Taylor-Dunn G0-010-00 Manual

The Best Way
To Go
About Your
Business
TAYLOR-DUNN
®
Originally Published [10/23/2018]
Revision [ ], contents subject to change
without notice Taylor-Dunn®Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
[phone]
(FAX) [phone]
Visit our Web site: www.taylor-dunn.com
READTHEOPERATOR’SMANUALBEFOREOPERATING
THIS VEHICLE.
Theoperator’smanualcontainsimportant information
regarding the safe operation of this vehicle.
WARNING
Service Manual
MANUAL #:
2019 G-100
Model Numbers:
G0-010-00
9929758
10/23/2018

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.
This manual is designed primarily for use by authorized Taylor-Dunn® service technicians in a
properly equipped shop and should be kept available for reference. All references to left and right
side of the vehicle are from the operator’s perspective when seated in a normal riding position.
The service personnel are responsible for the service and maintenance of the vehicle. At no
time shall a service person allow any untrained personnel to service or repair this or any Taylor-
Dunn® vehicle. For the purposes of training, a qualied service person may oversee the repairs
or services being made to a vehicle by an individual in training. At no time shall an untrained
individual be allowed to service or repair a vehicle without supervision. This manual is not a
training guide.
Personnel performing service and repair shall have knowledge of:
• Basicstandardautomotiverepairprocedures
• Operationofinternalcombustionengines
• BasicDCelectricaltheory
• Useofdigitalandanalogmulti-meters
• Leadacidbatteries
Technicians should read the text and be familiar with the service procedures before starting any
repair. Certain procedures require the use of special tools. Use only the proper tools as specied.
Contact an authorized Taylor-Dunn® service technician if you have any doubt as to your ability
to perform any of the procedures outlined in this manual.
We appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Use the Contact form at www.
taylor-dunn.com to submit your information. Please include the part number of this manual along
with the revision number. Alternatively, you can submit your information in writing to:
Taylor-DunnManufacturing
AttnTechWriter
2114W.BallRoad
Anaheim,CA92804

© 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. 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. Printed in U.S.A.
2019 TAYLOR-DUNN G-100
Service Manual

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.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

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
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL

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
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor

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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE INFORMATION................................................................................1.2
MODEL NUMBER DESIGNATION .....................................................................1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION............................................1.2
VIN / ENGINE NUMBER LOCATION ...................................................................1.2
REFERENCEINFORMATION...........................................................................1.3
REPLACEMENT KEYS ................................................................................1.3
SPECIAL TOOLS ......................................................................................1.4
MASTER SPECIAL TOOLS TABLE ....................................................................1.5
GENERAL SPECIFICATIONS ..........................................................................1.12
TAYLOR-DUNN G-100................................................................................1.12
CLUTCHING CHART .................................................................................1.13
MISC. SPECIFICATIONS AND CHARTS . . . . . . . .. . .. ... ......................... .. . . .. . ...............1.14
CONVERSION TABLE ................................................................................1.14
SAE TAP / DRILL SIZES ..............................................................................1.15
METRIC TAP / DRILL SIZES ..........................................................................1.16
DECIMAL EQUIVALENTS ............................................................................1.17

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VEHICLE INFORMATION
MODEL NUMBER DESIGNATION
Example: R17RMA50A1
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 7 R M A 5 0 A 1
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN)
DESIGNATION
Example: 4XARUE573FG000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CHASSIS
DRIVELINE
CHASSIS
MODIFIER
ENGINE SIZE
ENGINE MODIFIER
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A R U E 5 7 3 F G 0 0 0 0 0 0
* 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.
The VIN qcan be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
The engine model and serial number wcan be found on a decal applied to the engine’s magneto cover.
GENERAL INFORMATION

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REFERENCE INFORMATION
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
GENERAL INFORMATION
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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.
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com
GENERAL INFORMATION

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MASTER SPECIAL TOOLS TABLE
ENGINE / COOLING SYSTEM
GENERAL
Bench Mount Engine Stand Adapter
PW-47053
PU-50624
Rolling Engine Stand Engine Stand Adapter
(Mounts To The Engine)
PU-50824-A
Engine Stand Sleeve Adapter
(Use With 2” Bore Stand)
PU-50625
Engine Stand Sleeve Adapter
(Use With 2.375” Bore Stand)
PW-47054
Flywheel Puller
PA-49316
Stator Cover Removal Handles
PA-49317 Valve Spring Compressor PV-1253 Water Pump Seal Installation Tool PU-50869
GENERAL INFORMATION
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ENGINE / COOLING SYSTEM
GENERAL
Crankshaft Removal / Installation
Tool Kit
PU-50784
Oil Filter Wrench
PU-50105 Oil Pressure Gauge PV-43531
Oil Pressure Gauge Adapter
PU-50569 Valve Spring Compressor Adapter PV-43513-A
GENERAL INFORMATION

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FUEL SYSTEM
Digital Wrench Kit
PU-47063-C Digital Wrench Smart
Link Module Kit
PU-47471
(Includes: PU-47470, PU-47469,
PU-47468)
*Serial Number Registration Card
PU-48731-A
*Digital Wrench® PC Interface Cable
PU-47470 *Digital Wrench® Vehicle
Interface Cable
PU-47469
*Digital Wrench® SmartLink Module
PU-47468
Digital Wrench® Wireless
Vehicle Link
PU-51435
Fuel Pressure Gauge Kit
PU-43506-A Fuel Pressure Gauge Adapter PV-48656
GENERAL INFORMATION
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FUEL SYSTEM
Fuel Pressure Gauge Adapter
PS-48762
Fluke 77 Digital Multi-Meter
(Fluke 77: PV-43568) Throttle Position Sensor Tester Kit
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)
GENERAL INFORMATION

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CVT SYSTEM
Clutch Bushing Replacement
Tool Kit
2871226
Drive Clutch Puller - Short
PA-48595 Drive Clutch Holding Tool 9314177-A
Drive Clutch Spider Removal
and Install Tool
2870341
Piston Pin Puller
2870386 Roller Pin Tool 2870910-A
Universal Clutch Compressor Tool
PU-50518-A Standard Clutch Alignment Tool 2870654 Clutch Center Distance Tool PU-50658-A
GENERAL INFORMATION
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TRANSMISSION
Bearing Seal Driver (50 mm)
2871282 Backlash Setting Tool
2871695 (Part of 2871702 Kit) Rear Driveshaft Seal Guide 2871699 (Part of 2871702 Kit)
Rear Output Seal Driver
2871698 (Part of 2871702 Kit) Snorkel Tool PA-50231 Transmission Nut Socket PU-50566
FINAL DRIVE
1 3/4” Straight Wrench
2870772 CV Boot Clamp Pliers
8700226 or PU-48951
Roller Pin Removal Tool
2872608
STEERING / SUSPENSION
Ball Joint Removal / Installation Tool
2870871 Strut Compression Tools
2871573, 2871574 Shock Absorber Spring Compression Tool
2870623
GENERAL INFORMATION

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BRAKES BODY / FRAME
Mity Vac® Pressure Test Tool
2870975
Multi-Function Pliers
2876389
ELECTRICAL
Battery Conductance Analyzer
PU-50296
Battery Hydrometer
PU-50338 Fluke® 77 Digital Multimeter
PV-43568
Hall Sensor Probe Harness
2460761 Static Timing Light Harness 2871745
Timing Light
2870630
Relay Bypass
PU-49466 Connector Test Kit
PV-43526
GENERAL INFORMATION
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GENERAL SPECIFICATIONS
TAYLOR-DUNN G-100
MODEL NUMBERS: R18RM250B1,R19RM250B1
CATEGORY DIMENSION /
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
Height 73″ / 185 cm
Wheel Base 73″ / 185 cm
Ground Clearance 10″ / 25.4 cm
Turning Radius 150″ / 381 cm
Dry Weight 1098 lbs. / 498 kg
Cargo Box Capacity 500 lbs. / 227 kg
Cargo Box Dimensions
(inside dimensions) L- 42″ x W-32″ x H-11.5″
(107 x 81 x 29 cm)
Vehicle Payload
1000 lbs. / 454 kg
(Includes weight of
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4kg
Hitch Tongue Capacity 150 lbs. / 68 kg
GENERAL INFORMATION

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Model Specifications
ENGINE
Platform Single overhead cam, 2 valve
4 stroke single cylinder.
Engine Displacement 500cc
Bore & Stroke 93 mm x 73.6 mm
Compression Ratio 10:1
Engine Idle Speed 1250 ±200 RPM
Engine Max Speed 7000 RPM
Valve Clearance (Intake) 0.006 ± 0.002" (0.152 ± 0.051
mm)
Valve Clearance (Exhaust) 0.010 ± 0.002" (0.254 ± 0.051
mm)
Oil Requirements PS4 synthetic
Oil Capacity 2.0 qts. (1.9 l)
Coolant Capacity 120 Oz (3.5 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-
tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity / Requirement 8.8 gal. (33.3 L) 87 Octane
(minimum)
ELECTRICAL
Alternator Max Output 560 W @ 3000 RPM
Headlights 2 single beam
55W quartz/halogen
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt
Indicator Light 1.0 W
Ignition Timing ECU Controlled
Spark Plug / Gap Autolite 5923 / 0.030” - 0.037”
(0.85 +/- 0.08 mm)
Battery / Amp Hr Yuasa Conventional 14 Amp
Hr / 12 Volt
DC Outlet Standard 12 Volt
Relays EFI / Chassis / Fan / Fuel
Pump / Headlight
Circuit Breaker Fan Motor: 20 Amp
Fuses Brake Light: 5 Amp
EFI: 20 Amp
Fuel Pump: 10 Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN
Transmission Type Automatic CVT
Shift Type In Line Shift - P/ H / L / N / R
Transmission Lubricant
Requirement Full Synthetic AGL 33.8 oz. (1000 ml)
STEERING / SUSPENSION
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Front Suspension Strut / A-arm
Front Travel 9″ (20.3 cm)
Rear Suspension Independent (IRS), Dual A-
arm, Anti-Sway Bar
Rear Travel 10″ (22.9 cm)
Spring Adjustment Cam adjustment (rear)
WHEELS / BRAKES
Front Wheel Size / Type 12 x 8 / Steel
Rear Wheel Size / Type 12 x 9 / Steel
Front Tire Model / Size AT489 / 24 x 8 - 12
Rear Tire Model / Size AT489 / 24 x 9 - 12
Tire Air Pressure Front: 10 psi (69 kPa)
Rear: 10 psi (69 kPa)
Brake System 4 Wheel Hydraulic Disc
Brake Fluid DOT 4
Parking Brake Transmission - Park Lock
CLUTCHING CHART
TAYLOR-DUNN G-100
ALTITUDE SHIFT
WEIGHT
DRIVE
SPRING
Meters
(Feet)
0-1800
(0-6000) 10 RHF (5632282)
Red /
Orange
(7044321)
1800-3700
(6000 - 12000) 10-40 (5633331)
Red /
Orange
(7044321)
GENERAL INFORMATION
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MISC. SPECIFICATIONS AND CHARTS
CONVERSION TABLE
UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
ft-lbs x 12 = in-lbs
in-lbs x 0.0833 = ft-lbs
ft-lbs x 1.356 = Nm
in-lbs x 0.0115 = kg-m
Nm x 0.7376 = ft-lbs
kg-m x 7.233 = ft-lbs
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm
inch x 25.4 = mm
mm x 0.03937 = inch
inch x 2.54 = cm
mile (mi) x 1.6 = km
km x 0.6214 = mile
ounces (oz) x 28.35 = grams (g)
fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)
cubic centimeters (cc) x .03381 = fluid ounces
grams (g) x 0.035 = ounces
pounds (lb) x 0.454 = kg
kilogram (kg) x 2.2046 = lbs
cubic inches (cu in) x 16.387 = cc
cubic centimeters (cc) x 0.061 = cubic inches
US quarts x 0.946 = liters (L)
liters (L) x 1.057 = US quarts
US gallons x 3.785 = liters (L)
liters (L) x 0.264 = US gallons
PSI x 6.895 = kilopascals (kPa)
kilopascals (kPa) x 0.145 PSI
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
GENERAL INFORMATION