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Polaris GEM e6 User Manual

Polaris GEM e6
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 e6 Specifications

General IconGeneral
BrandPolaris
ModelGEM e6
CategoryUtility Vehicle
LanguageEnglish

Summary

Introduction

General Warnings

Safety precautions to observe when working on the vehicle.

Fastener Usage

Guidelines for fastener usage and torque specifications.

Hoisting and Jacking

Procedures and safety notes for hoisting and jacking the vehicle.

Suspension and Steering

Wheel Alignment

Essential information for proper vehicle handling and passenger safety.

Suspension and Steering Diagnosis and Testing

Table of conditions, possible causes, and corrections for suspension issues.

Alignment

Description of toe-in/toe-out, measurement, and adjustment procedures.

Front Suspension

Description of the front suspension system and its components.

Rear Suspension

Description of the rear suspension system.

Steering

Description and operation of the vehicle's steering system.

Steering Diagnosis and Testing

Troubleshooting common steering conditions and their causes.

Steering Wheel

Description, operation, and removal/installation of the steering wheel.

Steering Column Assembly

Description, removal, and installation of the steering column assembly.

Steering Gear

Description, operation, diagnosis, and removal/installation of the steering gear.

Drivetrain

Drivetrain

Description of the drivetrain components and operation.

Halfshaft

Description, operation, diagnosis, removal, and installation of the halfshaft.

Differential

Description, operation, removal, and installation of the differential.

Brakes

Brake System

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

Brake Bleeding

Procedures for bleeding air from the brake system.

Front Brake Assembly

Description, operation, removal, and installation of the front brake assembly.

Rear Brake Assembly (2-4 Passenger Only)

Description, operation, removal, and installation of rear brake assemblies.

Electrical

Electrical System

Overview of the GEM electrical system components and layout.

Power System

Description of the power system providing primary power for drive and accessory systems.

Drive System

Description of the drive system components and their operation.

Diagnosis and Testing

Guidance for isolating problems within the drive and power systems.

Drive and Power System Error Codes

Explanation of error codes displayed on the LCD for drive/power system faults.

Drive and Power System Troubleshooting Charts

Charts to guide troubleshooting of electrical issues not covered by error codes.

Accelerator Pedal (Foot Pedal)

Description, operation, and testing of the accelerator pedal.

Battery

Description of battery types, layout, and characteristics.

Motor Controller

Description, operation, diagnosis, and replacement of the motor controller.

DC/DC Converter

Description, operation, diagnosis, removal, and installation of the DC/DC converter.

Motor

Description, operation, diagnosis, and testing of the electric motor.

PSDM

Description, operation, removal, and installation of the Power Signal Distribution Module.

Accessory System Component Replacement

Procedures for replacing individual accessory system components.

Wheels & Tires

Tires and Wheels

Description of GEM e-series wheels and tires.

Tire Inflation Pressures

Importance of proper tire inflation for safe operation.

Replacement Tires

Recommendations and warnings regarding replacement tire usage.

Diagnosis and Testing – Tire Wear Patterns

Illustrations of tire wear patterns and their causes/corrections.

Body

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