Polaris GEM E Series Bedienungsanleitung

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

INTRODUCTION 1 - 1

GEM Service Manual November 2007

CONTENTS

INTRODUCTION................................................................................................................................................................................1 - 2

GENERAL WARNINGS .....................................................................................................................................................................1 - 2

VEHICLE IDENTIFICATION/SAFETY CERTIFICATION LABEL.......................................................................................................1 - 3

FASTENER USAGE...........................................................................................................................................................................1 - 3

PARTS AND LUBRICANT RECOMMENDATION..............................................................................................................................1 - 5

MAINTENANCE SCHEDULES..........................................................................................................................................................1 - 5

HOISTING AND JACKING.................................................................................................................................................................1 - 6

1 - 2 INTRODUCTION

November 2007 GEM Service Manual

INTRODUCTION

Appropriate service methods and proper repair

procedures are essential for the safe, reliable

operation of your vehicles, as well as the safety of

the individual doing the work. This service manual

provides general directions for accomplishing

service and repair work with recommended

techniques. Following them will help ensure

reliability.

There are numerous variations in procedures,

techniques, tools, and parts for servicing your

vehicle, as well as in the skill levels of the

individuals doing the work. This manual cannot

possibly anticipate all such variations and provide

advice or cautions for each. Accordingly, anyone

who departs from the instructions provided in this

manual must first establish that he/she

compromises neither their personal safety nor

vehicle integrity by their choice of methods, tools,

or parts.

GENERAL WARNINGS

Observe the following safety precautions whenever

you are working on your vehicle:

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure

requires you to be under the vehicle.

• Be sure that the ignition switch is always in the

OFF position and that the key is removed.

• Be sure to switch the 72-volt master disconnect

to OFF.

• Set the parking brake and place wood blocks

(4" x 4" or larger) to the front and rear surfaces

of the tires to restrain the vehicle from

movement.

• Do not smoke while working on your vehicle.

Batteries produce hydrogen gas that is

extremely flammable and will explode upon

exposure to any ignition source.

• Remove rings, watches, loose jewelry, and

loose clothing when working on your vehicle to

avoid injury.

NOTE: The terms right-hand (RH) and left-hand

(LH) are relative to one sitting in the driver's

seat. Therefore, right-hand refers to the

passenger side, and left-hand refers to the

driver's side of the vehicle.

INTRODUCTION 1 - 3

GEM Service Manual November 2007

VEHICLE

IDENTIFICATION/SAFETY

CERTIFICATION LABEL

DESCRIPTION

A label, containing the Vehicle Identification

Number (VIN) and safety certification, is located

above the bench seat on the underside of the rear

roof panel on the driver's side.

The information on the label includes:

• Vehicle Identification Number (VIN)

• Month and year of manufacture

• Gross Vehicle Weight Rating (GVWR)

• Gross Front and Rear Axle Ratings (GAWR)

• Wheel size

• Tire size

• Cold tire pressure

Fig. 1 VIN/Certification Label

Fig. 2 VIN/Certification Location

1 - VIN/Certification Label Location (Typical - 2-passenger model

shown)

NOTE: The last six digits of the VIN are also

located on the rear frame support under the

bench seat cushion.

FASTENER USAGE

DESCRIPTION

WARNING: USE OF AN INCORRECT FASTENER

MAY RESULT IN COMPONENT DAMAGE OR

PERSONAL INJURY.

Fasteners and torque specifications references in

this Service Manual are identified SAE format.

During any maintenance or repair procedure, it is

important to salvage all fasteners (nuts, bolts, etc.)

for reassembly. If the fastener is not salvageable, a

fastener of equivalent specification must be used.

NOTE: Nylon lock nuts must always be

replaced.

1 - 4 INTRODUCTION

November 2007 GEM Service Manual

FASTENER USAGE (CONTINUED)

TORQUE SPECIFICATIONS

Description Thread

Size Use

Loctite®

242

Inch-Pounds Foot-

Pounds

Battery cables to battery post NO 95-105 in/lbs 5/16"

post

120-180 in/lbs 3/8"

post

---

Brake line to wheel/master cylinder NO 37 ---

Brake master cylinder to frame 5/16 - 18 NO 225 ---

Brake pedal assembly to frame 5/16 - 18 NO 225 ---

Brake pedal to push rod 3/8 - 16 NO --- 30

Brake, parking – cable mount to rear

suspension ½” x 13 NO --- 50

Control arm to frt. suspension frame M12 x 1.75 NO --- 30

Differential to frt. suspension frame 5/16 – 18 NO 225 ---

Front suspension frame to frame (lower) M12 x 1.75 YES --- 60

Front suspension frame to frame (upper) 3/8 – 16 YES --- 30

Ball joint pinch bolt M6 – 1 YES --- 30

Motor to differential ¼ - 20 YES 65 ---

Rack & pinion to frt. suspension frame M8 x 1.25 NO 225 ---

Rear suspension frame to frame M12 x 1.75 NO --- 60

Seat belt D-ring to frame NO --- 60

Seat belt end to frame NO --- 60

Seat belt latch assembly to frame NO --- 60

Seat belt latch assembly to bracket – bucket

seat NO --- 60

Seat belt retractor to bracket – bucket seat NO --- 60

Seat belt retractor to frame – bench seat NO --- 60

Shock absorber lower bolt M12 x 1.75 NO --- 60

Shock absorber upper bolt M12 x 1.75 NO --- 60

Steering column pinch bolt 3/8 – 16 NO --- 35

Steering column to dash frame 5/16 – 18 NO 225 ---

Steering wheel to steering shaft NO --- 20

Tie rod stud nut M10 x 1.5 NO --- 35

Wheel lug nuts 12mm NO --- 65

INTRODUCTION 1 - 5

GEM Service Manual November 2007

PARTS AND LUBRICANT

RECOMMENDATION

When service is required, GEM recommends that

only GEM replacement parts be used. GEM

provides the best-engineered products for servicing

GEM vehicles.

DESCRIPTION - LUBRICANTS AND GREASE

Only lubricants bearing designations defined by

The Society for Automotive Engineers (SAE)

should be used to service a GEM vehicle.

The National Lubricating Grease Institute (NLGI)

rates lubricating grease for quality and usage. All

approved products have the NLGI symbol (Fig. 3)

on the label. At the bottom of the symbol is the

usage and quality identification letters. The letter

"G" identifies wheel-bearing lubricant. The letter "L"

identifies chassis lubricant. The letter following the

usage letter indicates the quality of the lubricant.

The following symbols indicate the highest quality.

Fig. 3 NLGI Symbols

1 - Wheel bearing lubrication

2 - Chassis lubrication

3 - Chassis and wheel bearing lubrication

DESCRIPTION - DIFFERENTIAL

Use 30 SAE engine oil – 12.44:1/14.76:1, 16 oz..

DESCRIPTION - BRAKE FLUID

Use only DOT 3 brake fluid from an unopened

container when filling the master cylinder to prevent

contaminants from entering the brake system.

MAINTENANCE SCHEDULES

Perform the following inspections, and corrections

as necessary, on a monthly basis.

Item Description

1. Check all six batteries for proper water

levels (if applicable).

2. Check battery terminals for tight

connections.

3. Check battery terminals for corrosion.

4. Check tires for correct PSI and wear.

5. Check for proper operation of hand brake.

6. Check master cylinder for proper brake

fluid levels.

7. Check brake lines for leaks.

8. Check seat belts for proper operation.

9. Check headlights, horn, turn signals,

windshield wiper and brake lights for

proper operation.

10. Check battery hold-down bar to make

sure batteries are tightly secured.

11. Check for worn insulation and frayed

wires.

1 - 6 INTRODUCTION

November 2007 GEM Service Manual

HOISTING AND JACKING

Fig. 4 Hoisting/Jacking Locations

A vehicle can be lifted with:

• A single-post frame-contact hoist

• A twin-post, chassis hoist

• A ramp-type drive-on hoist

NOTE: When a frame-contact type hoist is

used, verify that the lifting pads are positioned

properly.

WARNING: THE HOISTING AND JACK LIFTING

POINTS PROVIDED ARE FOR A COMPLETE

VEHICLE. WHEN A CHASSIS OR DRIVETRAIN

COMPONENT IS REMOVED FROM A VEHICLE,

THE CENTER OF GRAVITY IS ALTERED

MAKING SOME HOISTING CONDITIONS

UNSTABLE. PROPERLY SUPPORT OR

SECURE VEHICLE TO HOISTING DEVICE WHEN

THESE CONDITIONS EXIST.

CAUTION: Do not attempt to lift a vehicle with a

floor jack positioned under an axle tube, body

side panel or sill, or front control arm. When

properly positioned, a floor jack can be used to

lift a GEM vehicle. Support the vehicle in the

raised position with jack stands at the locations

indicated.

SUSPENSION & STEERING 2 - 1

November 2007 GEM Service Manual

CONTENTS

WHEEL ALIGNMENT......................................................................................................................................................................2 - 2

ALIGNMENT...................................................................................................................................................................................2 - 4

FRONT SUSPENSION ...................................................................................................................................................................2 - 5

SPRING OVER SHOCK ABSORBER ASSEMBLY ........................................................................................................................2 - 6

CONTROL ARM ASSEMBLY (WITH BUSHINGS).........................................................................................................................2 - 7

REAR SUSPENSION......................................................................................................................................................................2 - 8

REAR SUSPENSION FRAME/AXLE (2-4 PASSENGER ONLY) (e2, e4, eS, eL)........................................................................2 - 8

REAR SUSPENSION FRAME/AXLE (6 PASSENGER & LONG BACK EXTRA DUTY) (e6, e6S, eLXD).....................................2 - 9

REAR HUB AND BEARING/SPINDLE (6 PASSENGER & LONG BACK EXTRA DUTY) (e6, e6S, eLXD)....................................2 - 10

STEERING......................................................................................................................................................................................2 - 11

STEERING WHEEL........................................................................................................................................................................2 - 13

STEERING COLUMN ASSEMBLY.................................................................................................................................................2 - 15

STEERING GEAR...........................................................................................................................................................................2 - 16

OUTER TIE ROD END....................................................................................................................................................................2 - 17

STEERING KNUCKLE....................................................................................................................................................................2 - 18

2 - 2 SUSPENSION AND STEERING

GEM Service Manual November 2007

INSPECTION - PRE-ALIGNMENT

WHEEL ALIGNMENT The steering system should be inspected for wear.

Any worn or damaged components must be

replaced before checking alignment. The pressure

of all four tires should be set to specification with a

high quality tire pressure gauge, not the pencil type,

before checking the alignment or performing a

driving inspection. Customer complaints of poor

handling or excessive front tire wear should be

confirmed by a test drive. The test drive should be

performed on a smooth level surface with plenty of

room to maneuver.

DESCRIPTION

Front wheel alignment is essential for proper

vehicle handling and passenger safety. Front-end

damage or replacement of any steering or front

suspension component will require inspection of the

alignment to determine if it is still within

specifications.

CAUTION: Never attempt to modify suspension

or steering components by heating or bending. Before starting wheel alignment, the following

inspection and necessary corrections must be

completed. Refer to Fig. 1 Tire Wear Chart and the

Suspension and Steering Diagnosis and Testing

Chart below for additional information.

1. Inspect tires for size, air pressure and tread

wear.

2. Inspect front wheel bearings for wear.

3. Inspect ball joints, linkage pivot points and

steering gear for looseness, roughness or

binding.

4. Inspect suspension components for wear and

noise.

5. Road test the vehicle.

Fig. 1 Tire Wear Chart

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