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

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9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual

SUSPENSION PIVOT POINT LUBRICATION

Grease all four front A-Arm pivot points

and all eight

rear 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.

MAINTENANCE

Summary of Contents for G0-010-00

Page 1: ...114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Visit our Web site www taylor dunn com READ THE OPERATOR S MANUAL BEFORE OPERATING THIS VEHICLE The operator s manual contains...

Page 2: ...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 performi...

Page 3: ...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 liab...

Page 4: ...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...

Page 5: ...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 CHAPT...

Page 6: ...yogel 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 Hi...

Page 7: ...HICLE IDENTIFICATION NUMBER VIN DESIGNATION 1 2 VIN ENGINE NUMBER LOCATION 1 2 REFERENCE INFORMATION 1 3 REPLACEMENT KEYS 1 3 SPECIAL TOOLS 1 4 MASTER SPECIAL TOOLS TABLE 1 5 GENERAL SPECIFICATIONS 1...

Page 8: ...IDENTIFICATION NUMBER VIN DESIGNATION Example 4XARUE573FG000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL Y...

Page 9: ...tify 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 us...

Page 10: ...d 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...

Page 11: ...7053 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...

Page 12: ...opyright TAYLOR DUNN 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 Sp...

Page 13: ...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 SmartLin...

Page 14: ...r 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 Commerciall...

Page 15: ...71226 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 C...

Page 16: ...rt 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 P...

Page 17: ...ool 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 Tim...

Page 18: ...8 147 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 dimensio...

Page 19: ...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 Acce...

Page 20: ...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 k...

Page 21: ...10 21 32 4 40 43 3 4 16 11 16 4 48 42 7 8 9 49 64 5 40 38 7 8 14 13 16 5 44 37 1 8 7 8 6 32 36 1 12 59 64 6 40 33 1 1 8 7 63 64 8 32 29 1 1 8 12 1 3 64 8 36 29 1 1 4 7 1 7 64 10 24 24 1 1 4 12 1 11 6...

Page 22: ...7 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 11 64 5 x 90 20 0 161 5 32 6 x 1 00 9 0 196 13 64 7 x 1 00 16 64 0 234 15 64 8 x 1 00 J 0 277 9 32 8 x 1 25 17 64 0 265 17 64 9 x 1 00...

Page 23: ...5 mm 0 1969 13 64 0 2031 7 32 0 2188 15 64 0 2344 6 mm 0 2362 1 4 0 25 17 64 0 2656 7 mm 0 2756 9 32 0 2813 19 64 0 2969 5 16 0 3125 8 mm 0 3150 21 64 0 3281 11 32 0 3438 9 mm 0 3543 23 64 0 3594 3 8...

Page 24: ...45 64 0 7031 18 mm 0 7087 23 32 0 7188 47 64 0 7344 19 mm 0 7480 3 4 0 750 49 64 0 7656 25 32 0 7813 20 mm 0 7874 51 64 0 7969 13 16 0 8125 21 mm 0 8268 53 64 0 8281 27 32 0 8438 55 64 0 8594 22 mm 0...

Page 25: ...INTENANCE AND SERVICE PRODUCTS 2 10 ENGINE 2 11 COMPRESSION AND LEAKDOWN TEST 2 11 ENGINE OIL LEVEL 2 11 OIL AND FILTER CHANGE 2 11 BREATHER HOSE 2 12 BREATHER VALVE INSPECTION 2 13 VALVE CLEARANCE 2...

Page 26: ...SPECTION 2 27 TOE ADJUSTMENT 2 27 CAMBER AND CASTER 2 28 SUSPENSION 2 29 SUSPENSION INSPECTION 2 29 SPRING PRE LOAD ADJUSTMENT 2 29 STABILIZER BAR PIVOT LUBRICATION 2 29 SUSPENSION PIVOT POINT LUBRICA...

Page 27: ...ter or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases BREAK...

Page 28: ...hen replacing the belt PERIODIC MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these operations more often for vehicles subjected to severe use E Emission related Control System Service California F...

Page 29: ...n 50 H 6 M Lubricate Rear Suspension 50 H 6 M Lubricate D E Throttle Cable Release Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Throttle body air intake ducts flange 50 H 6...

Page 30: ...earings 100 H 12 M Inspect replace as needed D Brake fluid 200 H 24 M Change every two years Spark arrestor 60 M Clean out D E Valve clearance 500 H 5000 8000 Inspect adjust Idle speed Adjust as neede...

Page 31: ...itting and grease Semi annually Rear A Arm All Season Grease Locate fitting and grease Semi annually Rear Stabilizer Bar Bushings If equipped with grease fittings All Season Grease Locate fitting and...

Page 32: ...ter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Coolant 50 50 Coolant Maintain coolant level in coolant reservoir bottle Check level daily change...

Page 33: ...fuel lines and injectors should be completely drained of gasoline NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never...

Page 34: ...2880513 50 50 Extended Life 1 US Gallon 3 8 L 4 per case 2880512 50 50 Extended Life 55 US Gallon Drum 208 L Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz...

Page 35: ...dipstick and fill tube from the right side of the vehicle A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the...

Page 36: ...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 14 Install the new filter and turn it by hand...

Page 37: ...Remove the CVTcover to access the drive clutch 3 Remove the rocker cover bolts q cover w and gasket NOTE It may be necessary to tap the cover lightly with a soft faced hammer to loosen it from the cyl...

Page 38: ...ANT LEVEL INSPECTION The recovery bottle q and radiator pressure cap w are located under the hood With the engine at operating temperature the coolant level should be between the MAX and MIN marks on...

Page 39: ...929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 2 15 9 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating MAINTENA...

Page 40: ...al To receive the full five year service interval benefit the vehicles s entire cooling system must be drained and replenished with the new 50 50 Extended Life antifreeze To quickly determine if a veh...

Page 41: ...u Bolt 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary 2 Check tightness of all hose clamps CAUTION Do not over tighten hose clamps at radiator or radiator fitting...

Page 42: ...and allow the coolant to completely drain Properly dispose of the used coolant 5 Remove the screws that retain the recovery bottle to the frame bracket Set the recovery bottle out of the way 6 Remove...

Page 43: ...lower radiator mounts are placed properly in the frame support 13 After the radiator is installed verify the rubber mounts e have remained in place 14 After installation and reassembly remove the pre...

Page 44: ...e all fuel lines every two years FUEL PUMP FILTER The fuel pump components on the G 100 are not serviceable If a component requires replacement the fuel pump assembly must be replaced NOTE See the Onl...

Page 45: ...ase to the sealing surfaces of the filter 5 Reinstall the air filter into the airbox container Be sure the filter fits tightly in the air box and engage the 2 clips ENGINE AIR INTAKE INSPECTION 1 Remo...

Page 46: ...it is tight against the bracket 5 Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable TRANSMISSION LUBRICATION NOTICE It is important to follow the transmission maintenance...

Page 47: ...ication 9 Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do not overfill REF DESCRIP...

Page 48: ...under the footrest frame 4 Remove the wheel nuts and washers and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and wheels chocked place the wheel in the correct position on the w...

Page 49: ...ibility 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 TIRE PRESSURE CAUTION Maintain...

Page 50: ...in this chapter TAYLOR DUNN recommends steering component repair and adjustment be performed by an authorized technician when replacing worn or damaged steering parts Use only genuine TAYLOR DUNN repl...

Page 51: ...and record Call this measurement B w Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to...

Page 52: ...d in Wheel Toe Alignment IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if do...

Page 53: ...rear shock absorber springs are adjustable Rotate the adjuster cam q either direction to increase or decrease spring tension Always adjust both left and right sides equally Vehicle loads effect suspe...

Page 54: ...N PIVOT POINT LUBRICATION Grease all four front A Arm pivot points q and all eight rear A Arm pivot points w See the maintenance chart for service intervals or grease as needed NOTICE Wheels removed f...

Page 55: ...een the MAX and MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forceful...

Page 56: ...the Specifications at the beginning of the Brakes Chapter w Rear Disc See the Specifications at the beginning of the Brakes Chapter WARNING Do not apply WD 40 or any petroleum product to brake discs...

Page 57: ...water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes...

Page 58: ...an be maintained by using a battery tender charger or by charging about once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will autom...

Page 59: ...lace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Install spark plugs and torque to specification Recommended Spark Plug Autolite 5924 TORQU...

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Page 61: ...OLING SYSTEM PRESSURE TEST 3 17 PRESSURE CAP TEST 3 17 RADIATOR 3 18 COOLANT DRAIN RADIATOR REMOVAL 3 18 THERMOSTAT REPLACEMENT 3 19 COOLING SYSTEM BLEEDING PROCEDURE 3 20 WATER PUMP COVER AND IMPELLE...

Page 62: ...9 PISTON RING INSTALLATION 3 59 PISTON CONNECTING ROD ASSEMBLY 3 60 CYLINDER INSTALLATION 3 61 CYLINDER HEAD INSTALLATION 3 62 VALVE SEALING TEST 3 63 VALVE CLEARANCE CHECK ADJUSTMENT 3 63 VALVE LASH...

Page 63: ...9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 3 3 CRANKCASE ASSEMBLY PTO SIDE 3 84 BALANCE SHAFT INSTALLATION TIMING 3 86 FINAL CRANKCASE ASSEMBLY 3 86 ENGINE COOLING SYSTEM...

Page 64: ...uge PU 50569 Oil Pressure Gauge Adapter PA 49317 Stator Cover Removal Handles PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PU 50689 Water Pump Mechanical Oil Seal Install...

Page 65: ...rt the engine and allow it to reach operating temperature while monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil 5W 50 at operating temperature and may...

Page 66: ...ing Width Intake Service Limit 0 0551 1 4 mm Valve Seat Contacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust Service Limit 0 0748 1 9 mm Valve Seat Angles 30...

Page 67: ...rvice Limit 0 0220 0 56 mm Oil Control Rails Standard 0 0098 0 0401 0 25 1 02 mm Oil Control Rails Service Limit 0 0480 1 22 mm Ring to Groove Clearance Top Ring Standard 0 0011 0 0037 0 030 0 095 mm...

Page 68: ...omponents can be serviced while the engine is mounted in the chassis ENGINE REMOVAL NOTE Some engine repair procedures can be performed without removing the engine assembly from the vehicle Refer to A...

Page 69: ...installation 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 11 Disconnect the ETC q T...

Page 70: ...ly out of the mounting grommet and remove the exhaust assembly as one 20 Place a support between the main frame and transmission case Do not pinch any lines 21 Use an overhead or portable engine hoist...

Page 71: ...Remove the engine stand adapter plate 3 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame CAUTION Have an assistant help guide the engine...

Page 72: ...ance Tool PU 50658 A 7 In sequence torque the eight engine coupler bracket fasteners to specification 8 Torque fasteners in order according to image TORQUE Rear Engine Coupler Fastener In Sequence In...

Page 73: ...20 Connect the fuel injector harness lead to the fuel injector 21 Connect the fuel line to the fuel rail 22 Connect the ignition coil harness connector and install the spark plug wire 23 Install the C...

Page 74: ...ally bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bol...

Page 75: ...DC of the compression stroke 2 With the valve cover and thermostat housing removed rotate the engine so the cam sprocket timing marks are aligned with the gasket surface as shown This will set TDC of...

Page 76: ...DUNN COOLING SYSTEM COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM REF DESCRIPTION NOTES q Radiator w Fan Shroud e Cooling Fan r Recovery Bottle t Radiator Drain Plug y Upper Radiator Hose u Lo...

Page 77: ...t dissipation resulting in possible engine damage Premium 50 50 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use COOLING SYSTEM PRESSURE TEST 1 Remove...

Page 78: ...are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitable drain pan underneath th...

Page 79: ...urns may result 2 Remove the pressure cap to relieve any system pressure see Pressure Cap Test 3 Drain coolant to a level below the thermostat housing 4 Tilt the cargo box 5 Remove the two bolts q ret...

Page 80: ...4 Remove the pressure cap w and add the necessary amount of 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...

Page 81: ...k 6 Completely drain cooling system and engine as outlined in this chapter 7 Raise and safely support the vehicle Remove the right rear wheel 8 Remove the eight bolts q attaching the water pump cover...

Page 82: ...r pump area and right hand side of engine block 4 Open the hood 5 Remove the pressure cap from the filler neck 6 Completely drain cooling system and engine as outlined in this chapter 7 Raise and safe...

Page 83: ...during the removal process or injury could result 16 Remove and discard the stator cover gasket CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service 17 Bring...

Page 84: ...vere engine damage may result 23 Clean and de grease the water pump drive shaft 24 Press in the water pump drive shaft into the bearing using PU 50869 25 Install the water pump drive shaft holding too...

Page 85: ...l seal is fully seated in cover or severe engine damage may result 28 Use the water pump mechanical seal installation tool in kit PU 50869 to fully install the new water pump mechanical seal d until i...

Page 86: ...and the water pump drive shaft blade are properly engaged Verify the stator cover is laying flat on the engine case CAUTION The flywheel contains powerful magnets Use caution when installing the stat...

Page 87: ...k 41 Install the coolant hose to the water pump cover and tighten hose clamp 42 Connect the stator wire connector and install a new tie strap securing the wiring to the front engine mount bracket 43 I...

Page 88: ...d Engine Idles But Will Not Accelerate Spark plug fouled weak spark Obstruction in air intake Air box removed reinstall all intake components Incorrect flywheel installation or sheared flywheel key Re...

Page 89: ...nt level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiat...

Page 90: ...r Head Standard Height 4 745 0 0020 120 53 0 05 mm Valve Seat Contacting Width Intake Standard 0591 0 0039 1 5 0 10 mm Contacting Width Intake Service Limit 0 0748 1 9 mm Contacting Width Exhaust Stan...

Page 91: ...Second Ring Standard 0 0094 0 0196 0 24 0 50 mm Second Ring Service Limit 0 0220 0 56 mm Oil Control Rails Standard 0 0098 0 0401 0 25 1 02 mm Oil Control Rails Service Limit 0 0480 1 22 mm Ring to Gr...

Page 92: ...3 32 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN ENGINE TORQUE SEQUENCES CYLINDER HEAD CAM CARRIER VALVE COVER WATER PUMP COVER ENGINE COOLING SYSTEM...

Page 93: ...3 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 3 33 STATOR COVER CRANKCASE ENGINE COOLING SYSTEM...

Page 94: ...n Crankcase Sealant 2871557 NOTICE Clean the case halves with ISOPROPYL ALCOHOL to remove all sealant before applying new sealant Alignment Pins MUST be installed prior to assembly IMPORTANT Clean the...

Page 95: ...REF DESCRIPTION NOTES q Oil Pickup Install until fully seated in bore hole Engine oil may be used to aid installation w Oil Pressure Regulator Assembly Torque 20 ft lbs 12 Nm e Piston Oil Jet Torque...

Page 96: ...3 36 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN CYLINDER OIL FILTER OIL PUMP BREATHER ENGINE COOLING SYSTEM...

Page 97: ...Nm u Oil Filter Lubricate seal with engine oil prior to filter installation i Gear Sprocket to be installed so that OUT is visible o Screw Torque 12 Nm Replace if loosened or removed a Gear Sprocket...

Page 98: ...3 38 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE COOLING SYSTEM...

Page 99: ...bly i Gear o Screw 44 ft lb 60 Nm Replace camshaft sprocket bolt if loosened or removed a Head Bolt See Cylinder Head Installation page 3 62 s Screw d Timing Chain Tensioner Torque 37 ft lbs 50 Nm Ens...

Page 100: ...3 40 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN SPARK PLUGS STARTER THROTTLE BODY VALVE COVER ENGINE COOLING SYSTEM...

Page 101: ...ue 89 in lbs 10 Nm r Fuel Injector Apply P80 rubber lubricant prior to assembly t Screw Torque 26 in lbs 2 8 Nm y T MAP Sensor Apply P80 rubber lubricant prior to assembly u Intake Boot Apply P80 rubb...

Page 102: ...3 42 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN PISTON CRANKSHAFT BALANCE SHAFT ENGINE COOLING SYSTEM...

Page 103: ...Nm Apply Loctite 272 Replace if loosened or removed t Rod Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and or bore y Crankshaft Crankshaft to be drawn through bearings in PTO case with...

Page 104: ...N IMPORTANT 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 IMPORT...

Page 105: ...t hand rear wheel well area 5 Replace valve cover seal w if oil leaks are evident CAMSHAFT CARRIER REMOVAL NOTICE The camshafts can be removed with the engine installed in the chassis 1 Rotate the eng...

Page 106: ...guide to prevent the chain from falling off the crankshaft 5 Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the engine 6 Carefully remove the camshafto from th...

Page 107: ...t Lobe Height Intake 2 0327 0 0038 51 63 0 097 mm Exhaust 2 0657 0 0038 52 47 0 097 mm EXHAUST CAMSHAFT DECOMPRESSION MECHANISM NOTICE Removal of the decompression mechanism is not necessary unless re...

Page 108: ...if excessive wear is evident 5 Upon installation torque all fasteners to specification and reassemble engine and vehicle as outlined in this chapter TORQUE Lower Cam Chain Guide Fasteners 10 ft lbs 12...

Page 109: ...d 2 Compress the valve spring by hand using valve spring compressor adapter Valve Spring Compressor Adapter PV 43513 A 3 Push down on the springe and remove the split keepers q 4 Slowly release valve...

Page 110: ...al different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinde...

Page 111: ...e 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 COMBUSTION CHAMBER CLEANING CAUTION Wear eye protection...

Page 112: ...seat pressure is reduced causing carbon accumulation and possible compression loss If the seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in bu...

Page 113: ...on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide o...

Page 114: ...d lift it from the crankcase supporting piston and connecting rod 5 Remove the cylinder from the engine 6 Remove and discard cylinder base gasket NOTICE Stuffing a clean rag around the connecting rod...

Page 115: ...of engine 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a heat gun CAUTION Do not apply heat to the piston rings they may lose radia...

Page 116: ...cylinder size measurement from cylinder inspection Piston to Cylinder Clearance 00138 00256 035 065 mm Piston O D 3 6592 3 6598 92 943 92 957 mm PISTON ROD INSPECTION 1 Measure piston pin bore inside...

Page 117: ...Groove Clearance Top Ring 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 PISTON RING INSTALLED GAP 1 Place each...

Page 118: ...red on arbor and to bring the stone approximately 1 2 1 3 cm beyond the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been cleared an...

Page 119: ...n groove until butt ends are on PTO side of piston see illustration 1 NOTICE Ends must butt squarely together and must not overlap 2 Install lower ring with end gap positioned as shown in Step 3 3 Ins...

Page 120: ...ne side of piston with gap at the top 12 00 position or bottom 6 00 position NOTICE Never re use a piston pin circlip 3 When installing the piston be sure the piston marking EX is positioned towards t...

Page 121: ...fy all ring end gaps are correctly located on piston Place cam chain and guides in alignment with chain room 6 Carefully compress rings with fingers or commercially available spring compression tool a...

Page 122: ...cylinder locating it on the alignment pins 3 Carefully set the cylinder head y in place on alignment pins NOTICE Install new cylinder head bolts 4 Install and finger tighten the four new cylinder hea...

Page 123: ...ys inspect valve clearance prior to camshaft installation or final engine assembly NOTE Valve clearance should only be checked on a cold engine 1 Install the cam chain guides and cam chain before cams...

Page 124: ...ut of specification NOTE Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes Mark each component or place them in an organized rack as you...

Page 125: ...mm 0 09 mm 2 Divide the 3 digit tappet number by 100 i e 450 100 4 5 mm 3 Add the results of step 1 and step 2 i e 0 09 mm 4 5 mm 4 59 mm 4 Multiply that answer by 100 to obtain the correct new tappet...

Page 126: ...415 5139458 362 3 625 362 5139458 418 4 175 418 5139458 365 3 650 365 5139458 420 4 200 420 5139458 368 3 675 368 5139458 422 4 225 422 5139458 370 3 700 370 5139458 425 4 250 425 5139458 372 3 725 37...

Page 127: ...ot aligned 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 11 Torque...

Page 128: ...right TAYLOR DUNN 14 Install the hydraulic cam chain tensioner w into the cylinder and torque to specification TORQUE Cam Chain Tensioner 37 ft lbs 50 Nm 15 Rotate crankshaft through two revolutions a...

Page 129: ...et should have notch marks q aligned with gasket surface Stator Cover Flywheel Removed Flywheel Key faces down and insert a 1 4 drive socket extension through the crankcase and into the crankshaft loc...

Page 130: ...COVER INSTALLATION 1 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 2 Install a new valve cover seal w 3 Install the four valve cover bolts q 4 Torque valve cover bo...

Page 131: ...ase at any time during the removal process or injury could result CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service 2 Remove starter drive gear and shaft q...

Page 132: ...3 Rotate gear counterclockwise The gear should immediately lock in position and not slip 4 Inspect inside of hub q for wear galling or uneven surface 5 Inspect crankshaft bearing surface e for abnorm...

Page 133: ...in clutch hub with flange of clutch i engaged in recess NOTICE The one way clutch can be installed into the hub incorrectly This will cause engine cranking issues 2 Clean screw threads in flywheel to...

Page 134: ...the crankshaft as shown IMPORTANT Do NOTapply loctite to the taper 6 Align the flywheel keyway with flywheel key on the crankshaft 7 By hand lightly press the flywheel inward while rotating the freew...

Page 135: ...tor cover 3 Remove the 2 boltsw that secure the stator wire routing bracket to the stator cover 4 Remove the stator e from the stator cover STATOR STATOR COVER INSTALLATION 1 Clean and degrease screws...

Page 136: ...nto the crankshaft locating hole 3 Remove the oil pump sprocket bolts e and washers Discard the bolts and replace with new for assembly Remove the sprockets and chain rfrom the engine 4 Inspect the oi...

Page 137: ...ntation dots that must be installed inward upon assembly 8 Remove the center gerotor pin and shaft from the oil pump cover NOTICE There is a spacer in between the inner oil pump gerotor and the oil pu...

Page 138: ...n a through the oil pump drive shaft 4 Slide the gerotor w onto the drive shaft and lock them into position on the drive pin 5 Install the washer e onto the drive shaftr 6 Install the oil pump cover t...

Page 139: ...5W 50 Synthetic Engine Oil Oil Pressure Minimum Specification using 5W 50 full synthetic at operating temperature 10 PSI 1200 RPM Minimum 40 PSI 7000 RPM Minimum 12 Prepare Inter mag and mag side cran...

Page 140: ...an cause engine damage Always reinstall the breather valve after removing it for service 6 Install the left side panel CRANKCASE SEPARATION NOTICE Before the crankcase can be separated be sure the ent...

Page 141: ...te crankcase by tapping with a soft faced hammer in reinforced areas and lift MAG crankcase off PTO case BALANCE SHAFT REMOVAL INSPECTION 1 Rotate crankshaft to align the timing marks as shown below 2...

Page 142: ...case bore The inner race should be firm with minimal side to side movement and no detectable up and down radial movement CRANKSHAFT REMOVAL 1 Remove the engine from the engine stand and place the asse...

Page 143: ...arance 0 00590 01771 15 45mm 2 Measure the connecting rod small end I D B Small End I D Standard 0 8665 0 8670 22 010 22 023 mm Service Limit 0 08682 22 053 mm 3 Place the crankshaft in a truing stand...

Page 144: ...tion Tool PU 50784 Install plate q over adapter w Evenly attach the assembly q onto the PTO side crankcase flange using the four bolts provided with tool Place the nut and large washer onto the cranks...

Page 145: ...shaft removal installation tool to properly drive the crankshaft seal into the crankcase Crankshaft Removal Installation Tool PU 50784 Center plate q over the crankshaft so it is resting on the cranks...

Page 146: ...aning sealing surface Be sure the oil pickup and oil pressure valve are fully installed 2 Apply a thin film of Crankcase Sealant PN 2871557 evenly to a clean and oil free MAG crankcase mating surface...

Page 147: ...ngine stand adapter onto the engine PTO side mounting ears as shown below Engine Stand Adapter PU 50824 A 9 Select the proper engine stand sleeve adapter and install it onto the engine stand adapter E...

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Page 149: ...COMPONENT LOCATIONS LEFT VIEW 4 7 EFI COMPONENT LOCATIONS RIGHT VIEW 4 8 LINE HOSE ROUTING 4 9 FUEL LINE ROUTING 4 9 VENT LINE TERMINATION FITTING 4 9 AIR BOX INTAKE SYSTEM 4 10 AIR BOX AIR FILTER ASS...

Page 150: ...OR REPLACEMENT 4 30 FUEL INJECTOR TROUBLESHOOTING 4 31 ENGINE COOLANT TEMPERATURE SENSOR 4 32 ECT OVERVIEW 4 32 ECT SENSOR TEST 4 32 SYSTEM OPERATION TEST 4 32 RESISTANCE VS TEMPERATURE TEST 4 32 EFI...

Page 151: ...nd throttle position These primary signals are compared to the programming in the ECU software and the ECU adjusts the fuel delivery and ignition timing outputs based on the inputs During operation th...

Page 152: ...isted 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...

Page 153: ...overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately Do not induce vomiting If you spill gasoline on your skin or...

Page 154: ...y It is recommended to use the DSA USB to serial port adaptor which can be purchased through DSA at www diagsys com DIGITAL WRENCH SMARTLINK MODULE KIT PU 47471 This module kit contains the necessary...

Page 155: ...4 7 EFI COMPONENT LOCATIONS EFI COMPONENT LOCATIONS LEFT VIEW REF Component 1 Instrument Cluster 2 Ignition Switch 3 Regulator Rectifier 4 Battery 5 ECU 6 Fuse Relay Box 7 Starter Motor Solenoid 8 Ig...

Page 156: ...0 Service Manual Copyright TAYLOR DUNN EFI COMPONENT LOCATIONS RIGHT VIEW REF COMPONENT 11 Fuel Pump Sender 12 High Tension Wire Spark Plug 13 Throttle Body ETC 14 Speed Sensor Mounted to Transmission...

Page 157: ...minates at the fuel vent connector r that is inserted in the frame VENT LINE TERMINATION FITTING This fitting should be inspected and tested using a Mity Vac to ensure proper venting Connect the Mity...

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Page 159: ...OTES q Cover Airbox w Seal Cover e Airbox r Plug Drain t Air Filter y Intake Boot u Clamp Gear i Clamps Gear Torque to 24 in lbs 2 5 Nm o Pre Filter a Box Intake s Plug Drain d Screw Torque to 8 ft lb...

Page 160: ...ottom of the air box assembly to the transmission bracket 5 Remove the air box assembly Air Box Installation Procedure 1 Install the air box bottom assembly back into the engine compartment 2 Reinstal...

Page 161: ...ine the cause of the Check Engine light by referencing the Instrument Cluster Trouble Code Display and Diagnostic Trouble Code Table or by using Digital Wrench The ECU requires a minimum of 7 0 volts...

Page 162: ...ons provided in Digital Wrench 1 Carefully follow the ECU replacement instructions provided in Digital Wrench to ensure that all essential data contained within the original ECU is transferred to the...

Page 163: ...y authorization Use Digital Wrench to perform all troubleshooting of this component Use a Volt Ohm meter to test the vehicle harness continuity between the ETC connector and ECU connector Refer to the...

Page 164: ...t varies as the pedal is pressed Reference the Data Display section and be sure the Pedal Position is displayed With the ignition key on for at least 15 seconds and engine not running the Pedal Positi...

Page 165: ...n positive battery cables from the battery 4 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump q Move the fuel line out of the way for t...

Page 166: ...23 Nm 3 Reinstall the RH fender panel the fuel cap and all previously removed fasteners 4 Connect the fuel pump electrical harness the fuel line and the vent line Verify the fuel line is locked in to...

Page 167: ...ns Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do n...

Page 168: ...re a minimum of 7 volts is present NOTICE If the voltage was below 7 VDC test the battery ignition switch relay s wiring harness and ECU 7 If the reading is between 7 and 14 volts turn key switch off...

Page 169: ...allows the exhaust to cool and fuel pressure to drop 1 Remove the seat to access the fuel pump 2 Disconnect the battery negative cable 3 Ensure that static has been discharged from you by touching a...

Page 170: ...tank hold float arm to the pump body and tilt assembly to ensure float arm does not get caught or bent during installation 15 Gently push down on fuel pump flange ensuring flange is centered 16 Roughl...

Page 171: ...vice Manual Copyright TAYLOR DUNN 4 23 22 Connect battery 23 Install the seat 24 Test the fuel pump by turning on the key and listening for the pump to activate Cycle the key several times to prime th...

Page 172: ...he temperature and pressure are in your environment when the key is turned on engine not running When the vehicle is started manifold absolute pressure will be around 9 PSI cold engine and drop to aro...

Page 173: ...running CPS TEST NOTICE The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a problem with this sensor circuit test as follows RESISTANCE TEST 1 Access the CPS connector 2...

Page 174: ...t allow direct air gap measurement 1 Disconnect the CPS q from the main harness 2 Remove the CPS 3 Measure the distance between the sensor mounting flange and the bottom face of the sensor 4 Rotate th...

Page 175: ...e Cooling System chapter 8 Install the stator cover if removed see Engine Cooling System chapter 9 Install a NEW or known good CPS see CPS Replacement 10 Fill and bleed the coolant system see Engine C...

Page 176: ...f the ignition coil windings Spark is induced by the ECU opening the ground leg of the coil circuit This causes the magnetic field in the primary to collapse causing self induction and a great voltage...

Page 177: ...ectromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector contains a series of calibrated openings which directs the fuel in...

Page 178: ...e servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop 1 Tilt the cargo box 2 Be sure the engine has cooled enough to work on 3 Remove the seat and disconnect the negative...

Page 179: ...zed If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be i...

Page 180: ...CE VS TEMPERATURE TEST CAUTION Contact with boiling water or steam may cause burns 1 Disconnect the ECT from the main harness 2 Remove the ECT 3 Fill a pot of water 1 2 way with water 4 Place a pot of...

Page 181: ...ice any fuel system component while engine is running or ignition switch on USE CARE when removing or installing the ECU connector as well as all other harness connections on the unit Properly connect...

Page 182: ...ostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded NOTE List refers to all possible Diagnostic Trouble Codes DTC DIAGNOSTIC TROUBLE CODE TABLE COMPONENT...

Page 183: ...e Too High 3 P0108 Voltage Too Low 4 P0107 Mechanical System Not Responding 7 P1106 Abnormal Rate of Change 10 P0109 Intake Air Temperature T MAP Valid But Above Normal 105 0 Data Erratic or Intermitt...

Page 184: ...mputation 400 31 P121D Gear Sensor Signal Date Erratic or Intermittent 523 2 P0914 Voltage Above Normal 3 P0917 Voltage Too Low 4 P0916 Abnormal Rate of Change 9 P1914 ECU Memory EEPROM Read Write Fai...

Page 185: ...Valid But Above Normal 3597 0 P16A3 Valid But Below Normal 1 P16A6 Voltage Too High 3 P16A2 Voltage Too Low 4 P16A1 Valid But Above Normal least severe 16 P16A5 Valid But Below Normal least severe 18...

Page 186: ...t 520276 2 P150C Neither Position Sensor Passed Test 12 P150B Throttle Body Control Power Stage Not Plausible 520277 2 P151A Voltage Above Normal 3 P150D Voltage Below Normal 4 P150E Signal Error 8 P1...

Page 187: ...tion Cut Off Level 2 Condition Exists 520289 31 P1543 Controller Option Setting Not Programmed Out of Calibration 520290 13 P1544 Throttle Body Control Requested Throttle Angle Not Plausible Condition...

Page 188: ...ble codes Analyze real time engine data Reflash ECU calibration files Perform guided diagnostic procedures Create customer service account records Perform output state control tests DIGITAL WRENCH VER...

Page 189: ...5 Click on Digital Wrench Version Updates NOTE You must already have the current version installed before adding an update Updates will not install if you are using an older version loaded on your PC...

Page 190: ...lable within Digital Wrench for all supported Trouble Codes that is any fault that will turn on the Check Engine indicator In addition guided diagnostics are also available for many other electrical s...

Page 191: ...and ECU information in a grid meter or chart format Enter customer and vehicle information and view ECU Identification View information from the main ECU sensors Load the Vehicle Home Page Set up dat...

Page 192: ...at is used by a variety of people and in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE...

Page 193: ...to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be in...

Page 194: ...t the reflash process will begin Do not touch the vehicle or PC during the process 15 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a su...

Page 195: ...ooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel qual...

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Page 197: ...VT DISASSEMBLY 5 7 CVT ASSEMBLY 5 8 DRIVE BELT 5 9 BELT REMOVAL 5 9 BELT INSPECTION 5 9 BELT INSTALLATION 5 10 CVT BREAK IN DRIVE BELT CLUTCHES 5 10 CLUTCH ALIGNMENT OFFSET CENTER DISTANCE 5 11 INSPEC...

Page 198: ...r PU 50518 Universal Clutch Compressor Tool 2871025 Clutch Bushing Replacement Tool Kit 2870654 Standard Clutch Alignment Tool PART NUMBER SPECIAL SUPPLIES N A Loctite 680 8560054 RTV Silicone Sealer...

Page 199: ...er than the preload in the spring the outer sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotate...

Page 200: ...t the end of this chapter for more information 1 Belt Tension Drive to Driven Clutch Alignment Offset and Belt Inspection 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and...

Page 201: ...only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn C...

Page 202: ...ERVICE CVT SEALING GUARD AND DUCT COMPONENTS REF DESCRIPTION NOTES q Outer Clutch Cover w Clutch Cover Seal e Inner Clutch Cover r CVT Intake Duct t CVT Exhaust Duct y Drain Plug u Clamp Torque to 10...

Page 203: ...of rotation and remove drive belt see DRIVE BELT Belt Removal 8 Remove the driven clutch retaining bolt and driven clutch assembly 9 Install the Drive Clutch Holder 10 Remove the drive clutch retainin...

Page 204: ...es on the shaft 9 Install the inner clutch sheave thrust washers 3 and noting clutch sheave orientation outer clutch sheave Torque retaining bolt to specification TORQUE Driven Clutch Retaining Bolt 3...

Page 205: ...h mounting bolt 5 Remove the outer sheave 6 Remove the belt from the vehicle BELT INSPECTION 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt H...

Page 206: ...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 CVT BREAK IN...

Page 207: ...show a properly installed tool Clutch Center Distance Tool PU 50658 or PU 50658 A NOTE Images for Reference only The tool shown should only be used to check center to center distance The location the...

Page 208: ...gine to transmission coupler bolts to specification TORQUE Engine To Trans Coupler Bolts In Sequence 55 ft lb 75 Nm 7 Torque the two rear transmission isolator fasteners e to specification 8 Remove th...

Page 209: ...ON REF DESCRIPTION q Clutch Bolt Replace if removed 47 ft lbs 63 5 Nm s Washers w Lock Washer d One Way Bearing EBS e Flat Washer f Bolt r Cover Screws 100 in lbs 12 Nm g Shift Weight t Spring h Nut 2...

Page 210: ...ove and inspect the clutch spring See Drive Clutch Spring Specifications for spring inspection 6 Remove the limiter spacer w and inspect for wear Replace if excessive wear is evident 7 Inspect area on...

Page 211: ...nd weights Inspect the contact surface of the weight q The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts w for wear or galling If weights or bolts ar...

Page 212: ...ool PN 2870341 NOTICE 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 Moveabl...

Page 213: ...o replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation Roller Pin Tool PN 2870910 2 Rubber backed buttons can be used in TAYLOR DUNN cl...

Page 214: ...tions on the shaft with only a slight amount of drag 2 Verify there is no binding or rough spots If problems are noted continue with disassembly CLUTCH INSPECTION NOTICE Remove cover spring and spider...

Page 215: ...sure the thickness and compare to specification Replace if worn or damaged MEASUREMENT PTFE Washer Thickness Standard 030 76 mm Service Limit 025 64 mm BUSHING SERVICE NOTICE Special Tools Required Ad...

Page 216: ...Remove nut from puller rod and set aside 4 Install puller adapter Item 10 from kit Puller Adapter PN 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide she...

Page 217: ...rom outside of clutch cover insert removal tool Item 3 into cover bushing 26 With inside of cover toward vise slide cover onto puller 27 Install nut onto puller rod and hand tighten Turn puller barrel...

Page 218: ...h balance and belt to sheave clearance be sure to reinstall the original quantity and thickness of washers spacers beneath the spider during assembly 3 Compress spider buttons for each tower and insta...

Page 219: ...CE ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Subassembly Stationary Boss u Cup Spring Boss w Roller Clutch i Plate Retainer e Washer Thrust o Screw 9 ft lbs 12 Nm r Ring Retaining E Ring Externa...

Page 220: ...down until it touches the spring cup 6 Using a T30 Torx driver remove the five screws that secure the spring retainer to the inner clutch sheave 7 Turn the compression tool handle counter clockwise to...

Page 221: ...on the spring washer spring spring cup and retaining ring into moveable sheave Do not apply oil or grease to the bearings 4 Place the clutch into the universal clutch compressor Apply and hold downwar...

Page 222: ...hout spring to determine problem area Replace belt A Replace ramp buttons B Inspect movable sheave for excessive bushing clearance Replace the clutch Engine RPM above specified operating range Incorre...

Page 223: ...gh vs low range Clear obstruction Inspect system Clean repair or replace as necessary Seal CVT system ducts Remove weight Inform operator Instruct operator on guidelines for operation in proper drivin...

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Page 225: ...S 6 6 SHIFT LEVER 6 7 REMOVAL 6 7 INSTALLATION 6 7 SHIFT CABLE 6 8 INSPECTION 6 8 ADJUSTMENT 6 8 TRANSMISSION SERVICE 6 9 TRANSMISSION REMOVAL 6 9 TRANSMISSION INSTALLATION 6 10 TRANSMISSION INTERNALS...

Page 226: ...8 ft lbs 11 Nm Speed Sensor Screw 10 ft lbs 14 Nm Transmission Case Screws 18 ft lbs 24 Nm Transmission Fill Drain Plugs 14 ft lbs 19 Nm Transmission Rear Isolator Bolt 40 ft lbs 54 Nm Transmission R...

Page 227: ...isted 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...

Page 228: ...6 4 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN TRANSMISSION ASSEMBLY VIEW TRANSMISSION...

Page 229: ...ubassembly LH Case 83 Diff Solenoid 15 Washer 48 Subassembly RH Case 84 Switch Rotary 2 pin 16 Pin Dowel 6 x 20 49 Drum Shift 85 O ring 17 Pin Spring Slotted 6 x 12 50 Gear Sector 16T 86 O ring 18 Rin...

Page 230: ...To access the TAYLOR DUNN Parts Catalog please visit The TAYLOR DUNN website at www taylor dunn com LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant AGL PN 2878068 Quart Capacity 41 oz 12...

Page 231: ...r Remove the console from the vehicle 3 Remove the clip t and washer y retaining the shift cable u to the shift lever and disconnect the cable end from the lever 4 Remove the retaining ring i and slid...

Page 232: ...damaged 3 If adjustment is required loosen the lower jam nut q and pull the cable out of the mount to move the upper jam nut w 4 Adjust the shift cable so there is the same amount of cable travel whe...

Page 233: ...nting bolt q 7 Remove the breather hose w loosen the air intake duct clamps e remove the duct mounting bolt r and remove the intake duct t 8 Disconnect the main harness from the ETC and TPS at the thr...

Page 234: ...et assembly to the frame Remove the bolt h that attaches the rear mount to the transmission Remove the mount assemblies from the vehicle 18 Using an overhead lift or an assistant lift the transmission...

Page 235: ...r distance tool 7 Remove the spacer or support between the vehicle frame and engine 8 Install and properly route the gear position switch connector i speed sensor connector o crankshaft position senso...

Page 236: ...Nm 16 Properly lower the vehicle 17 Install cone washers and castle nuts for the driveshafts Torque to specification TORQUE Castle Nut110 ft lbs 150 Nm 18 Install a new cotter pin into each castle nut...

Page 237: ...solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the...

Page 238: ...e the switch 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 6...

Page 239: ...the transmission 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 transmissio...

Page 240: ...n lift shift fork Y and torsion spring out of transmission housing 19 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly V Lift the pinion shaft assembly straight up to...

Page 241: ...everse shaft see Figure 8 2 26 To disassemble the shift shaft rail remove the snap ring X from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compre...

Page 242: ...him Z from the snorkel shaft 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 33 Lightly tap on th...

Page 243: ...ar prior to disassembly 2 Remove the 6 screws retaining the differential cover and remove the cover 3 Remove the 6 planet gears and each side gear assembly from the ring gear 4 Inspect the female side...

Page 244: ...Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as shown Planet Gear Bushing Replacement 5 Press the old bushing out of the planet gear 6 Thoroughly clea...

Page 245: ...h as shown Female Side Gear Bushing Replacement 12 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to...

Page 246: ...Assemble the side gears and place them onto the ring gear along with the 6 planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover...

Page 247: ...6 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 6 23 GEAR SHAFT BEARING INSPECTION TRANSMISSION...

Page 248: ...ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaf...

Page 249: ...ould still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole op...

Page 250: ...t cannot be installed after assembling the transmission 17 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 18 Install shift fork S and torsion spring into t...

Page 251: ...mbly if previously disassembled see illustrations 22 Install the idler gear shaft assembly A and gear cluster assembly B into the transmission housing all at the same time 23 Install the rear output s...

Page 252: ...Be sure the shift forks are engaged into the engagement dogs NOTICE Shift fork pins should be offset towards the input shaft as shown above 26 Inspect the shift drum for any damage or wear Inspect the...

Page 253: ...til it seats flush with the housing The rear output shaft seals H and pinion shaft seal J can be installed using a standard bushing installation tool Seals should be installed just past the case lead...

Page 254: ...e transmission and gear sector cover mating surfaces thoroughly 38 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 39 Install the sector cover and align t...

Page 255: ...Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmi...

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Page 257: ...LACEMENT 7 4 HUB INSTALLATION 7 5 FRONT HUB WHEEL EXPLODED VIEW 7 6 REAR BEARING CARRIER 7 7 INSPECTION 7 7 REMOVAL 7 7 DISASSEMBLY 7 8 ASSEMBLY 7 8 INSTALLATION 7 9 REAR DRIVE SHAFT 7 10 REAR DRIVE S...

Page 258: ...00226 CV Boot Clamp Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com FINAL DRIVE TORQUE TABLE ITEM SPECIFICATION Brake Caliper Mount Bolt 46 ft lbs 62 Nm Fr...

Page 259: ...and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts washers and wheel 4 Remove the two brake caliper mount...

Page 260: ...gh spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing h...

Page 261: ...f necessary to align cotter pin holes 7 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions 8 Install center cap 9 Rotate hub It shou...

Page 262: ...DUNN FRONT HUB WHEEL EXPLODED VIEW REF DESCRIPTION NOTES q Cotter Pin w Castle Nut 90 ft lbs 122 Nm e Washer r Wheel Nut Steel Wheel Nuts 36 ft lbs 49 Nm Aluminum Wheel Nuts 30 ft lbs 90 41 Nm 90 t W...

Page 263: ...otate smoothly without binding or rough spots Correct as necessary REMOVAL 1 Elevate the rear end of the vehicle and safely support the vehicle under the main frame area 2 Remove wheel nuts washers an...

Page 264: ...must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down...

Page 265: ...earing carrier with the upper A arm If previously removed install new upper A arm bushings Install the upper bearing carrier fastener NOTICE The lower shock bolt may need to be removed to allow the up...

Page 266: ...e the shaft 5 Remove the rear drive shaft using short sharp jerks to free the circlip from the transmission 6 Refer to the DRIVE SHAFT SERVICE section if repairing the drive shaft REAR DRIVE SHAFT INS...

Page 267: ...ce ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not...

Page 268: ...nt should be replaced 8 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 9 Visually inspect the joi...

Page 269: ...d hammer to tap the joint onto the drive shaft until it locks into place 16 Pull on the joint to make sure it is securely locked in place 17 Remove excess grease from the CV joint s external surfaces...

Page 270: ...ing joint and slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise 5 Using a soft faced hammer or brass drift strike the inner race...

Page 271: ...e joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush...

Page 272: ...l out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize...

Page 273: ...NG WHEEL REMOVAL 8 5 STEERING SHAFT BEARING REPLACEMENT 8 5 STEERING SHAFT STEERING RACK REMOVAL 8 6 FRONT STRUT 8 8 ASSEMBLY VIEW 8 8 FRONT STRUT CARTRIDGE REPLACEMENT 8 9 BALL JOINT REPLACEMENT 8 9...

Page 274: ...9 Nm Steering Wheel Nut 65 ft lbs 88 Nm Strut Casting Pinch Bolt 26 ft lbs 35 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Tie Rod End Jamb Nut 14 ft lbs 19 Nm Tie Rod End Mounting Nut 40 ft lbs 54...

Page 275: ...8 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 8 3 STEERING ASSEMBLY STEERING ASSEMBLY VIEW STEERING SUSPENSION...

Page 276: ...G w WHEEL STEERING e SHAFT STEERING UPPER LOWER r ASM GEAR BOX STEERING t CAP STEERING WHEEL y ASM SHOCK OIL LOCKING u BOLT i BOLT 40 ft lbs 54 Nm o SCREW a BOLT s NUT d NUT 16 ft lbs 22 Nm f NUT 40 f...

Page 277: ...shaft and the two wave washers are above it 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 specific...

Page 278: ...4 9 Install the steering wheel and hand tighten the nut 10 Reinstall the steering shaft assembly in the vehicle Install the lower portion of the steering shaft onto the steering gear box assembly Torq...

Page 279: ...tie rod ends to the steering knuckle 6 Remove the five fasteners u retaining the steering rack to the frame 7 Reverse procedure for installation Torque fasteners to specification TORQUE Steering Rack...

Page 280: ...13 17 ft lbs 18 23 Nm d Washers w Washer f Ball Joint e Rubber Spacer g Screws r Upper Pivot Ball h Ball Joint Bracket t Spacer 15 ft lbs 20 Nm j Retaining Ring y Lower Pivot Ball k Wheel Bearing u Sp...

Page 281: ...ation Do not over torque nut TORQUE Strut Mounting Nut top 15 ft lbs 21 Nm BALL JOINT REPLACEMENT 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUT...

Page 282: ...at to ease installation Drive new joint into strut housing until fully seated 9 Apply Loctite 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent T...

Page 283: ...lizer linkage to the upper A arm 3 Remove the fastener w attaching the upper A arm to the bearing carrier 4 Remove the fasteners attaching the upper A arm to the frame and remove the upper A arm from...

Page 284: ...n TORQUE Control Arm Fasteners 40 ft lbs 54 Nm 2 Attach lower A arm to bearing carrier Torque NEW fastener to specification TORQUE Bearing Carrier Fasteners 40 ft lbs 54 Nm 3 Route the brake line over...

Page 285: ...Service Manual Copyright TAYLOR DUNN 8 13 ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Lower A Arm y Bushing w Upper A Arm u Pin e Bearing Carrier i Grease Zerk r Wheel Bearing o Nuts 40 ft lbs 54...

Page 286: ...ct the stabilizer bar for straightness 5 Inspect the stabilizer bar bushings and replace if needed 6 Inspect the rubber bushings on the stabilizer linkage rod and replace if needed If replacing the st...

Page 287: ...shock from the vehicle 3 Reverse the procedure to reinstall the shock Torque NEW fasteners to specification TORQUE Shock Fasteners 40 ft lbs 54 Nm SHOCK REPLACEMENT 1 Using a spring compressor compre...

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Page 289: ...BRAKE PEDAL 9 8 PEDAL REMOVAL 9 8 PEDAL INSTALLATION 9 8 BRAKE SERVICE PROCEDURES 9 9 BRAKE BLEEDING FLUID CHANGE 9 9 BRAKE BURNISHING PROCEDURE 9 10 FRONT BRAKE PADS 9 11 PAD REMOVAL DISASSEMBLY 9 1...

Page 290: ...SEMBLY 9 21 REAR CALIPER INSPECTION 9 22 REAR CALIPER ASSEMBLY 9 22 REAR CALIPER INSTALLATION 9 22 REAR BRAKE DISC 9 24 DISC RUNOUT 9 24 BRAKE DISC INSPECTION 9 24 DISC REMOVAL REPLACEMENT 9 24 TROUBL...

Page 291: ...78 mm 0 170 4 32 mm Rear Brake Disc Runout 0 010 254 mm TORQUE SPECIFICATIONS ITEM TORQUE Bleeder Screws 47 in lbs 5 Nm Brake Disc Mounting Bolts Front 18 ft lbs 25 Nm Brake Disc Mounting Bolts Rear 2...

Page 292: ...UBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc...

Page 293: ...es self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow...

Page 294: ...EW ASSEMBLY VIEW REF DESCRIPTION NOTES q Master Cylinder w Banjo Bolt Torque to 15 ft lbs 20 Nm e Caliper Mounting Bolts Torque to 46 ft lbs 62 Nm r Pad Adjuster Screw Torque to 48 ft lbs 5 5 Nm t Bra...

Page 295: ...jo 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 5 Loosen the brake line banjo bolts r and allow...

Page 296: ...lip q and clevis pin w from the master cylinder e to free it from the brake pedal r 2 Remove the brake pedal pivot fastener and bushings t off the mount bracket PEDAL INSTALLATION 1 Reverse steps for...

Page 297: ...bleeder screw w 7 Attach a tight fitting clear hose to the bleeder fitting 8 Place a small amount of fresh brake fluid into a small clear container and place the other end of bleeder hose into the co...

Page 298: ...hould be no less than 1 2 1 3 cm 17 Check brake system for fluid leaks BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend...

Page 299: ...iper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTICE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston...

Page 300: ...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 PAD ADJUSTMENT 1 Install the ad...

Page 301: ...ALIPER ASSEMBLY VIEW REF DESCRIPTION NOTES q Adjuster Screw Finger Tighten w Bleeder Screw 30 60 in lbs 3 4 6 8 Nm e Caliper Body r Square O Rings Apply Dot 4 Brake Fluid t Piston Apply Dot 4 Brake Fl...

Page 302: ...move brake pad adjuster screw q 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket w and dust boot e 4 Remove piston r and square...

Page 303: ...id P N 2872189 Install piston w with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with disc brake...

Page 304: ...rew w and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined earlier in this chapter 5 Install wheels and torque wheel nuts to specification TORQ...

Page 305: ...t 140 3 56 mm MEASUREMENT Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read...

Page 306: ...removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston into caliper bore slowly with pads installed NOTICE Brake fluid will be...

Page 307: ...ke Caliper Mounting Bolts 46 ft lbs 62 Nm 3 Turn adjuster screw back in finger tight using a hex wrench Then back off 1 2 turn 4 Slowly pump the brake pedal until pressure has been built up Maintain a...

Page 308: ...S CALIPER ASSEMBLY VIEW REF DESCRIPTION NOTES q Socket Set Screw w Bleeder Screw 47 in lbs 5 Nm e Caliper Assembly r Dust Boots t Square O Rings Apply DOT 4 Brake Fluid y Piston Apply DOT 4 Brake Flui...

Page 309: ...luid has drained into the container remove the two caliper mounting bolts and remove caliper 4 Clean disc caliper body and pistons with brake cleaner or alcohol REAR CALIPER DISASSEMBLY 1 Remove brake...

Page 310: ...ter REAR CALIPER ASSEMBLY 1 Install new square O rings q in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag 2 Coat the piston with clean DOT 4 Brake Fluid PN...

Page 311: ...el and wheel nuts Carefully lower the vehicle 4 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when p...

Page 312: ...limit REF PART SERVICE LIMIT q Front Disc See the Specifications at the beginning of the Brakes Chapter w Rear Disc See the Specifications at the beginning of the Brakes Chapter WARNING Do not apply...

Page 313: ...36 Nm Rear Hub Castle Nut 110 ft lbs 150 Nm Front Hub Castle Nut 90 ft lbs 122 Nm 7 Install rear brake caliper see BRAKE CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter...

Page 314: ...ly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator PEDAL VIBRATION Disc damaged Disc worn runout or thickness variance exceeds service limit CAL...

Page 315: ...SSEMBLY VIEW 10 3 DASH INSTRUMENTS CONTROLS 10 4 HOOD DASH FRONT FASCIA 10 5 FLOOR REAR FENDERS 10 6 SEAT MOUNTING SEAT BELTS 10 7 REAR CARGO BOX 10 8 CARGO BOX TAILGATE BOX SUPPORT 10 8 BOX REMOVAL 1...

Page 316: ...62 69 Nm Steering Wheel Nut 65 ft lbs 88 Nm Strut Casting Pinch Bolt 26 ft lbs 35 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Tie Rod End Jamb Nut 14 ft lbs 19 Nm Tie Rod End Mounting Nut 40 ft lb...

Page 317: ...eld Mount Upper y Grab Handle u Screw M8 x 1 25 x 20 QTY 8 18 ft lb 24 Nm i Screw M10 x 1 5 x 20 QTY 6 36 ft lb 49 Nm o Bolt M8 x 1 25 x 20 QTY 2 10 ft lbs 14 Nm a Screw M10 x 1 25 x 30 QTY 4 36 ft lb...

Page 318: ...R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN DASH INSTRUMENTS CONTROLS REF DESCRIPTION NOTES q Instrument Cluster w Bezel e Key Switch r 12V Accessory Plug t Turf Switch y Dash Pane...

Page 319: ...TAYLOR DUNN 10 5 HOOD DASH FRONT FASCIA REF Description 1 Rivet 2 Screw 3 Washer 4 Hood Mount Bracket 5 Shoulder Washer 6 Nylok Nut 7 Hood 8 Headlight Bezel 9 Screw 10 Headlight 11 Screw 12 Dash Pane...

Page 320: ...01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN FLOOR REAR FENDERS REF DESCRIPTION NOTES q Front Floor w Main Floor e Floor Cover r Cup Holder t Push Rivet y Screws Torque to 5 ft lbs 7...

Page 321: ...100 Service Manual Copyright TAYLOR DUNN 10 7 SEAT MOUNTING SEAT BELTS REF DESCRIPTION NOTES q Seat Back w Seat Base e LH Seat Belt Assm r RH Seat Belt Assm t Seat Base Frame y Screw 24 in lbs 3 Nm u...

Page 322: ...10 8 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN REAR CARGO BOX CARGO BOX TAILGATE BOX SUPPORT BODY FRAME...

Page 323: ...F DESCRIPTION NOTES q Cargo Box w Box Frame e Tailgate Inner Panel r Tailgate Outer Panel t Box Tilt Shock y Box Tilt Latch u Heat Shield i Tailgate Tube o Tailgate Mount Bracket a Bushing s Tailgate...

Page 324: ...6 With both hinge pins removed remove the box from the frame 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 c...

Page 325: ...ect the head lamp harnesses Remove the two pivot screws retaining the hood and remove the hood from the bumper 2 Remove the three bolts from the lower portion of the bumper 3 Remove the two fasteners...

Page 326: ...ws retaining the front of the dash to the frame 3 Open the glove box and remove the Torx head screw from the dash 4 Remove the Torx head screw retaining the left portion of the dash 5 Remove the eight...

Page 327: ...ets q are seated properly on upper windshield mount plate 4 Check lower mounting brackets w are properly inserted into cut outs of dash panel 5 Turn clamps out to secure windshield to unit ROOF Remova...

Page 328: ...Manual Copyright TAYLOR DUNN 3 Lift the rear of the roof upward to unseat it from the unit 4 While holding the rear section of the roof up slide it forward 5 Once the retaining hooks e are out of the...

Page 329: ...ront retaining hooks on the bottom of the roofq 3 With the retaining hooks lined up slide the roof towards the rear of the unit 4 While holding the roof at rear bottom edge slide downward until it loc...

Page 330: ...10 16 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN 6 Install the four M6 screws e into the rear section of the roof TORQUE 12 15 in lbs 1 35 1 7 Nm BODY FRAME...

Page 331: ...even Torx head screws retaining the center floor 4 Remove the Torx head screws retaining the front floor cover 5 Remove the Torx head screws retaining the main floor and remove the main floor from the...

Page 332: ...treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fe...

Page 333: ...AGNOSTIC MODE 11 10 INSTRUMENT CLUSTER PINOUTS 11 11 INSTRUMENT CLUSTER REMOVAL 11 11 INSTRUMENT CLUSTER INSTALLATION 11 11 VEHICLE SPEED SENSOR 11 12 SPEED SENSOR LOCATION 11 12 SPEED SENSOR TESTING...

Page 334: ...N 11 24 BATTERY INSPECTION 11 25 BATTERY REMOVAL INSTALLATION 11 25 CONVENTIONAL BATTERY TESTING 11 26 OCV OPEN CIRCUIT VOLTAGE TEST 11 26 VOLTAGE DROP TEST 11 26 SPECIFIC GRAVITY TEST 11 26 LOAD TEST...

Page 335: ...nt readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter Thi...

Page 336: ...ay Orange White Brown White Green by pressing the connector lock and pulling on the connector Do not pull on the wiring 3 Inspect the switch connections and test the switch for continuity 4 When the s...

Page 337: ...Do not power the solenoid with 12 Volts for more than 1 second or damage may occur to solenoid IGNITION HEADLIGHT SWITCH 1 Open the hood see Chapter 5 2 Disconnect the ignition switch harness by depre...

Page 338: ...features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including...

Page 339: ...our or 24 hour formats 7 Engine Temperature Indicator LED icon illuminates when the ECM determines the engine is overheating The indicators will initially flash to indicate the engine is overheating T...

Page 340: ...isplays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the M...

Page 341: ...hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 7 Toggle the MODE button until the odometer is displayed 8...

Page 342: ...d icons will turn off DIAGNOSTIC MODE The diagnostic mode is accessible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were acti...

Page 343: ...t cluster 2 Disconnect the wire connectors from the back side of the instrument cluster 3 Push the instrument cluster out from the back side of the dash panel while securely holding the panel and rubb...

Page 344: ...Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from...

Page 345: ...ate the T25 Torx head adjustment screw through the wheel well see illustration Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height 6...

Page 346: ...the tab on the bulb locates properly in the housing HEADLIGHT HOUSING REMOVAL 1 Open the hood 2 Remove bulb from housing with wire harness attached and set aside 3 Remove fasteners holding headlight h...

Page 347: ...tal multi meter to test the harness to ensure the lamp is receiving 12 14 DC volts and that a ground path is present Lamps can be bench tested by applying 12 14 volts directly as the LED tail brake la...

Page 348: ...ooling system is full and purged of air Refer to Chapter 2 Maintenance for cooling system information FAN CONTROL CIRCUIT BYPASS TEST 1 Disconnect harness from the engine coolant temperature sensor lo...

Page 349: ...ition This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike tha...

Page 350: ...nsion lead cap q from the spark plug 4 Remove fasteners w retaining the ignition coil and remove coil assembly from the vehicle 5 Install new ignition coil assembly and tighten fasteners to specificat...

Page 351: ...ed by the key switch supplies B to the chassis circuits Chassis Relay FUSE BOX PIN WIRE COLOR OPERATION 33 Red Blue Relay coil 12v from EFI Splice 34 Red High side 12v from Start Solenoid 37 Red 12v o...

Page 352: ...ION 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 FUSE SIZE FEATURE SUPPORTED 5...

Page 353: ...even point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will r...

Page 354: ...ADS TO OHMS READING Battery Charge Coil Y1 Y2 or Y3 to Ground Open Line Infinity NOTICE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage...

Page 355: ...Copyright TAYLOR DUNN 11 23 CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condi...

Page 356: ...Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILD...

Page 357: ...and baking soda solution paying particular attention that any acid is washed off the terminals Dry the battery case BATTERY INSPECTION The battery is located under the seat on the drivers side 1 Insp...

Page 358: ...ltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high volta...

Page 359: ...the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge at 0 1Ah for max of 15 hours The battery is faulty if it does not achieve a specific gravity of 1 270 afte...

Page 360: ...gear or loose flywheel STARTER DRIVE Pinion Gear Anti Kick out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly The replacement spring is P...

Page 361: ...rminals A and B If there is no continuity or high resistance replace the starter solenoid STARTER SOLENOID OPERATION To energize the starter solenoid the following must occur The brake must be applied...

Page 362: ...11 30 9929758 R01 2019 TAYLOR DUNN G 100 Service Manual Copyright TAYLOR DUNN STARTING SYSTEM TESTING FLOW CHART ELECTRICAL...

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