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Polaris GEM e4 Service Manual
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ELECTRIC
AL 5 - 76
November
2007
GEM Service Manual
HARNESS AND CONNECTOR DRAWINGS
CONVERTER HARNESS
CONVERTER HA
RNESS CONNECTIONS
Connector Number
Connects To
Number of Pins in Connector
1 DC/DC
Converter
12
2,3
72 Volt Ground, 12 Volt Ground
1
4 PSDM
J4
6
122
124
Table of Contents
Section 1
3
Table of Contents
3
Introduction
4
General Warnings
4
Vehicle Identification/Safety Certification Label
5
Fastener Usage
5
Parts and Lubricant Recommendation
7
Maintenance Schedules
7
Hoisting and Jacking
8
Section 2
9
Wheel Alignment
10
Alignment
12
Front Suspension
13
Spring over Shock Absorber Assembly
14
Control Arm Assembly (with Bushings)
15
Rear Suspension
16
REAR SUSPENSION FRAME/AXLE (2-4 PASSENGER ONLY) (E2, E4, Es, El)
16
REAR SUSPENSION FRAME/AXLE (6 PASSENGER & LONG BACK EXTRA DUTY) (E6, E6S, Elxd)
16
REAR HUB and BEARING/SPINDLE (6 PASSENGER & LONG BACK EXTRA DUTY) (E6, E6S, Elxd)
18
Steering
19
Steering Wheel
21
Steering Column Assembly
23
Steering Gear
24
Outer Tie Rod End
25
Steering Knuckle
26
Section 3
31
Brake System
32
Brake Bleeding
33
Front Brake Assembly
35
REAR BRAKE ASSEMBLY (2 - 4 PASSENGER ONLY) (E2, E4, Es, El)
37
REAR BRAKE ASSEMBLY (6 PASSENGER & LONG BACK EXTRA DUTY) (E6, E6S, Elxd)
39
Brake Pedal Assembly to Frame 5/16
41
Brake Pedal to Push Rod 3/8 - 16 no
41
Brake Pedal Assembly
41
Master Cylinder Assembly
42
Park Brake Lever Assembly
43
Parking Brake Cable Assembly
44
Brake, Parking - Cable Mount to Rear ½" X 13 no
46
Parking Brake Cable Assembly (6 Passenger Only)
46
Park Brake Cable Tension Adjustment
47
Section 4
48
Electrical System
49
Power System
50
Drive System
51
Yes
59
Yes
60
Yes
61
Accelerator Pedal (Foot Pedal)
64
Battery
65
Charger
74
Motor Controller
79
DC/Converter
80
Main Contactor
81
Motor
82
Motor to Differential YES
83
Wheel Lug Nuts 12Mm no
83
Motor Magnet and Speed Sensor (Tachometer)
84
Liquid Crystal Display (Lcd)
85
Psdm
86
Accessory System
88
Accessory System Component Replacement
93
Electrical Overview
95
Index
96
Harness and Connector Drawings
123
Section 5
141
Tires and Wheels
142
Radial-Ply Tires
143
Tire Inflation Pressures
143
Tires
143
Replacement Tires
144
Diagnosis and Testing - Pressure Gauges
145
Diagnosis and Testing - Tire Wear Patterns
145
Diagnosis and Testing - Tread Wear Indicators
145
Diagnosis and Testing - Tire Noise or Vibration
146
Repairing Leaks
146
Rotation
146
Wheels
146
Diagnosis and Testing - Wheel Inspection
147
Wheel Installation
147
Section 6
148
Seat Belts
149
Three-Point Seat Belt
150
Body Panels
151
Body Side Panel
151
Body Side Panel (6 Passenger Only)
152
Installation of Scuff Guards
153
Installation of Scuff Guards (Continued)
154
Installation of Scuff Guards (Continued)
156
Body Back Panel
157
Floor Panels (6 Passenger Only)
158
Bench Seats
159
Bucket Seat
160
Mudguard
161
Mudflap
162
Hood
163
Hood Latch Assembly
164
Dash
165
Dash Upper Panel
165
Dash Lower Panel
166
Pod Covers
167
Spat
168
Utility Bed
169
Trunkback/Golfback/ Clip-In Stake Bed
170
Pack Latch Assembly
171
Mirror - Center Rear View
173
Trunkback/Golfback/ Clip-In Stake Bed Leg Pocket
173
Mirror - Side Rear View
174
4
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Polaris GEM e4 Specifications
General
Brand
Polaris
Model
GEM e4
Category
Utility Vehicle
Language
English
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