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Taylor-Dunn G-100 2018, Owner'S Manual, Page: 59 / 111

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Taylor-Dunn G-100 2018 Owner'S Manual Download Page 59

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

REMARKS

HOUR-

S

CALEN-

DAR

MILES

(KM)

Frame fasteners

-

Pre-Ride

-

Engine Oil Level

-

Pre-Ride

-

XU
E

Air filter, pre-filter

-

Daily

-

Inspect; clean often; replace as
needed

Coolant

-

Daily

-

Check level

Head lamp / tail
lamp / worklight

-

Daily

-

Check operation; apply dielectric
grease to electrical connections if
replacing lamps

XU

E

Air filter

-

Weekly

-

Inspect; replace as needed

XU
D

Brake pad wear

10 H

Monthly

-

Inspect periodically

Battery

20 H

Monthly

-

Check terminals; clean; test

Fuel System

25 H

Monthly

-

Inspect; Cycle the Key to
pressurize the fuel pump; check
lines and fittings for leaks and
abrasion.

XU

Front Gearcase oil

25 H

Monthly

-

Perform a break-in oil level check

XU

Transmission fluid

25 H

Monthly

-

Perform a break-in oil level check

XU

Engine oil change
(break-in)

25 H

Monthly

-

Perform a break-in oil change at
one month

XU

General lubrication

50 H

3 M

-

Lubricate all grease fittings, pivots,
cables, etc.

Shift Linkage

50 H

6 M

-

Inspect, lubricate, adjust

D

Steering

50 H

6 M

-

Lubricate

XU

Front Suspension

50 H

6 M

-

Lubricate

XU

Rear Suspension

50 H

6 M

-

Lubricate

D
E

Throttle Pedal

50 H

6 M

500

(800)

Inspect; adjust; lubricate; replace if
necessary

E

Air intake ducts/
flange

50 H

6 M

500

(800)

Inspect ducts for proper sealing/air
leaks

Drive belt

50 H

6 M

500

(800)

XU

Cooling system

50 H

6 M

-

Inspect coolant strength
seasonally; pressure test system
yearly

XU

Engine oil and filter
change

100 H

6 M

1000

(1600)

Change oil and filter; (perform a
break-in oil change at one month)

57

MAINTENANCE

Summary of Contents for G-100 2018

Page 1: ...G 100 Owner s Manual 2018 ...

Page 2: ...he 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 ...

Page 3: ...Owner s Manual G 100 ...

Page 4: ...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 Eng...

Page 5: ...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 ...

Page 6: ...4 ...

Page 7: ...ath 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 ...

Page 8: ...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 ha...

Page 9: ...ce 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 q Vehicle Identification Number VIN w Engine Serial Number Vehicle Model Number Vehicle Identification Number VIN Engine Serial Number Key Number 7 INTRODUCTION ...

Page 10: ...8 ...

Page 11: ...ear 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 us...

Page 12: ...nformational 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 q Seat Belt Driver Warning e Proper Use Warning w Shift Caution r Max Payload Warning SHIFT CAUTION CAUTION To avoid transmission damage shift only when vehicle is stationary...

Page 13: ...ding 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 o...

Page 14: ...g 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...

Page 15: ... 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 agai...

Page 16: ...vely 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 t...

Page 17: ...idental 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 instructi...

Page 18: ...nger 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 a...

Page 19: ...r 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 JUM...

Page 20: ... 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...

Page 21: ...water or in water that exceeds the floor level of the vehicle Always follow proper procedures for operating in water as described in this owner s manual Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if...

Page 22: ... Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system EXPOSURE TO EXHAUST Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the eng...

Page 23: ...eeds higher than those for which it is designed Loss of control may occur at higher speeds Do not install any non Taylor Dunn approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non Taylor Dunn approved accessories could create a substantial safety hazard and increase the risk of bodily injury The Taylor Dunn limited warranty o...

Page 24: ...22 ...

Page 25: ...TROLS COMPONENT LOCATIONS q ROPS Frame u Cargo Box w Hip Bars i Fuel Cap e Front Bumper Brush Guard o Muffler r Headlights a Cargo Box Release Lever t Radiator s Electric Compartment y Tailgate 23 FEATURES AND CONTROLS ...

Page 26: ...itch r Gear Selector Shifter o Storage Tray t Turf Mode Switch a Storage Compartment AUXILIARY OUTLET The vehicle is equipped with a 12 volt accessory outlet on the dash Use the outlet to power an auxiliary light or other optional accessories or lights For service the dash outlet connection is under the dash 24 FEATURES AND CONTROLS ...

Page 27: ... Electrical circuits are on Electrical equipment can be used Lights Off Lights are off Electrical circuits are on Electrical equipment can be used Start Turn the key to the START position to engage the electric starter Turn the key to the LIGHTS ON position after starting the engine STANDARD TURF SWITCH IF EQUIPPED The standard Turf switch has two positions Differential Unlock 1WD Turf Mode Differ...

Page 28: ...Gear N Neutral R Reverse P Park Low gear is the primary driving range for the G 100 High gear is intended for use on hard packed surfaces with light loads Whenever the vehicle is left unattended always place the transmission in PARK TIP Maintaining shift linkage adjustment is important to assure proper transmission function Your Taylor Dunn dealer can assist in resolving any shifting problems 26 F...

Page 29: ...in or over obstacles Loading the vehicle onto a trailer Towing heavy loads STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Always make sure the steering wheel position does not impede proper...

Page 30: ...dal travel THROTTLE PEDAL Push the throttle pedal w down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open...

Page 31: ...ll be limited to 15 MPH 24 km h if the seat belt is not secured The center of the seat is NOTequipped with a seat belt Never allow a passenger to ride between the operator and passenger seats WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the vehicle To wear the seat belt properly follow this procedu...

Page 32: ...uts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents Rinse the entire length of the belt webbing Use a garden hose to flush out the retractor and...

Page 33: ...rating in a manner that could result in vehicle rollover EXTREME USE 30 AH BATTERY If your factory installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories you may need to purchase a 30 AH battery and a battery strap bracket Your Taylor Dunn dealer can assist Your dealer can provide any installation procedures that may differ for an ex...

Page 34: ...INSTRUMENT CLUSTER q Speedometer w Indicator Lamps e Mode Button r Rider Information Center 32 FEATURES AND CONTROLS ...

Page 35: ...he EPS system is inoperative Your dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Seat Belt This lamp is a reminder to the operator to ensure all riders are wearing their seat belts before operating The driver s seat belt is equipped with a sea...

Page 36: ...l icon will flash Refuel immediately e Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval r Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied ...

Page 37: ...o the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings CLOCK MODE TIP The clock must be reset any time the b...

Page 38: ...ogs the total hours the engine has been in operation TACHOMETER MODE The engine RPM is displayed digitally TIP Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation PROGRAMMABLE SERVICE INTERVAL When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine...

Page 39: ...ys only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until...

Page 40: ...38 ...

Page 41: ... hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first 3 hours of use ENGINE AND DRIVETRAIN BREAK IN 1 Fill the fuel tank with gasoline Always exercise extreme caution whenever handling gasoline 2 Check the oil level Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Compl...

Page 42: ...fe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition ITEM REMARKS PAGE Brake system pedal travel Ensure proper operation page 28 page 72 Brake fluid Ensure proper level page 72 Front suspension Inspect lubricate if necessary page 59 Rear suspension Inspect lubricate if necessary page 59 St...

Page 43: ...blic street road or highway including dirt and gravel roads unless designated for off highway use 7 Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 8 Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your skills and e...

Page 44: ...e and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely STARTING THE ENGINE 1 Position the vehicle on a level surface outdoors or in a well ventilated area 2 Sit in the driver s seat and fasten the seat belt Secure th...

Page 45: ... stopping the engine BRAKING 1 Release the throttle pedal completely When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine braking 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls TIP If the throttle pedal and brake pedal are applied simultaneously engine power...

Page 46: ...ping turning maneuvering using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed WARNING Operating in TURF mode if equipped when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the grou...

Page 47: ...ir seat belt 5 Make sure all cab nets or doors are properly secured 6 Do not carry more than the recommended number of passengers for your vehicle 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a pas...

Page 48: ...h level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly ...

Page 49: ...he other side of the hill DRIVING DOWNHILL When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down 4 Apply the brakes slightly to aid in slowing DRIVING ON A SIDEHILL SIDEHILLING Driving on a sidehill is no...

Page 50: ...ter 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your vehicle 5 Afte...

Page 51: ...ilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6 Engage the park brake if equipped 7 Remove the ignition switch key to prevent unauthorized use PARKING ON AN INCLINE Avoid pa...

Page 52: ...loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or ...

Page 53: ...elt life use low gear when hauling or towing heavy cargo TOWING LOADS WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when towing 1 Never load more than 150 lbs 68 1 kg tongue weight on the towing bracket 2 When towing a disabled vehicle place the disabled vehicle s transmission in neutral Do not operate the ve...

Page 54: ... the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 8 Stand clear and pull up on the cargo box release lever 9 Lift the front of the cargo box to dump the cargo 10 Lower the cargo box and push down...

Page 55: ...Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONTROL SYSTEM Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is locat...

Page 56: ...54 ...

Page 57: ...e for performing the scheduled maintenance identified in this owner s manual Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts g...

Page 58: ...res more often for vehicles subjected to severe use D Have an authorized dealer or other qualified person perform these services E Emission Control System Service California WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized dealer or other qualified person perform these services Perform all services...

Page 59: ... Monthly Perform a break in oil level check XU Transmission fluid 25 H Monthly Perform a break in oil level check XU Engine oil change break in 25 H Monthly Perform a break in oil change at one month XU General lubrication 50 H 3 M Lubricate all grease fittings pivots cables etc Shift Linkage 50 H 6 M Inspect lubricate adjust D Steering 50 H 6 M Lubricate XU Front Suspension 50 H 6 M Lubricate XU ...

Page 60: ...unts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect D E Spark plug 100 H 12 M 1000 1600 inspect replace as needed XU Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches 100 H 12 M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12 M Inspect replace as needed D Brake fluid 200 H 24 M Chan...

Page 61: ...tervals outlined in the Periodic Maintenance Chart Always use the recommended engine oil Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart OIL REC...

Page 62: ...on in PARK 3 Always clean away all dirt and debris from the dipstick area q before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall and tighten the dipstick 5 Remove the dipstick and check the oil level 6 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL w and ADD e marks Do not overfill 7 Reinstall and tighten the dip...

Page 63: ...llow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Reinstall the sealing washer on the drain plug TIP The sealing surfaces on drain plug...

Page 64: ... 15 Start the engine Allow it to idle for one to two minutes 16 Stop the engine Inspect for leaks 17 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 18 Dispose of used filter and oil properly TRANSMISSION MAIN GEARCASE Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart Maintai...

Page 65: ... torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use Taylor Dunn recommended spark plugs or their equivalent SPARK PLUG GAP TORQUE MODEL ELECTRODE GAP NEW OR USED PLUG TORQUE Taylor Dunn G 100 031 7 9 mm 9 ft lbs 12 Nm SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation The spark plug firing end condit...

Page 66: ...ry system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into...

Page 67: ...low through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slo...

Page 68: ...on a level surface 2 Lift the hood View the coolant level in the overflow bottle w 3 If the coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the cap and use a funnel to add coolant through the filler opening Reinstall the cap TIP If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Your...

Page 69: ...thers Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer or other qualified service person as outlined in the owner s manual Always make sure the CVT housing is securely in place during operation BELT REPLACEMENT DEBRIS REMOVAL If a belt fails always clean any debris from the cl...

Page 70: ...ck for signs of damage to seals on the transmission and engine If any seals appear to be damaged your vehicle requires prompt service Your Taylor Dunn dealer can assist TIP Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the CVTcomponent...

Page 71: ...Place the transmission in PARK 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than five 5 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 7 Test for belt slippage If the belt slips repeat the process 8 Your v...

Page 72: ...ery least to water below the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Remove the spark plugs Turn the engine over several times using the electric start 4 Dry the spark plugs and reinstall or replace with new plugs 5 Attempt to start the engine If necessary repeat the drying procedure 6 Take the vehicle in for service as soon as possible...

Page 73: ...traight upward and out of the air box 5 With the filter removed clean the intake boot and air box thoroughly and wipe well with a clean dry cloth NOTICE Dirt or debris in the intake boot could result in severe engine damage Always clean all dirt and debris from the intake boot before installing the filter 6 Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to c...

Page 74: ...on from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine several more times 6 If partic...

Page 75: ...very two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper leve...

Page 76: ...ean any grease using an approved brake cleaner or alcohol 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 0 030 0 762 mm STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on 1 Position the vehicle on level ground 2 Lightly turn the stee...

Page 77: ... second highest preload settings without a total combined payload in the vehicle of 450 lbs 204 kg or more Payload includes the driver approved accessories and cargo Never exceed the stated load capacity for this vehicle TIRES WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always...

Page 78: ...Nut Aluminum Wheels Front and Rear 30 ft lbs 41 Nm PLUS 1 4 TURN or 90 degrees 2 Piece Flange Nut Steel Wheels Front and Rear 36 ft lbs 49 Nm Hub Nut Rear 110 ft lbs 150 Nm Front 90 ft lbs 122 Nm WHEEL REMOVAL 1 Position the vehicle on a level surface 2 Place the transmission in PARK Stop the engine 3 Loosen the wheel nuts slightly 4 Elevate the side of the vehicle by placing a suitable stand unde...

Page 79: ...S If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse The fuses located in the relay fuse box under driver s seat base provide current protection for components such as the EFI system main harness lights and accessories If you suspect that a f...

Page 80: ...EPS OPT 20A LIGHTS 20A DRIVE 10A ACCESSO RY 20A 78 MAINTENANCE ...

Page 81: ...kin Allow lamps to cool before servicing To replace the headlight lamp do the following 1 Access the headlamp wiring harnesses through the front wheel wells 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp TIP Make sure the tab on the lamp locates properly in the housing 5 Reinstal...

Page 82: ... conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water ...

Page 83: ... the negative black cable first When reinstalling the battery always connect the negative black cable last To remove the battery do the following 1 Remove the seat to access the battery compartment 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Disconnect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of t...

Page 84: ...NING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 I...

Page 85: ...t important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool be...

Page 86: ... AND STORAGE WASHING THE VEHICLE Keeping your Taylor Dunn vehicle clean will not only improve its appearance but it can also extend the life of various components NOTE High water pressure may damage components Taylor Dunn recommends washing the vehicle by hand or with a garden hose using mild soap NOTE Certain products including insect repellents and chemicals will damage plastic surfaces Do not a...

Page 87: ...nd decals Electrical components and wiring Air intake components 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 Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine...

Page 88: ...t labels and instructions REMOVING CORROSION If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above STORAGE TIPS NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could o...

Page 89: ... engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the in...

Page 90: ...ng the vehicle 1 Apply the brakes 2 Place the transmission in PARK Stop the engine 3 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle Engage the park brake 4 Remove the key to prevent loss during transporting 5 Secure the fuel cap and seat Ensure that the seat is attached correctly and is not loose WARNING Cargo and other loose vehicle parts may f...

Page 91: ...0 oz 3 5 l Overall Length 110 in 279 4 cm Overall Width 58 in 147 3 cm Overall Height 73 in 185 cm Wheelbase 73 in 185 cm Cargo Box Dimensions Inside 32x42x11 5 in 81x107x29 cm Ground Clearance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacity 1500 lbs 680 4 kg Hitch Tongue Capacity 150 lbs 68 kg Max Cargo Box Load 500 lbs 227 kg Engine Single overhead cam 2 valve 4 stroke single cyli...

Page 92: ... Size 40 mm Ignition System Digital CDI Driving System Type CVT Shift Type Single Lever console Gear Reduction Low 28 84 1 Gear Reduction Reverse 25 83 1 Gear Reduction High 9 65 1 Drive Ratio Front 3 818 1 Tire Size Front 24 x 8 12 Tire Size Rear 25 x 9 12 Tire Pressure Front 10 psi 69 kPa Tire Pressure Rear 10 psi 69 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlights 2 s...

Page 93: ...n to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Belt slippage from water or snow ingestion into the CVT system Dry ...

Page 94: ... and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your Taylor Dunn dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your Taylor Dunn dealer can assist ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat ran...

Page 95: ...ug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre f...

Page 96: ...t spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your dealer can assist Ove...

Page 97: ...will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Taylor Dunn within ten days of purchase Upon receipt of this registration Taylor Dunn will record the registration for warranty No veri...

Page 98: ... other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or work...

Page 99: ...RRANTY TAYLOR DUNN SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PU...

Page 100: ...to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin ...

Page 101: ... provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increa...

Page 102: ... OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND ...

Page 103: ... person may maintain replace or repair the emission control devices or systems on your vehicle An authorized TAYLOR DUNN dealer can perform any service that may be necessary for your vehicle TAYLOR DUNN also recommends TAYLOR DUNN parts however equivalent parts may be used for such service It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer redu...

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Page 105: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 103 MAINTENANCE LOG ...

Page 106: ...104 ...

Page 107: ...rossing Hillsides 18 CVT Break in Clutches Belt 40 D Descending Hills Improperly 18 Diagnostic Display Mode 37 Display Units 35 Drive Belt Wear Burn 91 Driving Downhill 47 Driving in Reverse 49 Driving on a Sidehill 47 Driving on Slippery Surfaces 46 Driving Over Obstacles 46 Driving Through Water 48 Driving Uphill 47 Driving with a Passenger 45 Dumping the Cargo Box 52 E Electromagnetic Interfere...

Page 108: ...s 59 M Maintenance Chart Key 56 Maintenance Log 103 N New Operator Driving Procedures 44 Noise Emission Control System 53 Notice 98 O Obstacles 46 Odometer Mode 36 Oil and Filter 87 Oil and Filter Change 61 Oil Check 60 Oil Recommendations 59 Operating Improperly in Reverse 18 Operating Over Obstacles 19 Operating Through Water 19 Operating With a Load on the Vehicle 16 Operating Without Instructi...

Page 109: ...fications 89 Stabilize the Fuel 86 Stalling While Climbing a Hill 18 Standard Turf Switch 25 Starting the Engine 42 Steering Wheel 27 Steering Wheel Inspection 74 Stopping the Engine 43 Storage 86 Suspension Adjustment 75 T Tachometer Mode 36 Tire Tread Depth 76 Tires 75 Towing Loads 51 Trail Etiquette 42 Transmission 62 Transporting the Vehicle 88 Trip Meter Mode 36 Turning Improperly 17 U U S A ...

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Page 111: ...To locate your nearest dealer visit www taylor dunn com Taylor Dunn Manufacturing Company 2114 West Ball Rd Anaheim CA 92804 Part No 9928677 Rev 01 ...

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