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Polaris GEM e4 - Service Manual

Polaris GEM e4
174 pages
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GEM Service Manual - REV 1 - 4/19/2012 November 2007
1 – INTRODUCTION ............................... 1-1
2 – SUSPENSION AND STEERING ....... 2-1
3 – DRIVETRAIN ..................................... 3-1
4 – BRAKES............................................ 4-1
5 – ELECTRICAL .................................... 5-1
6 – WHEELS AND TIRES ....................... 6-1
7 – BODY................................................. 7-1

Table of Contents

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Polaris GEM e4 Specifications

General IconGeneral
BrandPolaris
ModelGEM e4
CategoryUtility Vehicle
LanguageEnglish

Summary

introduction

general warnings

Key safety precautions to follow when working on the vehicle.

hoisting and jacking

Procedures and safety precautions for lifting the vehicle.

suspension and steering

wheel alignment

Essential for proper vehicle handling and passenger safety; requires inspection.

suspension and steering diagnosis and testing

Troubleshooting common suspension and steering issues and their causes.

alignment

Details on measuring and adjusting front wheel toe-in for alignment.

front suspension

Describes how the front suspension adapts to road surfaces and its components.

rear suspension

Comprised of frame, axle, and spring/shock absorbers for wheel control.

rear suspension frame axle 2-4 passenger only

Details the rear frame/axle assembly for specific passenger models.

rear suspension frame axle 6 passenger and long back extra duty

Details the rear frame/axle assembly for 6-passenger models.

steering

Details the components and operation of the vehicle's steering system.

steering gear

Explains the rack and pinion steering gear and its function in directing wheels.

drivetrain

drivetrain

Overview of the drivetrain system including motor, gearbox, and drive shafts.

halfshaft

Details the halfshaft assembly, its components, and potential issues.

differential

Explains the differential's function in transferring power to the wheels.

brakes

brake system

Overview of the hydraulic brake system with front disc and rear drum brakes.

brake bleeding

Procedure for removing air from the hydraulic brake system.

front brake assembly

Details the components of the front brake assembly: caliper, rotor, and pads.

rear brake assembly 2-4 passenger only

Describes the rear brake assembly for specific passenger models.

rear brake assembly 6 passenger and long back extra duty

Details the rear brake assembly for 6-passenger models.

electrical

electrical system

Overview of the GEM vehicle's electrical system components and their interactions.

power system

Provides primary power for drive and accessory systems using a 72V battery setup.

drive system

Components and operation of the system that powers vehicle movement.

drive and power system error codes

Lists error codes displayed by the motor controller for troubleshooting.

battery

Information on the 72V battery system, types, and characteristics.

motor controller system

Schematic of the motor controller system and its interconnections.

motor

Details the electric motor that supplies power to the drivetrain.

wheels and tires

tires and wheels

Overview of GEM e-series wheels and tire specifications by model.

body

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