor Synchronicity Fault Sensor Condition Exists 520308 P1533 Difference Exceeds Limit ECU Fault - ICO Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.39 © Copyright TAYLOR-DUNN...
Page 188: Digital Wrench® Operation
• Perform output state control tests. 3. If a newer update is available, it should be downloaded before using Digital Wrench® (see “Digital Wrench® Updates”). NOTE Always operate with the latest update. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.40 © Copyright TAYLOR-DUNN...
Page 189: Digital Wrench® Updates
PC. 6. If the update file date listed is newer than your current version and update (see Chapter 4 to download the file). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.41 © Copyright TAYLOR-DUNN...
Page 190: Digital Wrench® Communication Errors
DIGITAL WRENCH® SERIAL NUMBER LOCATION Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.42 © Copyright TAYLOR-DUNN...
Page 191: Digital Wrench® Feature Map
Configuration Screen. record functions. Perform specialized testing and adjustment functions Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.43 © Copyright TAYLOR-DUNN...
Page 192: Ecu Replacement
Software Version and Update ID page recent calibrations (see Chapter 4 – Digital Wrench® 2. Connect SmartLink Module cables to PC and vehicle. Updates page 3. Open the Digital Wrench® program. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.44 © Copyright TAYLOR-DUNN...
Page 193 10. Enter or paste the Request Code into the box. 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.45 © Copyright TAYLOR-DUNN...
Page 194: Etc Learn Procedure
13. Enter or paste the Authorization Key in the box back at step 1. located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.46 © Copyright TAYLOR-DUNN...
Page 195: Fuel System Troubleshooting
• Spark Plug fouled • Poor fuel quality (old fuel) • Failed sensor or disconnected wiring • Fouled spark plug • Injector failure • Failed sensor or disconnected wiring 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 4.47 © Copyright TAYLOR-DUNN...
Page 198: General Information
PU-50518 Clutch Bushing 2871025 Replacement Tool Kit Standard Clutch Alignment Tool 2870654 PART SPECIAL SUPPLIES NUMBER Loctite™ 680 8560054 RTV Silicone Sealer Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 199: Cvt System Overview
Rather than vary throttle position, as a conventional governor does, the CVT system changes engine load requirements by either upshifting or backshifting. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 200: Cvt Break-In (Drive Belt / Clutches)
CVT system and also to prevent water and other contaminants from entering the CVT area. This is especially critical on units subjected to frequent water fording. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 201: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your TAYLOR-DUNN dealer. Shift transmission to Low during loading Clutch malfunction. of the vehicle to prevent belt burning.
Page 202: Cvt System Service
CVT Intake Duct CVT Exhaust Duct Drain Plug Clamp Torque to 10 ft-lbs (14 Nm) Screw Torque to 60 in-lbs (7 Nm) Bolt Torque to 24 in-lbs (3 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 203: Cvt Disassembly
Make note of cable and hose routings for drive belt (see “DRIVE BELT - Belt Removal”). assembly. 8. Remove the driven clutch retaining bolt and driven clutch assembly. 9. Install the Drive Clutch Holder. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 204: Cvt Assembly
Torque retaining bolt to specification. TORQUE Driven Clutch Retaining Bolt: 38 ft-lbs (51 Nm) 10. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 205: Drive Belt
See the Troubleshooting Chart at the end 4. Remove the driven clutch mounting bolt. of this chapter for possible causes. 5. Remove the outer sheave. 6. Remove the belt from the vehicle. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 206: Belt Installation
5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and (8) screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 50 in-lbs (5 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.10 © Copyright TAYLOR-DUNN...
Page 207: Clutch Alignment / Offset / Center Distance
NOTE Images for Reference only. The tool shown should only be used to check center to center distance. The location the tool rests on the shafts may vary. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.11 © Copyright TAYLOR-DUNN...
Page 208 8. Remove the Clutch Center Distance tool and reassemble the CVT system as outlined in this chapter. TORQUE Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.12 © Copyright TAYLOR-DUNN...
Page 209: Drive Clutch Service
Bolt Cover Screws Shift Weight 100 in-lbs (12 Nm) Spring 25 in-lbs (2.8 Nm) Limiter Spacer Button Spider Washer 210 ft-lbs (284 Nm) Sheave Bushing Roller Bushing Spacer 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.13 © Copyright TAYLOR-DUNN...
Page 210: Clutch Disassembly
With the spring resting on a flat surface, measure its free length from the outer coil surfaces. Also check to see that 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.14 © Copyright TAYLOR-DUNN...
Page 211: Shift Weight Inspection
NOTICE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.15 © Copyright TAYLOR-DUNN...
Page 212: Spider Removal
It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.16 © Copyright TAYLOR-DUNN...
Page 213: Roller, Pin, And Thrust Washer Inspection
DUNN clutches if the hollow roller pin is changed to the solid roller pin. NOTE The rubber side of the button is positioned toward the solid roller pin. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.17 © Copyright TAYLOR-DUNN...
Page 214: Bearing Inspection
2. Verify there is no binding or rough spots. If problems Inspect for damage and wear. are noted continue with disassembly. 2. Remove the moveable clutch sheave . Inspect for damage and wear. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.18 © Copyright TAYLOR-DUNN...
Page 215: Bushing Service
5. Visually inspect PTFE thrust washers for damage. Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT PTFE Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.19 © Copyright TAYLOR-DUNN...
Page 216 4. Install puller adapter (Item 10 from kit). rod. Remove bushing from tool and discard. Drive Clutch Bushing Installation Puller Adapter: 12. Place main adapter (Item 8) on puller. PN 2871226 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.20 © Copyright TAYLOR-DUNN...
Page 217 29. Remove nut from puller rod and set aside. 30. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 31. Apply Loctite™ 609 evenly to bushing bore in cover. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.21 © Copyright TAYLOR-DUNN...
Page 218: Clutch Assembly
To maintain proper clutch balance and belt-to-sheave Drive Clutch Cover Screw: clearance. be sure to reinstall the original quantity and 8 ft-lbs (10 Nm) thickness of washers / spacers beneath the spider during assembly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.22 © Copyright TAYLOR-DUNN...
Page 219: Driven Clutch Service
Cup, Spring Boss Roller, Clutch Plate, Retainer Screw Washer, Thrust 9 ft-lbs (12 Nm) Ring, Retaining E-Ring External Label, Clutch Boss Subassembly, Moveable Boss Washer, Thrust Spring, Compression 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.23 © Copyright TAYLOR-DUNN...
Page 220: Clutch Disassembly / Inspection
7. Turn the compression tool handle counter-clockwise to relieve spring pressure and allow the spring cup and retaining ring to move out from the moveable sheave. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.24 © Copyright TAYLOR-DUNN...
Page 221: Clutch Assembly
Apply and hold downward pressure on the spring cup. Torque the retaining ring bolts to specification. TORQUE Clutch Spring Retaining Ring Bolts: 12 ft-lbs (16 Nm) 5. Install driven clutch assembly and drive belt. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.25 © Copyright TAYLOR-DUNN...
Page 222: Cvt System Troubleshooting
-Drive belt worn too narrow. -Replace belt. Harsh drive clutch engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment belt. with shim washers beneath spider. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.26 © Copyright TAYLOR-DUNN...
Page 223 -Replace belt. Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 5.27 © Copyright TAYLOR-DUNN...
Page 226: General Information
2871699 (Part of Rear Driveshaft Seal Guide 2871702 Kit) Bearing Seal Driver (50 mm) 2871282 PU-50566 Transmission Nut Socket PU-50658 Clutch Center Distance Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 227: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. TAYLOR-DUNN recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 229 Shim 2.040 OD x 1.63 ID Gear, 48T 102. Bearing, Needle Subassembly, Shift Fork Screw, Cap M8 - 1.25 x 25 104. Bearing, Ball Sprocket, 48T Bracket, Wire Harness 105. Bearing, Ball 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 230: Transmission Gears
TRANSMISSION TRANSMISSION GEARS LUBRICATION Please refer to the TAYLOR-DUNN Parts Catalog for FLUID CAPACITY gear tooth counts and part numbers Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity: 41 oz. (1200 ml) To access the TAYLOR-DUNN Parts Catalog, please visit The TAYLOR-DUNN website at: www.taylor-dunn.com...
Page 231: Shift Lever
3. Remove the clip and washer retaining the shift the gear shift lever (lever, cable, console, shift knob) cable to the shift lever and disconnect the cable end from the lever. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 232: Shift Cable
7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 233: Transmission Service
, remove the duct mounting bolt remove the intake duct 13. Remove vent hose from transmission. 8. Disconnect the main harness from the ETC and TPS at the throttle body. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 234: Transmission Installation
Remove the mount assemblies from the vehicle. 18. Using an overhead lift or an assistant, lift the transmission up and out of the chassis. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.10 © Copyright TAYLOR-DUNN...
Page 235 11. Install and properly route the vent hose. 12. Install inner clutch cover, outlet duct, drive clutch, driven clutch, belt and outer clutch cover (see Chapter 6). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.11 © Copyright TAYLOR-DUNN...
Page 236 19. Install the throttle body, air box assembly and ducting. 20. Reconnect the TPS and ETC harnesses. 21. Connect the (-) negative battery cable and reinstall the seat base. 22. Reinstall the cargo box. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.12 © Copyright TAYLOR-DUNN...
Page 237: Transmission Internals Service
This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.13 © Copyright TAYLOR-DUNN...
Page 238: Transmission Disassembly
5. Remove the sector cover bolts (F) and remove the sector cover (G). NOTICE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.14 © Copyright TAYLOR-DUNN...
Page 239 12. Lift up on the shift shaft rail (Q) and move the rail assembly rearward to allow the shift fork pins to be removed from the shift drum (R). Remove the shift drum (R) from the transmission housing. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.15 © Copyright TAYLOR-DUNN...
Page 240 53T gear and needle bearing off the housing. reverse shaft (see Figure 8-1). 22. Remove the retaining ring and engagement dog from the reverse shaft (see Figure 8-1). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.16 © Copyright TAYLOR-DUNN...
Page 241 (X) from the end of the shift rail on either side. CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.17 © Copyright TAYLOR-DUNN...
Page 242 31. Use an arbor press to remove the snorkel tube from the snorkel shaft. 32. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.18 © Copyright TAYLOR-DUNN...
Page 243: Planetary Differential Disassembly
If bushing replacement is required, proceed to Planetary Differential Bushing Replacement”. 2. Remove the (6) screws retaining the differential cover and remove the cover. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.19 © Copyright TAYLOR-DUNN...
Page 244: Planetary Differential Bushing Replacement
Differential Cover Bushing Replacement 8. Press the old bushing out of the differential cover. 9. Thoroughly clean the bore of the differential cover and check for any unwanted burs. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.20 © Copyright TAYLOR-DUNN...
Page 245 14. Press the new bushing into the side gear until it bottoms out. 11. Install the bushing to the specified depth as shown. Female Side Gear Bushing Replacement 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.21 © Copyright TAYLOR-DUNN...
Page 246: Planetary Differential Assembly
TORQUE Differential Cover Screws: 3. Align and install the differential cover using the 22 ft-lbs (30 Nm) previously made scribe marks. 4. Apply Loctite® 2760™ to cover screws. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.22 © Copyright TAYLOR-DUNN...
Page 247: Gear / Shaft / Bearing Inspection
TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.23 © Copyright TAYLOR-DUNN...
Page 248: Snorkel Gear Backlash Procedure
7. Install the pinion shaft assembly. Be sure to properly mesh the snorkel shaft bevel gear with the pinion shaft bevel gear. 8. Apply Loctite® 242™ to the threads of the bearing cover retaining screws. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.24 © Copyright TAYLOR-DUNN...
Page 249 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.25 © Copyright TAYLOR-DUNN...
Page 250 Inspect case half mating surfaces for damage. 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.26 © Copyright TAYLOR-DUNN...
Page 251 23. Install the rear output shaft assembly (C). Rotate output shaft assembly to align slots with engagement dog. Ensure bearing is fully seated upon assembly. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.27 © Copyright TAYLOR-DUNN...
Page 252 28. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. NOTICE Shift fork pins should be offset towards the input shaft as shown above. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.28 © Copyright TAYLOR-DUNN...
Page 253 Seals should be installed just past the case lead-in chamfer (.070" or 1.8 mm from outer face of bore). 33. Install the spacer onto the shift drum shaft. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.29 © Copyright TAYLOR-DUNN...
Page 254 39. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. TORQUE Sector Cover Bolts: 11 ft-lbs (15 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.30 © Copyright TAYLOR-DUNN...
Page 255: Troubleshooting
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 6.31 © Copyright TAYLOR-DUNN...
Page 258: General Information
Wheel Lug Nuts (Steel Bosch Automotive Service Solutions: 1-800-345-2233 36 ft-lbs (49 Nm) Wheels) or http://polaris.service-solutions.com Wheel Lug Nuts 30 ft-lbs + 90º (41 Nm + (Aluminum Wheels) 90º) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 259: Front Hub / Bearing
Use wire to hang the caliper to prevent possible damage to the brake line. 5. Remove hub cap, cotter pin , front spindle nut and washer. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 260: Hubstrut Bearing Replacement
Replace hubstrut housing if damaged. Bearing Installation 1. Thoroughly clean the hubstrut housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 261: Hub Installation
8. Install center cap. 9. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 262: Front Hub/Wheel Exploded View
Washer Wheel Nut Steel Wheel Nuts: 36 ft-lbs (49 Nm) Aluminum Wheel Nuts: 30 ft-lbs + 90º (41 Nm + 90º) Washer Tire Front Hub Stud Brake Disc Bolt 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 263: Rear Bearing Carrier
6. Remove the upper and lower A-arm fasteners from the bearing carrier 7. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 264: Disassembly
4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. 5. Replace the bearing carrier bushings if worn or damaged. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 265: Installation
Install a new cotter pin TORQUE Rear Hub Castle Nut: 110 ft-lbs (150 Nm) NOTICE The lower shock bolt may need to be removed to allow the upper A-arm to move freely. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 266: Rear Drive Shaft
3. Install the drive shaft into the rear bearing carrier. 4. Perform “REAR BEARING CARRIER Installation” procedure to properly reassemble the vehicle. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.10 © Copyright TAYLOR-DUNN...
Page 267: Drive Shaft Service
CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.11 © Copyright TAYLOR-DUNN...
Page 268 11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in it’s groove machined in the shaft. 12. Install a NEW circlip on the end of the shaft. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.12 © Copyright TAYLOR-DUNN...
Page 269 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.13 © Copyright TAYLOR-DUNN...
Page 270: Inner Plunging Joint / Boot Replacement
3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.14 © Copyright TAYLOR-DUNN...
Page 271 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.15 © Copyright TAYLOR-DUNN...
Page 272: Drive Shaft Assembly View
22. Position the boot lip in its groove. Install and tighten the large clamp using the Axle Boot Clamp Tool. Axle Boot Clamp Tool PU-48951 or 8700226 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 7.16 © Copyright TAYLOR-DUNN...
Page 274: General Information
15 ft-lbs (21 Nm) (Top) Tie Rod End Jamb Nut 14 ft-lbs (19 Nm) Tie Rod End Mounting 40 ft-lbs (54 Nm) Wheel Lug Nuts (Steel 36 ft-lbs (49 Nm) Wheels) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 276 BOLT 40 ft-lbs (54 Nm) SCREW BOLT 16 ft-lbs (22 Nm) 40 ft-lbs (54 Nm) 36 ft-lbs (49 Nm) 65 ft-lbs (88 Nm) BUSHING, STEERING PIN, COTTER LOCTITE® 271 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 277: Steering Wheel Removal
1. Center the wheels and install the steering wheel so it is properly centered on the steering shaft. 2. Install the steering wheel nut. Torque nut to specification. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 278: Steering Shaft / Steering Rack Removal
14. 9. Install the steering wheel and hand tighten the nut. 2. Remove upper and lower dash panels. 3. Remove the steering wheel tilt assembly fasteners. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 279 46–51 ft-lbs (62-69 Nm) fasteners retaining the both tie rod ends to the steering knuckle. 6. Remove the five fasteners retaining the steering rack to the frame. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 280: Front Strut
Spacer Retaining Ring 15 ft-lbs ( 20 Nm) Wheel Bearing Lower Pivot Ball Spring Retainer Hubstrut Spring Cam Adjuster Bumper Washer Spacer Front Strut Bolts 20 ft-lbs (27 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 281: Front Strut Cartridge Replacement
2. Elevate and safely support machine under footrest/ frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. 3. Remove wheel nuts and wheels. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 282 10. Install A-arm on ball joint and torque castle nut to specification. TORQUE Ball Joint Nut: 30 ft-lbs (41 Nm) 11. Install new cotter pin with open ends toward rear of machine. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.10 © Copyright TAYLOR-DUNN...
Page 283: Rear A-Arms
3. Remove the fastener attaching the upper A-arm to new A-arm. the bearing carrier. Lower A-arm Removal 8. Remove the fastener attaching the lower A-arm to the bearing carrier. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.11 © Copyright TAYLOR-DUNN...
Page 284: Installation
36 ft-lbs (49 Nm) TORQUE Bearing Carrier Fasteners: WARNING 40 ft-lbs (54 Nm) Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.12 © Copyright TAYLOR-DUNN...
Page 285 STEERING / SUSPENSION ASSEMBLY VIEW DESCRIPTION DESCRIPTION Bushing Lower A-Arm Upper A-Arm Bearing Carrier Grease Zerk Nuts Wheel Bearing 40 ft-lbs (54 Nm) Snap Ring 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.13 © Copyright TAYLOR-DUNN...
Page 286: Assembly View
8. Torque the stabilizer retaining bolts and upper rubber bushing nuts to specification. 9. If the stabilizer linkage was removed, torque the lower shock retaining bolt to specification. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.14 © Copyright TAYLOR-DUNN...
Page 287: Assembly View
3. Reverse the procedure to reinstall the shock. Torque NEW fasteners to specification. TORQUE Shock Fasteners: 40 ft-lbs (54 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 8.15 © Copyright TAYLOR-DUNN...
Page 289 REAR CALIPERS..................9.20 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual...
Page 291: General Information
110 ft-lbs (150 Nm) Master Cylinder Mount 17 ft-lbs (23 Nm) Bolts SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Mity Vac™ Pressure Test 2870975 Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 292: Brake System Notes
If noise does not change when brake is applied check Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 293: Hydraulic Brake System Operation
Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 294: Brake System Assembly View
Torque to 46 ft-lbs (62 Nm) Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm) Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm) Screw Torque to 12–15 ft-lbs (16–20 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 295: Master Cylinder
(20 Nm) Banjo Bolts Torque to 15 ft-lbs (20 Nm) CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 296: Brake Pedal
2. Remove the brake pedal pivot fastener and bushings off the mount bracket. PEDAL INSTALLATION 1. Reverse steps for foot brake installation. 2. Tighten pivot bolt sufficiently. Refer to the general torque specifications in Chapter 1. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 297: Brake Service Procedures
5. Begin bleeding procedure with caliper furthest from 13. Tighten bleeder screw and remove bleeder hose. master cylinder. Torque bleeder screw to specification. TORQUE Bleeder Screw: 47 in-lbs (5.3 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual © Copyright TAYLOR-DUNN...
Page 298: Brake Burnishing Procedure
Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times to maximize pad service life. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.10 © Copyright TAYLOR-DUNN...
Page 299: Front Brake Pads
Brake fluid will be forced through compensating port pads should be replaced. into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.11 © Copyright TAYLOR-DUNN...
Page 300: Pad Assembly / Installation
Maintain at least 1/2"(12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Fill master cylinder to max level 6. Validate brakes function properly with test drive 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.12 © Copyright TAYLOR-DUNN...
Page 301: Front Caliper
30–60 in-lbs (3.4–6.8 Nm) Caliper Body Square O-Rings Apply Dot 4 Brake Fluid Piston Apply Dot 4 Brake Fluid Dust Boots Caliper Bracket Caliper Pins Apply Brake Disc Caliper Lube Pads 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.13 © Copyright TAYLOR-DUNN...
Page 302: Front Caliper Removal
3. Remove mounting bracket and dust boot MEASUREMENT Front Caliper Piston Bore I.D.: Std. 1.5050-1.5040” (32.27-30.202 mm) Service Limit 1.5060” (38.252 mm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.14 © Copyright TAYLOR-DUNN...
Page 303: Front Caliper Assembly
Piston should slide in and out 46 ft-lbs (62 Nm) of bore smoothly, with light resistance. 2. Install brake line and tighten securely with a flare nut wrench. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.15 © Copyright TAYLOR-DUNN...
Page 304 5. Install wheels and torque wheel nuts to specification. TORQUE Steel Wheel Lug Nuts: 36 ft-lbs (49 Nm) 6. Burnish brake pads as outlined in this chapter 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.16 © Copyright TAYLOR-DUNN...
Page 305: Front Brake Disc
2. Clean mating surface of disc and hub 3. Install disc on hub. 4. Apply Loctite® 272 to new bolts, install and tighten to specification. TORQUE Front Brake Disc Mounting Bolts: 18 ft-lbs (25 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.17 © Copyright TAYLOR-DUNN...
Page 306: Rear Brake Pads
Support caliper so as not to kink or bend brake wear. line. MEASUREMENT Brake Pad .030″ (0.762 mm) 3. If any one pad is less than the service limit then all pads should be replaced. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.18 © Copyright TAYLOR-DUNN...
Page 307: Rear Pad Installation
Maintain at least 1/2"(12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 5. Fill master cylinder to Max level. 6. Burnish brakes as outlined in this chapter. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.19 © Copyright TAYLOR-DUNN...
Page 308: Rear Calipers
Caliper Assembly Dust Boots Square O-Rings Apply DOT 4 Brake Fluid Piston Apply DOT 4 Brake Fluid Caliper Pins Apply Disc Brake Caliper Lube Caliper Mount Brake Pads 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.20 © Copyright TAYLOR-DUNN...
Page 309: Caliper Removal
REAR CALIPER DISASSEMBLY 1. Remove brake pad adjuster screw 2. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.21 © Copyright TAYLOR-DUNN...
Page 310: Rear Caliper Inspection
Service Limit: 1.498” (38.05 mm) TORQUE 3. Inspect the brake disc and pads as outlined for brake Rear Caliper Mounting Bolts: pad replacement in this chapter. 46 ft-lbs (62 Nm). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.22 © Copyright TAYLOR-DUNN...
Page 311 If the brake drags, re-check assembly and installation. NOTICE If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE PADS - Brake Burnishing Procedure”). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.23 © Copyright TAYLOR-DUNN...
Page 312: Rear Brake Disc
4. Clean the wheel hub mating surface and install new disc on wheel hub. 5. Apply Loctite® 272 to new bolts, install and torque to specification. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.24 © Copyright TAYLOR-DUNN...
Page 313 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.25 © Copyright TAYLOR-DUNN...
Page 314: Troubleshooting
• Residue build up under caliper seals • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 9.26 © Copyright TAYLOR-DUNN...
Page 315 ................10.18 DECAL REPLACEMENT 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.1...
Page 316: General Information
15 ft-lbs (21 Nm) (Top) Tie Rod End Jamb Nut 14 ft-lbs (19 Nm) Tie Rod End Mounting 40 ft-lbs (54 Nm) Wheel Lug Nuts (Steel 36 ft-lbs (49 Nm) Wheels) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.2 © Copyright TAYLOR-DUNN...
Page 317: Chassis / Body Assembly Views
Screw - M10 x 1.5 x 30 (QTY.4) 36 ft-lb (49 Nm) Nut - M10 1.5 (QTY.10) Nut - M8 x 1.25 (QTY.8) Nut - M10 x 1.25 (QTY.4) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.3 © Copyright TAYLOR-DUNN...
Page 318: Dash Instruments / Controls
BODY / FRAME DASH INSTRUMENTS / CONTROLS REF. DESCRIPTION NOTES Instrument Cluster Bezel Key Switch 12V Accessory Plug Turf Switch Dash Panel 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.4 © Copyright TAYLOR-DUNN...
Page 319: Hood / Dash / Front Fascia
HOOD / DASH / FRONT FASCIA REF. Description Rivet Screw Washer Hood Mount Bracket Shoulder Washer Nylok Nut Hood Headlight Bezel Screw Headlight Screw Dash Panel Dash Screw Push Rivet Glovebox Cover 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.5 © Copyright TAYLOR-DUNN...
Page 320: Floor / Rear Fenders
BODY / FRAME FLOOR / REAR FENDERS REF. DESCRIPTION NOTES Front Floor Main Floor Floor Cover Cup Holder Push Rivet Screws Torque to 5 ft-lbs (7 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.6 © Copyright TAYLOR-DUNN...
Page 321: Seat Mounting / Seat Belts
REF. DESCRIPTION NOTES Seat Back Seat Base LH Seat Belt Assm RH Seat Belt Assm Seat Base Frame Screw 24 in-lbs (3 Nm) Bolt 40 ft-lbs (54 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.7 © Copyright TAYLOR-DUNN...
Page 322: Rear Cargo Box
BODY / FRAME REAR CARGO BOX CARGO BOX - TAILGATE / BOX SUPPORT 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.8 © Copyright TAYLOR-DUNN...
Page 323 Box Tilt Shock Box Tilt Latch Heat Shield Tailgate Tube Tailgate Mount Bracket Bushing Tailgate Latch Screw Torque to 8 ft-lbs (11 Nm) Screw Torque to 5 ft-lbs (7 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.9 © Copyright TAYLOR-DUNN...
Page 324: Box Removal
Two people may be needed to remove the box from the frame. CAUTION Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.10 © Copyright TAYLOR-DUNN...
Page 325: Body Component Removal
2. Remove the three bolts from the lower portion of the bumper. 3. Remove the two fasteners from each side of the upper portion of the bumper. 4. Carefully remove the bumper from the vehicle. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.11 © Copyright TAYLOR-DUNN...
Page 326: Rear Fender
7. Remove the five push rivets from under the dash panel. Unhook all electrical components to allow the panel to be completely removed. 8. Carefully remove the dash assembly from the vehicle. WINDSHIELD Removal 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.12 © Copyright TAYLOR-DUNN...
Page 327: Roof
4. Check lower mounting brackets are properly inserted into cut-outs of dash panel. 2. Remove four M6 fasteners on rear section of roof. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.13 © Copyright TAYLOR-DUNN...
Page 328 5. Once the retaining hooks are out of their slot unit. remove the roof from the unit. 4. While holding the rear section of the roof up, slide it forward. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.14 © Copyright TAYLOR-DUNN...
Page 329 3. With the retaining hooks lined up, slide the roof towards the rear of the unit TORQUE 12–15 in. lbs. (1.35 – 1.7 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.15 © Copyright TAYLOR-DUNN...
Page 330 BODY / FRAME 6. Install the four M6 screws into the rear section of the roof. TORQUE 12–15 in. lbs. (1.35–1.7 Nm) 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.16 © Copyright TAYLOR-DUNN...
Page 331: Floors
3. Remove the seven Torx-head screws retaining the adequate clearance to remove the front floor section. center floor. 4. Remove the Torx-head screws retaining the front floor cover. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.17 © Copyright TAYLOR-DUNN...
Page 332: Decals
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 10.18 © Copyright TAYLOR-DUNN...
Page 333 FUSES / CIRCUIT BREAKER ............... . 11.20 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.1...
Page 334 ............11.30 STARTING SYSTEM TESTING FLOW CHART 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.2...
Page 335: General Information
• 12 VDC Power Point • Headlights • For resistance readings, isolate the component to be • Ignition Switch tested. Disconnect it from the wiring harness or power supply. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.3 © Copyright TAYLOR-DUNN...
Page 336: Switches / Controls
If the rear differential fails to switch from operational modes: 4. When the switch is in Turf Mode, there should be continuity between the White/Green, and Orange/ White wire terminals. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.4 © Copyright TAYLOR-DUNN...
Page 337: Ignition / Headlight Switch
• Turn the ignition key to START. There should be continuity between switch pins A and B; C and D; E and F. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.5 © Copyright TAYLOR-DUNN...
Page 338: Instrument Cluster
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.6 © Copyright TAYLOR-DUNN...
Page 339: Rider Information Display
10. TURF Indicator - Illuminated when the TURF switch is in the TURF position. 11. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.7 © Copyright TAYLOR-DUNN...
Page 340: Information Display Area
To reset the trip meter: 1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.8 © Copyright TAYLOR-DUNN...
Page 341 7. Toggle the MODE button until the odometer is displayed. 8. Press and hold the MODE button until the hour segment flashes. Release the button. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.9 © Copyright TAYLOR-DUNN...
Page 342: Diagnostic Mode
This number equates to the suspected area of fault (SPN). • The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode (FMI). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.10 © Copyright TAYLOR-DUNN...
Page 343: Instrument Cluster Pinouts
Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster. Apply pressure on the bezel while pressing down on the instrument cluster. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.11 © Copyright TAYLOR-DUNN...
Page 344: Vehicle Speed Sensor
3. Pass a screwdriver back and forth in front of the sensor tip. 4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.12 © Copyright TAYLOR-DUNN...
Page 345: Headlights
NOTE Do not touch Headlight bulb glass or premature failure will occur. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.13 © Copyright TAYLOR-DUNN...
Page 346: Headlight Housing Removal
3. Remove fasteners holding headlight housing to hood. 2. Install and tighten fasteners retaining headlight housing to hood 4. Remove headlight housing from hood. 3. install headlight bulb. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.14 © Copyright TAYLOR-DUNN...
Page 347: Tail Light / Brake Light
4. Reinstall the assembly by reversing this procedure. 5. Test after installation to verify proper function of tail, brake, and turn signal lamps. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.15 © Copyright TAYLOR-DUNN...
Page 348: Cooling System
Be sure cooling system is full and purged of air. temperature sensor and connector terminals. Refer to Chapter 2 “Maintenance” for cooling system information. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.16 © Copyright TAYLOR-DUNN...
Page 349: Ignition Coil
(+) at the Coil 0.5 Ω Test spark plug. Connection Between High Tension Secondary 7.0 k Ω ± 5% Lead Caps Test PRIMARY TEST SECONDARY TESTS 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.17 © Copyright TAYLOR-DUNN...
Page 350: Ignition Coil And Ht Lead Replacement
(if equipped). TORQUE Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 6. Connect harness connection to the ignition coil. 7. Reconnect battery cable and install the drivers seat. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.18 © Copyright TAYLOR-DUNN...
Page 351: Relays
FUSE WIRE COLOR OPERATION Red / Blue Relay coil 12v from EFI Splice High side 12v from Start Solenoid 12v output to Splice, Chassis Gray ECU controlled ground 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.19 © Copyright TAYLOR-DUNN...
Page 352: Fuses / Circuit Breaker
EFI system, main harness, lights and accessories. FUSE SIZE FEATURE SUPPORTED Brake Light 10 A Drive System, Fuel Pump 20 A EFI, Lights, Accessories 20 A Circuit Breaker 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.20 © Copyright TAYLOR-DUNN...
Page 353: Charging System
With lights on, charging should occur at or below 2000 RPM. CHARGING SYSTEM ALTERNATOR TESTS Three tests can be performed using a multimeter to determine the condition of the stator (alternator). 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.21 © Copyright TAYLOR-DUNN...
Page 354 21 VAC ± 25 % legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 3000 49 VAC ± 25 % 5000 80 VAC ± 25 % 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.22 © Copyright TAYLOR-DUNN...
Page 355: Charging System Testing Flow Chart
CHART Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.23 © Copyright TAYLOR-DUNN...
Page 356: Battery Service
State of California to NOTICE cause cancer and birth defects or other reproductive Never activate a battery on the vehicle. Electrolyte harm. WASH HANDS AFTER HANDLING. spillage can cause damage. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.24 © Copyright TAYLOR-DUNN...
Page 357: Battery Inspection
5. Check the vent tube. Make sure it’s not kinked, pinched or otherwise obstructed. BATTERY REMOVAL / INSTALLATION See Chapter 2 “Maintenance” for battery service procedures. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.25 © Copyright TAYLOR-DUNN...
Page 358: Conventional Battery Testing
SPECIFIC GRAVITY 25% Charged 12.0 V State of Charge* YuMicron™ Type 0% Charged 11.9 V or less 100% Charged 1.275 75% Charged 1.225 50% Charged 1.175 25% Charged 1.135 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.26 © Copyright TAYLOR-DUNN...
Page 359: Load Test
Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.27 © Copyright TAYLOR-DUNN...
Page 360: Starter System
7042039). Use either of the following methods to remove lock ring in its groove. and install a new garter spring. Premium Starter Drive Grease PN 2871460 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.28 © Copyright TAYLOR-DUNN...
Page 361: Starter Solenoid Bench Test
12V power via the White / Red wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.29 © Copyright TAYLOR-DUNN...
Page 362: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual 11.30 © Copyright TAYLOR-DUNN...

Taylor-Dunn G0-010-00 Service And Replacement Parts Manual

General Information 1 Chapter 1 General Information

Maintenance Chapter 2 Maintenance 2

Engine / Cooling System Chapter 3 Engine / Cooling System

Fuel System Chapter 4 Fuel System

Cvt System Chapter 5 Cvt System

Quick Links

Chapters

Troubleshooting

Related Manuals for Taylor-Dunn G0-010-00

Summary of Contents for Taylor-Dunn G0-010-00