Taylor-Dunn G-100 2018 User manual

G-100
Owner’s Manual
2018

WARNING
Read, understand, and follow all of the instructions and
safety precautions in this manual and on all product labels.
Failure to follow the safety precautions could result in
serious injury or death.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
For videos and more information about a safe
riding experience with your Polaris vehicle, scan
this QR code with your smartphone.

Owner’s Manual
G–100

POLARIS® and TAYLOR-DUNN® are trademarks of POLARIS Industries Inc.
Copyright 2017 Polaris Industries Inc. 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. Depictions
and/or procedures in this publication are intended for reference use only. No
liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or
in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are
provided as translations of the original instructions.
Printed in U.S.A.
2018 Taylor-Dunn® G-100 Owner’s Manual
9928677

Introduction . . . . . . . . . . . . . . . . . . . . 5
Safety.......................9
Features and Controls . . . . . . . . . . . . . . 23
Operation . . . . . . . . . . . . . . . . . . . . 39
Emission Control Systems . . . . . . . . . . . . . 53
Maintenance . . . . . . . . . . . . . . . . . . 55
Specifications . . . . . . . . . . . . . . . . . . 89
Troubleshooting . . . . . . . . . . . . . . . . . 91
Warranty . . . . . . . . . . . . . . . . . . . . 95
Maintenance Log . . . . . . . . . . . . . . . . 103
3

4

INTRODUCTION
This Taylor-Dunn vehicle is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
WARNING
WARNING indicates a hazardous situation that, if not avoided, may result in
death to the operator, bystanders or person(s) inspecting or servicing the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in
minor personal injury or damage to the vehicle.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
The Prohibition Safety Sign indicates an action NOT to
take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that
NEEDS to be taken to avoid a hazard.
5
INTRODUCTION

WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your Taylor-Dunn® vehicle is not a toy and
can be hazardous to operate. This vehicle handles differently than cars, trucks
or other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your local
dealer. Understand all safety warnings, precautions and operating procedures
before operating the vehicle. Keep this manual with the vehicle.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and
have a valid driver’s license to operate this vehicle.
• All operators should take a training course.
• No person under the age of 12 may ride as a passenger in this vehicle. All
riders must be able to sit with backs against the seat, both feet flat on the floor
and both hands on the steering wheel (if driving) or on a passenger hand
hold.
• Never permit a guest to operate this vehicle unless the guest has reviewed
the owner’s manual and all safety labels and has completed a safety training
• Always keep hands, feet and all other body parts inside the vehicle at all
times.
• Always wear the proper clothing when operating or riding in this vehicle. All
riders should wear substantial footwear, long pants and a close-fitting shirt. A
hard hat or helmet and approved eye protection are recommended when
appropriate for working or riding conditions.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
6
INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers and key number in the spaces
provided. Remove the spare key and store it in a safe place. An ignition key can
be duplicated only by ordering a Taylor-Dunn key blank (using your key number)
and mating it with one of your existing keys. The ignition switch must be
replaced if all keys are lost.
qVehicle Identification Number
(VIN)
wEngine Serial Number
Vehicle Model Number:
Vehicle Identification Number (VIN):
Engine Serial Number:
Key Number
7
INTRODUCTION

8

SAFETY
SAFETY TRAINING
Safety training is a top priority for Taylor-Dunn. All operators of this vehicle
should take a ROHVA approved training course.
ROHVA (Recreational Off-Highway Vehicle Association) provides both an online
safety e-course and a hands-on safety course. Visit www.rohva.org.
Your Taylor-Dunn vehicle is considered an off-road vehicle. Familiarize yourself
with all laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance program
is designed to ensure that all critical components on your vehicle are thoroughly
inspected at specific intervals.
For more information about recreational off-road vehicle safety in the
United States, visit www.rohva.org, call 866-267-2751.
SAFE RIDING GEAR
Always wear the proper clothing when operating or riding in this vehicle. All
riders should wear substantial footwear, long pants and a close-fitting shirt. A
hard hat or helmet and approved eye protection are recommended when
appropriate for working or riding conditions. Taylor-Dunn recommends wearing
approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE.
Never operate or ride in this vehicle while barefoot or while wearing sandals or
tennis shoes.
Workplace safety regulations may require the use of safety glasses, safety
shoes and a hard hat or helmet. Familiarize yourself with local requirements, be
prepared for operating conditions and wear the appropriate safety gear.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust
system can elevate temperatures in the driver and passenger cab area. The
condition occurs most frequently when a vehicle is being operated in high
ambient temperatures at low speeds and/ or high load conditions for an
extended period of time. The use of certain windshield, roof and/or cab systems
may contribute to this condition by restricting airflow. Any discomfort due to heat
buildup in this area can be minimized by wearing proper riding apparel and by
varying speeds to increase airflow.
9
SAFETY

SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions of the labels on the vehicle carefully. If any of the labels
depicted in this manual differ from the labels on your vehicle, always read and
follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your
Taylor-Dunn dealer to purchase a replacement. Replacement safety labels are
provided by Taylor-Dunn at no charge. The part number is printed on the label.
qSeat Belt / Driver Warning eProper Use Warning
wShift Caution rMax Payload Warning
SHIFT CAUTION
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle.
APPLY BRAKE TO START. When this vehicle is not in operation, or unattended,
place shift in the park position.
10
SAFETY

SEAT BELT/DRIVE RESPONSIBLY WARNING
WARNING
Be Prepared
• Fasten seat belts.
• Wear an approved helmet and protective gear.
• ALWAYS use vehicle cab nets and/or doors if equipped.
• Each rider must be able to sit with back against seat, feet flat on the floor, and
hands on steering wheel or handholds. Stay completely inside the vehicle.
Drive Responsibly Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding, skidding, or fishtailing, and never
do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even from a stop.
• Plan for hills, rough terrain, ruts, and other changes in traction and terrain.
Avoid paved surfaces.
• Avoid side hilling (riding across slopes).
Be Sure Riders Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk to injury:
• Keep a firm grip on the steering wheel or handholds and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
Rollovers have caused severe injuries and death, even on flat, open areas.
PROPER USE WARNING
WARNING
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway
vehicle access) - collisions with cars and trucks can occur.
• Do not exceed seating capacity: 2 occupants.
Driving on public roads may be hazardous and could be a violation of the law.
11
SAFETY

PASSENGER/TIRE PRESSURE WARNING
The Passenger/Tire Pressure Warning qis located in the cargo box.
WARNING
• Passengers can be thrown off. This can cause serious injury or death.
• Never carry passengers in cargo box.
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
• Reduce speed and allow greater
distance for braking when carrying
cargo.
• Overloading or carrying tall, off-
center, or unsecured loads will
increase your risk of losing control.
Loads should be centered and
carried as low as possible in box.
• For stability on rough or hilly terrain,
reduce speed and cargo.
• Be careful if load extends over the
side of the box.
MAXIMUM CARGO BOX LOAD 500 lbs. (226 kg)
TIRE PRESSURE IN PSI (KPa) FRONT 10 (69)
REAR 10 (69)
MAXIMUM WEIGHT CAPACITY INCLUDES
WEIGHT OF OPERATOR, PASSENGER,
CARGO AND ACCESSORIES
1000 lbs. (454 kg)
Read Operation & Maintenance Manual for more detailed loading information.
FUEL TRANSPORT WARNING
The Fuel Transport Warning qis
located in the cargo box.
WARNING
NEVER carry fuel or other flammable
liquids on this vehicle. Failure to follow
this instruction could lead to serious
burn injuries or death.
12
SAFETY

CLUTCH COVER WARNING
WARNING
The Clutch Cover Warning qis
located on the clutch cover.
• Moving parts hazard under belt-
clutch guard. To prevent serious
injury, do not operate vehicle with
guard removed.
• Do not modify engine or clutch.
Doing so can cause part failure,
possible imbalance, and excessive
engine RPM which can result in
serious injury or death.
SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
OPERATOR SAFETY
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.
• Read this entire manual and all labels carefully. Follow the operating
procedures described.
• Never allow anyone under the age of 16 to operate this vehicle and never
allow anyone without a valid driver's license to operate this vehicle.
• Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
• All riders must be able to sit with backs against the seat, both feet flat on the
floor and both hands on the steering wheel (if driving) or on a passenger hand
hold.
• All riders should wear substantial footwear, long pants and a close-fitting shirt.
A hard hat or helmet and approved eye protection are recommended when
appropriate for working or riding conditions. Seat belt must be worn at all
times.
• Always keep hands and feet inside the vehicle at all times.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
13
SAFETY

• To reduce rollover risk, be especially careful when encountering obstacles
and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads (unless
marked for off-road use).
• Never consume alcohol or drugs before or while operating this vehicle.
• Never operate at excessive speeds. Always travel at a speed proper for the
terrain, visibility and operating conditions, and your experience.
• Never attempt jumps or other stunts.
• Always inspect the vehicle before each use to make sure it's in safe operating
condition.
• Always follow the inspection procedures described in this manual.
• Always travel slowly and use extra caution when operating on unfamiliar
terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning. Practice turning at slow speeds
before attempting to turn at faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized Taylor-Dunn dealer if it
has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your abilities.
Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in this manual.
Check the terrain carefully before attempting to climb a hill. Never climb hills
with excessively slippery or loose surfaces. Never apply throttle suddenly.
Never make sudden gear changes. Never go over the top of a hill at high
speed.
• Always follow the proper procedures outlined in this manual for traveling
downhill and for braking on hills. Check the terrain carefully before
descending a hill. Never travel downhill at high speed. Avoid going downhill at
an angle, which would cause the vehicle to lean sharply to one side. Travel
straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles such as large rocks or fallen trees. Always follow
the proper procedures outlined in this manual when operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as ice,
travel slowly and exercise caution to reduce the chance of skidding or sliding
out of control.
• Never operate your vehicle in fast-flowing water or in water deeper than that
specified in this manual. Wet brakes may have reduced stopping ability. Test
your brakes after leaving water. If necessary, apply them lightly several times
to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle when
operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid
turning at sharp angles in reverse.
• Always use the proper size and type of tires specified in this manual. Always
maintain proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of non-Taylor-
Dunn approved accessories.
14
SAFETY

• Never exceed the stated load capacity for this vehicle. Cargo should be
properly distributed and securely attached. Reduce speed and follow the
instructions in this manual for hauling cargo or pulling a trailer. Allow a greater
distance for braking.
• Always place the transmission in PARK before getting out of the vehicle.
• Always stop the engine before refueling. Make sure the refueling area is well
ventilated and free of any source of flame or sparks. Gasoline is extremely
flammable.
• Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use by someone under the age of 16 or without a driver’s
license and proper training, or accidental starting.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction
increases the risk of an accident. The operator must
understand how to operate the vehicle properly in
different situations and on different types of terrain.
Review the Operator Driving Procedures outlined on
page 44.
All operators must read and understand the owner's
manual and all warning and instruction labels before
operating the vehicle. Never allow a guest to
operate this vehicle until the guest has reviewed the
Operator Driving Procedures outlined on page 44.
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years of
age or anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and both
hands on the steering wheel.
15
SAFETY

USING ALCOHOL OR DRUGS
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
FAILURE TO INSPECT BEFORE OPERATING
Failure to inspect and verify that the vehicle is in safe operating condition before
operating increases the risk of an accident. Always perform the pre-ride
inspection before each use of your vehicle to make sure it's in safe operating
condition. Always follow the inspection and maintenance procedures and
schedules described in this owner’s manual.
SEAT BELTS
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances.
The operator MUST wear the seat belt at all times.
CARRYING A PASSENGER
The G-100 is a 2-seat vehicle. A passenger must always be seated in the
passenger seat with seat belt secured. Never carry more than two passengers in
a 2-seat vehicle. Carrying a passenger in the cargo box could result in a fall from
the vehicle or contact with moving components. Never carry a passenger in the
cargo box of this vehicle.
OPERATING WITH A LOAD ON THE VEHICLE
The weight of both cargo and operator impacts vehicle operation and stability.
For your safety and the safety of others, carefully consider how your vehicle is
loaded and how to safely operate the vehicle. Follow the instructions in this
manual for loading, tire pressure, gear selection and speed.
•Do not exceed vehicle weight capacities.The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When determining the weight you are adding to the vehicle,
include the weight of the operator, accessories, loads in the rack or box and
the load on the trailer tongue. The combined weight of these items must not
exceed the maximum weight capacity.
• The recommended tire pressures are listed in the specifications section of this
manual and on a label on the vehicle.
16
SAFETY

Always follow these guidelines:
UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:
Operator and/or cargo exceeds half the
maximum weight capacity
1. Slow down.
2. Verify tire pressure.
3. Use extra caution when operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing
IMPROPER TIRE MAINTENANCE
Operating this vehicle with improper tires or with improper or uneven tire
pressure could cause loss of control or accident. Always use the size and type of
tires specified for your vehicle. Always maintain proper tire pressure as
described in the owner's manual and on safety labels.
OPERATING ON PUBLIC ROADS
Operating this vehicle on public streets, roads or highways could result in a
collision with another vehicle. Never operate this vehicle on any public street,
road or highway, including dirt and gravel roads (unless designated for off-
highway use).
OPERATING AT EXCESSIVE SPEEDS
Operating this vehicle at excessive speeds increases the operator's risk of
losing control. Always operate at a speed that's appropriate for the terrain, the
visibility and operating conditions and your skills and experience.
JUMPS AND STUNTS
Exhibition driving increases the risk of an accident or rollover. DO NOT do power
slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.
TURNING IMPROPERLY
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this owner’s
manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
17
SAFETY

IMPROPER HILL CLIMBING
Improper hill climbing could cause loss of control or rollover. Use extreme
caution when operating on hills. Always follow proper procedures for hill climbing
as described in this owner's manual.
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of control or rollover. Always
follow proper procedures for traveling down hills as described in this owner’s
manual.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or rollover. Avoid crossing the side of any hill unless absolutely
necessary. If crossing a hillside is unavoidable, always follow proper procedures
as described in this owner's manual.
STALLING WHILE CLIMBING A HILL
Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain
a steady speed when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is fully stopped. Place the
transmission in reverse and slowly allow the vehicle to roll straight downhill while
applying light brake pressure to control speed.
If you begin rolling downhill:
Never apply engine power. Apply the brakes gradually until the vehicle is fully
stopped. Place the transmission in reverse and slowly allow the vehicle to roll
straight downhill while applying light brake pressure to control speed.
OPERATING IN UNFAMILIAR TERRAIN
Failure to use extra caution when operating on unfamiliar terrain could result in
an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause
loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always
be alert to changing terrain conditions.
OPERATING IMPROPERLY IN REVERSE
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
Before shifting into reverse gear, always check for obstacles or people behind
the vehicle. When it's safe to proceed, back slowly.
18
SAFETY