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Polaris GEM eLXD User Manual

Polaris GEM eLXD
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 eLXD Specifications

General IconGeneral
BrandPolaris
ModelGEM eLXD
CategoryUtility Vehicle
LanguageEnglish

Summary

Introduction

General Warnings

Observing safety precautions when working on the vehicle is crucial. Always wear safety glasses and use safety stands.

Fastener Usage

Guidelines on fastener usage, torque specifications, and the importance of using correct fasteners for safety.

Hoisting and Jacking

Procedures and safety notes for hoisting and jacking the vehicle, including proper lifting points.

Suspension and Steering

Wheel Alignment

Essential steps for front wheel alignment, including pre-alignment inspections and necessary corrections.

Suspension and Steering Diagnosis and Testing

Diagnostic steps and possible causes for common suspension and steering issues.

Alignment

Detailed explanation of toe-in/toe-out measurement and the procedure for adjusting toe.

Front Suspension

Description of the front suspension system and torque specifications for its components.

Rear Suspension

Description of the rear suspension system and its components like frame/axle.

Steering

Overview of the steering system components and their operation.

Steering Diagnosis and Testing

Common steering problems, possible causes, and recommended corrective actions.

Steering Gear

Information on the rack and pinion steering gear, including removal and installation.

Drivetrain

Drivetrain System Overview

Description of the drivetrain system, including motor, gearbox, differential, and halfshafts.

Brakes

Brake System

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

Brake Bleeding

Procedures for bleeding the brake system to remove air, including manual and pressure bleeding.

Front Brake Assembly

Details on the front brake assembly, including its components, removal, and installation.

Electrical

Power System

Description of the power system, its purpose, components, and operation.

Drive System

Description of the drive system, its components, operation, and basic troubleshooting steps.

Drive and Power System Error Codes

List of drive and power system error codes, their fault descriptions, and corrective actions.

Accelerator Pedal (Foot Pedal)

Description, operation, diagnosis, and testing of the accelerator pedal, including removal/installation.

Battery

Description of the battery system, types, and important notes on battery characteristics.

Charging System

Description of the charging system, including operation, caution, and replacement procedures.

Motor Controller System

Details on the motor controller system, its function, operation, diagnosis, and troubleshooting.

PSDM

Description of the Power Signal Distribution Module (PSDM), its operation, removal, and installation.

Accessory System Troubleshooting Chart

Troubleshooting chart for accessory system issues, including possible causes and corrections.

Power Distribution

Diagram and explanation of the power distribution system, including fuses.

Wheels and Tires

Tires and Wheels

Overview of GEM e-series wheels and tires, including wheel and tire charts.

Tire Inflation Pressures

Importance of proper tire inflation for safe operation and handling, and checking procedures.

Replacement Tires

Recommendations for replacement tires and warnings about using improper sizes or overloading.

Diagnosis and Testing - Tire Wear Patterns

Identifying tire wear patterns and their causes, including under-inflation and incorrect toe.

Body

Seat Belts

Description of GEM vehicles' automotive-type seatbelts and monthly inspection for signs of wear.

Hood Latch Assembly

Description, operation, removal, disassembly, assembly, and installation of the hood latch.

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