Polaris GEM E Series User manual

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