Possible causes for a Polaris GEM E Series cart starting and then shutting down immediately when accelerating include:

1. Faulty Contactor – If voltage on the black/green wire does not drop from 72V to 0V when the accelerator is pressed, the contactor may need to be replaced.
2. Failed Motor Controller – If error code 51 appears, the motor controller may have failed due to a shorted motor.
3. Shorted Motor – If the motor has shorted windings, it could cause the controller to fail and shut down operation. Inspect the motor for burnt windings or shorts.
4. Burnt Contactor Points – A voltage drop test across the contactor points can reveal excessive resistance, which may indicate burnt points that need replacement.

To diagnose, check the contactor operation, inspect the motor and controller for faults, and test for voltage drops at key points.

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Marcin

February 26, 2025

Witam potrzebuje regulator obrotów silnika Polaris gem 72v

1 comments:

Mr. Anderson

February 26, 2025

The motor speed controller for the Polaris GEM E Series 72V is referred to in the service manual. If you need to locate or replace it, refer to the circuit diagrams and troubleshooting charts in the manual. If the controller needs replacement, follow the diagnostic steps outlined under Drive and Power System Error Codes.

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Summary of Contents for Polaris GEM E Series

Page 1 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 GEM Service Manual - REV 1 - 4/19/2012 November 2007...
Page 3: Table Of Contents
INTRODUCTION 1 - 1 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.................................
Page 4: Introduction
1 - 2 INTRODUCTION INTRODUCTION NOTE: The terms right-hand (RH) and left-hand (LH) are relative to one sitting in the driver's seat. Therefore, right-hand refers Appropriate service methods and proper repair passenger side, and left-hand refers to the procedures are essential for the safe, reliable driver's side of the vehicle.
Page 5: Vehicle Identification/Safety Certification Label
INTRODUCTION 1 - 3 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: Fig.
Page 6 1 - 4 INTRODUCTION FASTENER USAGE (CONTINUED) TORQUE SPECIFICATIONS Description Thread Inch-Pounds Foot- Loctite® Pounds Size Battery cables to battery post 95-105 in/lbs 5/16" post 120-180 in/lbs 3/8" post Brake line to wheel/master cylinder Brake master cylinder to frame 5/16 - 18 Brake pedal assembly to frame 5/16 - 18 Brake pedal to push rod...
Page 7: Parts And Lubricant Recommendation
INTRODUCTION 1 - 5 PARTS AND LUBRICANT MAINTENANCE SCHEDULES RECOMMENDATION Perform the following inspections, and corrections as necessary, on a monthly basis. When service is required, GEM recommends that only GEM replacement parts be used. Item Description provides the best-engineered products for servicing GEM vehicles.
Page 8: Hoisting And Jacking
1 - 6 INTRODUCTION HOISTING AND JACKING 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, CENTER GRAVITY...
Page 9 SUSPENSION & STEERING 2 - 1 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 &...
Page 10: Wheel Alignment
2 - 2 SUSPENSION AND STEERING WHEEL ALIGNMENT INSPECTION - PRE-ALIGNMENT The steering system should be inspected for wear. DESCRIPTION Any worn or damaged components must be replaced before checking alignment. The pressure Front wheel alignment is essential for proper of all four tires should be set to specification with a vehicle handling and passenger safety.
Page 11 SUSPENSION AND STEERING 2 - 3 SUSPENSION AND STEERING DIAGNOSIS AND TESTING Condition Possible Causes Correction • • Loose or worn wheel bearing Replace front knuckle assembly Front end noise • • Loose or worn steering or suspension Tighten or replace components as components necessary •...
Page 12: Alignment
2 - 4 SUSPENSION AND STEERING ALIGNMENT ADJUSTING TOE 1. Center the front wheels. DESCRIPTION 2. Inspect the position of the pinch bolt that joins the steering column shaft to the steering gear. This bolt must be horizontal and under the shaft (see Figure 3).
Page 13: Front Suspension
SUSPENSION AND STEERING 2 - 5 FRONT SUSPENSION DESCRIPTION The front suspension is designed to allow each wheel adapt different road surfaces independently. The wheels are mounted to rotor assemblies, which in turn are mounted to the steering components attached to a control arm, that pivot up and down on bushings.
Page 14: Spring Over Shock Absorber Assembly
2 - 6 SUSPENSION AND STEERING SPRING OVER SHOCK REMOVAL - FRONT SHOCKS ABSORBER ASSEMBLY 1. Raise and support the vehicle on a suitable hoist. 2. Using a 3/4-inch wrench and socket, remove DESCRIPTION mounting bolts and nuts. 3. Remove the shock. The GEM e-series vehicles combine a spring and shock absorber into a single unit.
Page 15: Control Arm Assembly (With Bushings)
SUSPENSION AND STEERING 2 - 7 CONTROL ARM ASSEMBLY 4. If removing the upper control arm only, use a 3/4-inch wrench and socket and remove the (WITH BUSHINGS) spring/shock absorber lower mounting bolt. 5. Support the control arm assembly, then remove the bolts connecting control arm to front frame DESCRIPTION and the steering knuckle.
Page 16: Rear Suspension
2 - 8 SUSPENSION AND STEERING REAR SUSPENSION REAR SUSPENSION FRAME/AXLE DESCRIPTION (2-4 PASSENGER ONLY) The rear suspension is comprised of a frame that (e2, e4, eS, eL) includes the rear axle, and spring/shock absorbers. DESCRIPTION The rear suspension frame is attached to the rear of the vehicle frame by bolts in bushings.
Page 17 SUSPENSION AND STEERING 2 - 9 INSTALLATION 10. Note: Support the backing plate assemblies to protect the brake lines and parking brake cables. 1. Move the frame/axle assembly into position on 11. Remove the lower spring/shock bolts with a 3/4 the rear of vehicle frame.
Page 18: Rear Hub And Bearing/Spindle (6 Passenger & Long Back Extra Duty) (E6, E6S, Elxd)
2 - 10 SUSPENSION AND STEERING REAR HUB AND REMOVAL BEARING/SPINDLE 1. Raise and support the vehicle on a suitable hoist. (6 PASSENGER & LONG 2. Remove the hubcap. 3. Remove the tire and wheel assembly. BACK EXTRA DUTY) 4. Remove the brake drum. (e6, e6S, eLXD) 5.
Page 19: Steering
SUSPENSION AND STEERING 2 - 11 STEERING Fig. 8 Steering System Description OPERATION The steering system is comprised of: The steering column transmits rotation of the steering wheel to the pinion in the steering gear. • Steering wheel Rotation of the pinion moves the gear rack in the •...
Page 20 2 - 12 SUSPENSION AND STEERING STEERING DIAGNOSIS AND TESTING Condition Possible Causes Correction • • Rattle or clunk Gear mounting bolts loose Tighten bolts to specification • • Loose or damaged suspension Inspect and repair suspension components components • Replace steering column •...
Page 21: Steering Wheel
SUSPENSION AND STEERING 2 - 13 STEERING WHEEL DESCRIPTION The steering wheel assembly consists of two parts, the steering wheel and the steering wheel cover. OPERATION Splines on the steering wheel mounting hole match to splines on the steering shaft. These splines force the wheel and shaft to turn as a unit, thereby transmitting turning force to the steering gear.
Page 22 2 - 14 SUSPENSION AND STEERING Fig. 11 Steering Wheel Holes For Puller Fig. 12 Wheel Puller Installed 1 - Guide holes INSTALLATION 1. Using reference marks, align steering wheel to steering shaft and place on shaft. 2. Replace washer and attaching nut on end of shaft and tighten to press wheel completely on splines. Back off nut and tighten to 20 ft-lbs.
Page 23: Steering Column Assembly
SUSPENSION AND STEERING 2 - 15 STEERING COLUMN 4. Remove steering column/instrument covers. See Pod Covers in Body section. ASSEMBLY 5. Remove steering wheel with wheel puller or appropriate method. See Steering Wheel in this section. DESCRIPTION 6. Remove the pinch bolt attaching steering shaft to steering gear.
Page 24: Steering Gear
2 - 16 SUSPENSION AND STEERING STEERING GEAR DESCRIPTION The GEM uses a rack and pinion steering gear with integral tie rods. OPERATION Teeth on the pinion gear engage teeth on the rack. Turning motion of pinion gear causes rack to move either right or left.
Page 25: Outer Tie Rod End
SUSPENSION AND STEERING 2 - 17 TORQUE SPECIFICATIONS Description Thread Size Inch- Foot Loctite® Pounds Pounds Rack & pinion to frt. suspension frame M8 x 1.25 Steering column pinch bolt 3/8 - 16 Tie rod stud nut M10 x 1.5 Wheel lug nuts 12mm OUTER TIE ROD END...
Page 26: Steering Knuckle
2 - 18 SUSPENSION AND STEERING TORQUE SPECIFICATIONS Description Thread Size Inch- Foot Loctite® Pounds Pounds Brake line to wheel/master cylinder Caliper assembly to steering knuckle M8 x 1.25 Halfshaft to drum brake assembly M16 x 1.5 Ball joint pinch bolt M6 –...
Page 27 DRIVETRAIN 3 - 1 CONTENTS DRIVETRAIN...................................... 3 - 2 HALFSHAFT ...................................... 3 - 2 DIFFERENTIAL....................................3 - 4 November 2007 GEM Service Manual...
Page 28 3 - 2 DRIVETRAIN DRIVETRAIN When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete turn. difference must DESCRIPTION compensated for to prevent the tires from scuffing and skidding through turns. To accomplish this, the The drivetrain consists of a 72-volt motor, a differential allows the axle shafts to turn at unequal gearbox/differential and two constant velocity drive...
Page 29 DRIVETRAIN 3 - 3 INSTALLATION 7. Remove king pin pinch bolt and separate control arm. 8. The inner end is held on with a spring clip. 1. Apply Optimol Olistamoly 2 LN 584 LO grease Using a pair of short pry bars, gently force the or equivalent to the splines at the inner and inner end off the differential.
Page 30 3 - 4 DRIVETRAIN DIFFERENTIAL REMOVAL 1. Open the hood. DESCRIPTION 2. Remove the halfshafts. See Halfshafts in this section. The differential consists of a pinion gear and two 3. Remove motor. See Motor in Electrical section. side gears in a cast aluminum case. The drive 4.
Page 31 BRAKES 4 - 1 CONTENTS BRAKE SYSTEM ....................................4 - 2 BRAKE BLEEDING ..................................... 4 - 3 FRONT BRAKE ASSEMBLY ................................4 - 5 REAR BRAKE ASSEMBLY (2 - 4 PASSENGER ONLY) (e2, e4, eS, eL)..................4 - 7 REAR BRAKE ASSEMBLY (6 PASSENGER & LONG BACK EXTRA DUTY) (e6, e6S, eLXD)............4 - 9 BRAKE PEDAL ASSEMBLY ................................
Page 32: Brake System
4 - 2 BRAKES BRAKE SYSTEM NOTE: Brake fluid tends to darken over time. This is normal and should not be mistaken for contamination. 4. If fluid level is abnormally low, look for evidence of leaks at caliper, drum assemblies, hoses and lines, and master cylinder.
Page 33: Brake Bleeding
BRAKES 4 - 3 SPONGY PEDAL THUMP OR CLUNK NOISE A spongy pedal is most often caused by air in the Thumping or clunking noises during braking are system. However, thin brake rotors or brake drums frequently not caused by brake components. In or substandard brake lines and hoses can also many cases, such noises are caused by loose or cause a spongy pedal.
Page 34 4 - 4 BRAKES Fig. 2 Rear Bleed Screw (Typical) Fig. 3a Front Brake Bleeding Setup 1 - Bleed screw 1 - Hose 2 - Container for waste brake fluid 3. Starting at the right rear, attach one end of bleed hose to bleed screw and insert the opposite end in a glass container partially filled with brake fluid (Fig.
Page 35: Front Brake Assembly
BRAKES 4 - 5 FRONT BRAKE ASSEMBLY OPERATION When applying the brake pedal, pedal pressure DESCRIPTION forces the brake fluid through the brake line, from the master cylinder to each caliper. This pressure The front brake assembly consists of a caliper, pushes the caliper piston out, causing the brake rotor and brake pads.
Page 36 4 - 6 BRAKES TORQUE SPECIFICATIONS Description Thread Size Inch- Foot Loctite® Pounds Pounds Brake line to wheel/master cylinder Brake drum assembly to steering knuckle M8 x 1.25 Half shaft to drum brake assembly M10 x 1.5 Wheel lug nuts 12mm Rotor to Hub Caliper...
Page 37: Rear Brake Assembly (2 - 4 Passenger Only) (E2, E4, Es, El)
BRAKES 4 - 7 REAR BRAKE ASSEMBLY OPERATION (2 - 4 PASSENGER ONLY) When pressing on the brake pedal, pressure forces (e2, e4, eS, eL) the brake fluid through the brake line from the master cylinder to each wheel cylinder. The wheel cylinder has two pistons, each of which engage a DESCRIPTION brake shoe.
Page 38 4 - 8 BRAKES DISASSEMBLY INSTALLATION 1. Remove the two screws holding drum to NOTE: Be sure you have the correct (RH or LH) assembly, remove drum. drum brake assembly. 2. Remove the spring clips from pins at center of each shoe, and remove pins.
Page 39: Rear Brake Assembly (6 Passenger & Long Back Extra Duty) (E6, E6S, Elxd)
BRAKES 4 - 9 REAR BRAKE ASSEMBLY OPERATION (6 PASSENGER & LONG When pressing on the brake pedal, pressure forces the brake fluid through the brake line from the BACK EXTRA DUTY) master cylinder to each wheel cylinder. The wheel cylinder has two pistons, each of which engage a (e6, e6S, eLXD) brake shoe.
Page 40 4 - 10 BRAKES ASSEMBLY NOTE: Be sure you have the correct (RH or LH) drum brake assembly. 1. Position wheel cylinder on backing plate and attach with mounting bolt furthest from actuator 11. Install the tire and wheel assembly. Tighten the lever.
Page 41: Brake Pedal Assembly To Frame 5/16
BRAKES 4 - 11 BRAKE PEDAL ASSEMBLY OPERATION The brake pedal pivots on a shaft mounted on the DESCRIPTION bracket. Foot pressure causes downward motion of the pedal, forcing a push rod against a piston in the The brake pedal assembly is mounted on the dash master cylinder.
Page 42: Master Cylinder Assembly
4 - 12 BRAKES MASTER CYLINDER REMOVAL ASSEMBLY 1. Remove upper and lower dash panel. See Dash Panel Upper in Body section. 2. Remove the brake pedal to push rod bolt. DESCRIPTION 3. Disconnect the electrical connectors from the master cylinder. The master cylinder assembly is located under the 4.
Page 43: Park Brake Lever Assembly
BRAKES 4 - 13 PARK BRAKE LEVER OPERATION ASSEMBLY Pulling up on lever causes the park brake adjuster assembly to pull on the park brake cables. A DESCRIPTION ratchet holds the park brake lever in place, maintaining pressure on the cables. A push button The park brake lever is located between the driver on the end of the park brake cable disengages the and front passenger seats.
Page 44: Parking Brake Cable Assembly
4 - 14 BRAKES INSTALLATION PARKING BRAKE CABLE ASSEMBLY TWO PASSENGER, SHORT BED UTILITY, LONG BED UTILITY COUPE MODELS DESCRIPTION 1. Position the park brake lever assembly. 2. Replace the mounting bolts through park brake Two cables are attached to the park brake lever by lever brackets.
Page 45 BRAKES 4 - 15 REMOVAL 1. Chock the wheels. 2. Remove the lower seat. See Bench Seat in Body section. 3. Switch master disconnect OFF, and cover battery terminals to prevent electrical contact. 4. Release the park brake lever. 5. Remove the cables from the equalizer 6.
Page 46: Brake, Parking - Cable Mount To Rear ½" X 13 No
4 - 16 BRAKES PARKING BRAKE CABLE ASSEMBLY (6 PASSENGER ONLY) REMOVAL 1. Remove the rear brake shoes. See Brakes in this section. 2. Disconnect the parking brake cables from the tension equalizer. 3. Separate the parking brake cables at the front frame from the brake backing plate.
Page 47: Park Brake Cable Tension Adjustment
BRAKES 4 - 17 PARK BRAKE CABLE TENSION ADJUSTMENT 1. Chock wheels 2. Release park brake. 3. Locate threaded adjusting rod/cable assembly at the end of the lever. 4. Using 1/2" open-end wrenches, back off rear nut to release forward adjusting nut. 5.
Page 48 5 - 1 ELECTRICAL CONTENTS ELECTRICAL SYSTEM ..................................5 - 2 POWER SYSTEM ....................................5 - 3 DRIVE SYSTEM....................................5 - 4 ACCELERATOR PEDAL (FOOT PEDAL)............................5 - 17 BATTERY......................................5 - 18 CHARGER ......................................5 - 27 MOTOR CONTROLLER ..................................5 - 32 DC/CONVERTER....................................5 - 33 MAIN CONTACTOR...................................5 - 34 MOTOR......................................5 - 35 MOTOR MAGNET AND SPEED SENSOR (TACHOMETER) ......................5 - 37...
Page 49: Electrical System
ELECTRICAL 5 - 2 ELECTRICAL SYSTEM DESCRIPTION Fig. 1 Electrical System Diagram The electrical system of the GEM is shown in the NOTE: The master disconnect switch is located block diagram above. For purposes of operational in the lower dash unit of the fuse access panel description, the system is divided into three groups (see figure 4).
Page 50: Power System
5 - 3 ELECTRICAL POWER SYSTEM DESCRIPTION Fig. 2 Power System DIAGNOSIS AND TESTING The purpose of the power system is to provide primary power for the drive and accessory systems. The power system consists of the batteries, battery Diagnosis and testing of the power system is charger, fuse, key switch, temperature sensor, and integrated with the diagnosis and testing of the power harness (not shown in the block diagram).
Page 51: Drive System
ELECTRICAL 5 - 4 DRIVE SYSTEM The basic operation procedures described in the Owner's Manual must be followed for the drive system to operate properly. If the drive system DESCRIPTION does not operate, verify the following steps have been completed: •...
Page 52 5 - 5 ELECTRICAL DIAGNOSIS AND TESTING The purpose of this section is to aid in the isolation of problems with the drive system and power system. The primary means of troubleshooting the drive and power system is via error codes displayed on the LCD display (see figure 5, item 3).
Page 53 ELECTRICAL 5 - 6 DRIVE AND POWER SYSTEM ERROR CODES The motor controller monitors the drive system when the vehicle is powered up (key is in the ON position). The motor controller reports any problems detected by displaying error codes on the multi-purpose LCD display located in the center of the instrument pod.
Page 54 5 - 7 ELECTRICAL DRIVE AND POWER SYSTEM ERROR CODES (Continued) Error Code Fault Description Corrective Action Improper or no contact at the drive Refer Motor Controller Circuit Diagram mode switch (defective switch as troubleshooting the start switch circuit. There should be no indicated by a short inside or not in input voltage present at the motor controller connector, CH1 the correct position -between the...
Page 55 ELECTRICAL 5 - 8 DRIVE AND POWER SYSTEM ERROR CODES (Continued) Motor armature offset voltage is too Replace the motor controller. low. Armature transistor did not turn off Replace the motor controller. properly. Armature transistor did not turn off Replace the motor controller. properly.
Page 56 5 - 9 ELECTRICAL DRIVE AND POWER SYSTEM ERROR CODES (Continued) Error Code Fault Description Corrective Action Motor controller motor current First through Drive Power System sensor input is too low while Troubleshooting Chart A. If directed back to the Drive and running.
Page 57 ELECTRICAL 5 - 10 DRIVE AND POWER SYSTEM ERROR CODES (Continued) Error Code Fault Description Corrective Action No tachometer signal is detected. Defective wiring between tachometer and the motor controller. See Troubleshooting Diagram A. Replace tachometer. Armature current exceeds Continued operation of vehicle in high motor current amps for 3.5 seconds and the condition.
Page 58 5 - 11 ELECTRICAL Troubleshooting Diagram A Troubleshooting Diagram B Troubleshooting Diagram C GEM Service Manual November 2007...
Page 59: Yes
ELECTRICAL 5 - 12 DRIVE AND POWER SYSTEM TROUBLESHOOTING CHARTS The Drive and Power System Troubleshooting Chart A should be used as a guide to isolate electrical problems with the batteries, master disconnect switch, main contactor, and motor controller that are not covered by the fault codes.
Page 60: Yes
5 - 13 ELECTRICAL DRIVE AND POWER SYSTEM (Continued) Step Action 1. If voltage Remove the upper and lower dash panels and Proceed to Step 5. present, but less locate the power signal distribution module than VDC, (PSDM). Measure the voltage on the PSDM at the charge measuring points indicated.
Page 61: Yes
ELECTRICAL 5 - 14 DRIVE AND POWER SYSTEM (Continued) Step Action Apply foot brake, turn the key on, release emergency Proceed to Step 7. Proceed to Step 10. brake, momentarily step on accelerator pedal and measure the voltage between the white wire connected to the contactor coil and 72 volt negative terminal at PSDM.
Page 62 5 - 15 ELECTRICAL DRIVE AND POWER SYSTEM (Continued) Step Action With the master disconnect switch off, remove fuse Proceed to Step 10b. Replace fuse 13. 13 and check for continuity. With master disconnect switch on, measure Proceed to step 10c. Replace the PSDM.
Page 63 ELECTRICAL 5 - 16 DRIVE AND POWER SYSTEM (Continued) Drive and Power System Troubleshooting Chart B Condition Diagnostic Steps Correction LCD does not show MPH indications when the Check tachometer for Check for 12 volt between the car is moving. loose connections.
Page 64: Accelerator Pedal (Foot Pedal)
5 - 17 ELECTRICAL ACCELERATOR PEDAL decrease. When the accelerator pedal is completely down, the resistance should reach (FOOT PEDAL) approximately 80 ohms. If the resistance does not vary as described, replace the accelerator pedal. If the resistance is a constant very low DESCRIPTION resistance (possible short circuit) or constant high resistance (open circuit), there could be a...
Page 65: Battery
ELECTRICAL 5 - 18 BATTERY DESCRIPTION Six 12-volt lead acid (nine 8-volt 6-passenger & long back extra duty model option) batteries supply 72-volt power for the vehicle. Two are located under the spat or under the bed of the vehicle. Four are located under the front cushion on two- passenger models, and under the rear seat cushion on four-passenger models.
Page 66 5 - 19 ELECTRICAL OPERATION BATTERY CARBON PILE LOAD TEST The GEM vehicle has a battery control and Test batteries at 1/2 CCA for 15 seconds and the recharge system specially designed for electric voltage should not drop below 10.5 volts and with vehicle usage.
Page 67 ELECTRICAL 5 - 20 12-Volt Battery Only CAUTION: It is essential when replacing the cables on the battery that the positive cable is All 2005 – Current Models attached to the positive post and the negative cable is attached to the negative post. Battery 1.
Page 68 5 - 21 ELECTRICAL REMOVAL AND DISPOSAL 1. Turn off master disconnect switch. Fig. 12 Middle Seat Access Panel Removed (e6 models) 1 - Battery Fig. 10 Master Disconnect Switch 1 - Master disconnect switch REAR 2. Remove bench seat (see Bench Seats). 3.
Page 69 ELECTRICAL 5 - 22 BATTERY SAFETY WARNING: ALWAYS WEAR PROTECTIVE CLOTHING, GLOVES, AND GOGGLES WHEN HANDLING BATTERIES AND ELECTROLYTE. Improper use and care of batteries can result in serious personal injury or property damage. Always observe the following safety precautions: WARNING: DO NOT SMOKE NEAR BATTERIES.
Page 70 5 - 23 ELECTRICAL PROPER TORQUE VALUES FOR CONNECTION readings should within factory specification of 1.277 ± 0.007. If not, follow the HARDWARE steps below. Deka 8V Gel Batteries – 95 - 105 in-lbs. 1. Check and record voltage level(s) Deka 12V Gel/EV31 Batteries –...
Page 71 ELECTRICAL 5 - 24 4. After all the safety procedures specified by the Percentage of Specific Gravity Open-Circuit manufacturer have been followed, start the unit. Charge Corrected to 80° F Voltage 5. When unit shuts off, record the discharge time. 1.277 12.73 1.258...
Page 72 5 - 25 ELECTRICAL TESTING FOR DEFECTIVE CELLS Flooded batteries need water. More importantly, watering must be done at the right time and in the right amount or else the battery's performance and During a discharge, all cells in a battery set should longevity suffers.
Page 73 ELECTRICAL 5 - 26 CLEANING SMC – STORAGE MARTS CYCLE After time batteries, attract dust, dirt, and grime. In NOTE: Your GEM is equipped with a SMART addition, electrolyte expelled from the battery vent charge capability. Simply leave the vehicle caps due to over-watering and/or overcharging can plugged into a standard 110 VAC 15 A power form a conductive path that will cause the batteries...
Page 74: Charger
5 - 27 ELECTRICAL CHARGING The battery charge receptacle is located on the front hood assembly. It accepts a standard 3 wire (grounded) extension cord and should not exceed WARNING: CHARGE BATTERIES ONLY IN 25 feet in length 12 gauge or heavier. WELL-VENTILATED AREA.
Page 75 ELECTRICAL 5 - 28 CHARGING WHEN BELOW MINIMUM VOLTAGE disconnect switch OFF and is waiting to be connected to the battery pack, the charging algorithm number will be displayed for 11 The on-board charger has a safety feature, which seconds (see “Check / Change Charging does not allow it to turn on if the pack voltage is Algorithm”) before ultimately displaying an below 36 volts.
Page 76 5 - 29 ELECTRICAL errors. Some errors are serious and require 1. Disconnect the charger positive connect by human intervention to first resolve the problem flipping the master switch. Start with the switch and them to reset the charger by interrupting in the OFF position.
Page 77 ELECTRICAL 5 - 30 Pack recovery (PRC) algorithm selection is not the PRC algorithm is indicated by the ‘80%’ and stored in permanent memory. After selecting this ‘100%’ LEDs flashing together. When the PRC algorithm, connect the charger to the battery charge completes, or AC power is removed and without interrupting AC power.
Page 78 5 - 31 ELECTRICAL DELTA-Q WIRING ORIENTATION 1. Wires from the charger. 1. Black to motor controller negative. 2. Green to green spade in the front harness. (Interlock Relay Circuit) 3. Red to the Contactor left terminal 4. White to black spade from the rear harness (temp sensor harness).
Page 79: Motor Controller
ELECTRICAL 5 - 32 MOTOR CONTROLLER OPERATION The controller functions automatically when the DESCRIPTION master disconnect switch is in the ON position. There are no other direct operator interactions with the motor controller module. Operation of the motor controller is accomplished by actuation of the devices such as the accelerator pedal, and the drive mode switch.
Page 80: Dc/Converter
5 - 33 ELECTRICAL DC/CONVERTER DIAGNOSIS AND TESTING Diagnosis and testing of the DC/DC converter is DESCRIPTION covered in the Accessory System Troubleshooting Chart. The circuit diagrams provided in this manual are also useful in isolation of problems associated with the DC/DC converter. REMOVAL 1.
Page 81: Main Contactor
ELECTRICAL 5 - 34 MAIN CONTACTOR REMOVAL 1. Turn the master disconnect switch OFF. DESCRIPTION 2. Remove upper and lower dash. 3. Locate main contactor. 4. Remove electrical connections, noting connection and orientation for each wire. 5. Remove screws that mount contactor to the front bulkhead.
Page 82: Motor
5 - 35 ELECTRICAL MOTOR DESCRIPTION Fig 19 Motor Location Power to the drivetrain is supplied by a 72-volt electric motor, which is attached to the differential. The motor speed (RPM) is monitored by a small magnet and a speed sensor (tachometer) mounted to the center rear of the motor (see figure 20).
Page 83: Motor To Differential Yes
ELECTRICAL 5 - 36 REMOVAL 9. Remove 3 bolts from differential side of motor (see figure 21) with 7/16-inch wrench or socket, taking care to support motor, which weighs 30-40 pounds 10. Remove motor, noting the orientation of power posts for reassembly, and then pull straight out. INSTALLATION 1.
Page 84: Motor Magnet And Speed Sensor (Tachometer)
5 - 37 ELECTRICAL MOTOR MAGNET AND OPERATION SPEED SENSOR When the motor's armature rotates the magnet rotates also. The sensor detects the magnet's (TACHOMETER) motion, and transmits a signal through its pigtail to the motor controller. DESCRIPTION A small circular magnet is mounted to the motor REMOVAL spindle.
Page 85: Liquid Crystal Display (Lcd)
ELECTRICAL 5 - 38 LIQUID CRYSTAL DISPLAY REMOVAL (LCD) 1. Remove upper dash panel. See Upper Dash in Body, section 7. 2. Remove lower dash panel. See Lower Dash in DESCRIPTION Body, section 7. 3. Remove RH and LH pod covers. See Pod Covers in the Body section.
Page 86: Psdm
5 - 39 ELECTRICAL PSDM DESCRIPTION The Power Signal Distribution Module (PSDM) is an electrical component that acts as a central hub for all 72 and 12 volt power. OPERATION Both 72 and 12 volt inputs come into the PSDM and are dispersed through the fuses to the appropriate electrical components.
Page 87 ELECTRICAL 5 - 40 November 2007 GEM Service Manual...
Page 88: Accessory System
5 - 41 ELECTRICAL ACCESSORY SYSTEM DESCRIPTION Fig. 26 Accessory System Diagram GEM Service Manual November 2007...
Page 89 ELECTRICAL 5 - 42 The standard accessory system components for The power outlet is located in the center lower dash the GEM are essential for safe driving and consist (see figure 27 item 4) and is running on 12 VDC of the headlights, taillights, directional indicators, from the fuse protected DC/DC converter.
Page 90 5 - 43 ELECTRICAL As was the case with the drive system, the This manual cannot possibly accommodate all skill information provided in this section is a guide only. levels and provide advice for each. A basic There are numerous variations in the skill level of understanding of electronics and troubleshooting personnel that service this vehicle.
Page 91 ELECTRICAL 5 - 44 ACCESSORY SYSTEM TROUBLESHOOTING CHART (CONTINUED) Condition Possible Causes and Correction Diagnostic Steps The tail lamps do not Disconnect the taillight harness If the resistance to ground is higher than 100 work (when the lights from the rear harness. Using an ohms for either pin 2, 3, or 4, check for a loose are turned on), but the ohmmeter, measure resistance...
Page 92 5 - 45 ELECTRICAL ACCESSORY SYSTEM TROUBLESHOOTING CHART (CONTINUED) Condition Possible Causes and Correction Diagnostic Steps Radio does not work. Visually inspect fuses F10 and Replace the fuses if they are open. F3 or measure with an Use the Audio System Circuit Diagram to check ohmmeter to determine if it is the wire connection and 12 VDC at PSDM S, open.
Page 93: Accessory System Component Replacement
ELECTRICAL 5 - 46 ACCESSORY SYSTEM FRONT TURN INDICATOR LAMP REPLACEMENT COMPONENT REPLACEMENT 1. Open hood. 2. Remove lock nut from light and disconnect the red and black wires. FUSE REPLACEMENT 3. Replace light assembly. 4. Reverse the removal procedure to install. REAR TURN INDICATOR LAMP REPLACEMENT 1.
Page 94 5 - 47 ELECTRICAL LIGHT SWITCH REMOVAL TURN SIGNAL SWITCH REPLACEMENT 1. Remove the upper and lower dash panels. See 1. Remove the upper and lower dash panels. See Body, section 7. Body, section 7. 2. Remove steering column covers. See Body, 2.
Page 95: Electrical Overview
ELECTRICAL 5 - 48 ELECTRICAL OVERVIEW November 2007 GEM Service Manual...
Page 96: Index
5 - 49 ELECTRICAL INDEX AUDIO SYSTEM.......................... 5 - 66 CHARGING SYSTEM ........................5 - 51 DASH FAN........................... 5 - 64 DC/DC CONVERTER ........................5 - 54 DISPLAY............................5 - 59 FRONT LIGHTING........................5 - 67 HEATER ............................5 - 63 HORN/POWER OUTLET......................
Page 97 ELECTRICAL 5 - 50 POWER DISTRIBUTION November 2007 GEM Service Manual...
Page 98 5 - 51 ELECTRICAL CHARGING SYSTEM GEM Service Manual November 2007...
Page 99 ELECTRICAL 5 - 52 CHARGING SYSTEM (CONTINUED) e6S & eLXD OPTION November 2007 GEM Service Manual...
Page 100 5 - 53 ELECTRICAL PARK BRAKE CIRCUIT GEM Service Manual November 2007...
Page 101 ELECTRICAL 5 - 54 DC/DC CONVERTER November 2007 GEM Service Manual...
Page 102 5 - 55 ELECTRICAL MAIN CONTACTOR GEM Service Manual November 2007...
Page 103 ELECTRICAL 5 - 56 MAIN CONTACTOR (CONTINUED) e6S & eLXD OPTION November 2007 GEM Service Manual...
Page 104 5 - 57 ELECTRICAL MOTOR CONTROLLER SYSTEM GEM Service Manual November 2007...
Page 105 ELECTRICAL 5 - 58 MOTOR CONTROLLER SYSTEM (CONTINUED) November 2007 GEM Service Manual...
Page 106 5 - 59 ELECTRICAL DISPLAY GEM Service Manual November 2007...
Page 107 ELECTRICAL 5 - 60 DISPLAY (CONTINUED) November 2007 GEM Service Manual...
Page 108 5 - 61 ELECTRICAL DISPLAY (CONTINUED) GEM Service Manual November 2007...
Page 109 ELECTRICAL 5 - 62 HORN/POWER OUTLET November 2007 GEM Service Manual...
Page 110 5 - 63 ELECTRICAL HEATER GEM Service Manual November 2007...
Page 111 ELECTRICAL 5 - 64 DASH FAN November 2007 GEM Service Manual...
Page 112 5 - 65 ELECTRICAL SECURITY LIGHT BAR GEM Service Manual November 2007...
Page 113 ELECTRICAL 5 - 66 AUDIO SYSTEM November 2007 GEM Service Manual...
Page 114 5 - 67 ELECTRICAL FRONT LIGHTING – EXCEPT NEW YORK HI/LO BEAM OPTION GEM Service Manual November 2007...
Page 115 ELECTRICAL 5 - 68 FRONT LIGHTING – EXCEPT NEW YORK November 2007 GEM Service Manual...
Page 116 5 - 69 ELECTRICAL FRONT LIGHTING – NEW YORK GEM Service Manual November 2007...
Page 117 ELECTRICAL 5 - 70 REAR LIGHTING – EXCEPT NEW YORK November 2007 GEM Service Manual...
Page 118 5 - 71 ELECTRICAL REAR LIGHTING – NEW YORK GEM Service Manual November 2007...
Page 119 ELECTRICAL 5 - 72 REAR LIGHTING November 2007 GEM Service Manual...
Page 120 5 - 73 ELECTRICAL REAR LIGHTING (CONTINUED) GEM Service Manual November 2007...
Page 121 ELECTRICAL 5 - 74 TURN SIGNAL REMINDER CIRCUIT November 2007 GEM Service Manual...
Page 122 5 - 75 ELECTRICAL WIPER/WASHER GEM Service Manual November 2007...
Page 123: Harness And Connector Drawings
ELECTRICAL 5 - 76 HARNESS AND CONNECTOR DRAWINGS CONVERTER HARNESS CONVERTER HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector DC/DC Converter 72 Volt Ground, 12 Volt Ground PSDM J4 November 2007 GEM Service Manual...
Page 124 5 - 77 ELECTRICAL PIN LOCATIONS FOR CONVERTER HARNESS CONNECTORS Connector Illustration Connector Connects To Number of Pins in Number Connector DC/DC Converter 72 Volt Ground, 12 Volt Ground PSDM J4 GEM Service Manual November 2007...
Page 125 ELECTRICAL 5 - 78 HEADLIGHT HARNESS HEADLIGHT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector Headlight Harness Headlamp-Left Lamp-Turn-Left Lamp-Turn-Left (Ground) Headlamp-Right Lamp-Turn-Right Lamp-Turn-Right (Ground) November 2007 GEM Service Manual...
Page 126 5 - 79 ELECTRICAL PIN LOCATIONS FOR HEADLIGHT HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector Headlight Harness Headlamps (Power) Turn Lamps (Power) Turn Lamps (Ground) GEM Service Manual November 2007...
Page 127 ELECTRICAL 5 - 80 FRONT HARNESS FRONT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector PSDM J1 2,3,4 Motor-Wiper Horn Front Harness Switch-Brake Level Fluid 9,10 Switch-Brake Pressure 12 Volt Ground November 2007 GEM Service Manual...
Page 128 5 - 81 ELECTRICAL PIN LOCATIONS FOR FRONT HARNESS CONNECTORS Connector Illustration Connector Connects To Number of Pins in Number Connector PSDM J1 Horn, Motor-Wiper 2,3,4,5,6,9,10,11 Switch-Brake Pressure, Charger Front Harness Switch-Brake Level Fluid 12 Volt Ground GEM Service Manual November 2007...
Page 129 ELECTRICAL 5 - 82 INSTRUMENT PANEL HARNESS IP HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector PSDM J2 PSDM J3 Display D2 Display D1 Switch-Light Switch-Multifunction Switch-Key 9,10, 11, 12 Switch-Drive Mode 13,14 Switch-Trip/Odometer November 2007 GEM Service Manual...
Page 130 5 - 83 ELECTRICAL PIN LOCATIONS FOR IP HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector Display D2, PSDM J2 PSDM J3 Display D1 Switch-Drive Mode, 5,6,9,10,11,12,13,14 Switch-Trip Odometer, Switch-Light Switch-Multifunction Switch-Key GEM Service Manual November 2007...
Page 131 ELECTRICAL 5 - 84 CONTROLLER HARNESS CONTROLLER HARNESS CONNECTIONS Connector Number Connects to Number of Pins in Connector Module-Motor Controller Switch-Accelerator Pedal Tachometer Sensor, Motor Temperature November 2007 GEM Service Manual...
Page 132 5 - 85 ELECTRICAL CONTROLLER HARNESS (CONTINUED) CONTROLLER HARNESS CONNECTIONS Connector Number Connector to Number of Pins in Connector 5, 6 Main Contactor (Coil) PSDM 72 Volt Ground PSDM J5 GEM Service Manual November 2007...
Page 133 ELECTRICAL 5 - 86 PIN LOCATIONS FOR CONTROLLER HARNESS CONNECTORS Connector Illustration Connector Connects To Number of Pins in Number Connector Module-Motor Controller Switch-Accelerator Pedal Tachometer Switch-Motor Temperature November 2007 GEM Service Manual...
Page 134 5 - 87 ELECTRICAL Connector Illustration Connector Connects To Number of Pins in Number Connector PSDM 72 Volt Ground PSDM J5 GEM Service Manual November 2007...
Page 135 ELECTRICAL 5 - 88 MAIN HARNESS PASSENGER REAR HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector PSDM J6 72 Volt Ground PSDM-Disconnect Switch PSDM-BATT(-) 12 Volt Ground Charger - Battery Temp Sensor Switch-Park Brake November 2007 GEM Service Manual...
Page 136 5 - 89 ELECTRICAL MAIN HARNESS (CONTINUED) PASSENGER REAR HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector Lamp-CHMSL Lamp-CHMSL (Ground) Lamp-License Lamp-Back-Up Taillight Harness 14,15 Battery Temperature Sensor BATT (-) BATT (+) Main Harness GEM Service Manual November 2007...
Page 137 ELECTRICAL 5 - 90 PIN LOCATIONS FOR MAIN HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector PSDM J6 12 Volt Ground, 72 Volt Ground PSDM-Disconnect Switch, PSDM- 3,4,16,17 BATT(-), BATT 1(-), BATT 6(+) Charger for BTS, Switch-Park Brake, Lamp-CHMSL, Lamp-License,...
Page 138 5 - 91 ELECTRICAL Connector Illustration Connector Number Connects To Number of Pins in Connector Taillight Harness GEM Service Manual November 2007...
Page 139 ELECTRICAL 5 - 92 TAIL LIGHT HARNESS Underneath Side of the Flat Bed TAIL LIGHT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector Rear Harness 2,3,4 Lamp-Taillight-Left 5,6,7 Lamp-Taillight-Right November 2007 GEM Service Manual...
Page 140 5 - 93 ELECTRICAL PIN LOCATIONS FOR TAIL LIGHT HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector Rear Harness 2,3,5,6 Lamp-Taillight-Left, Lamp-Taillight-Right Lamp-Taillight-Left, Lamp-Taillight-Right GEM Service Manual November 2007...
Page 141 6 - 1 WHEELS & TIRES CONTENTS TIRES AND WHEELS ..............................6 - 2 TIRES ....................................6 - 3 RADIAL-PLY TIRES ................................ 6 - 3 TIRE INFLATION PRESSURES............................6 - 3 REPLACEMENT TIRES ..............................6 - 4 DIAGNOSIS AND TESTING - PRESSURE GAUGES..................... 6 - 5 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS..................
Page 142: Tires And Wheels
WHEELS & TIRES 6 - 2 TIRES AND WHEELS DESCRIPTION The GEM e-series uses steel wheels with a 4 and 5 bolt (e6, e6S & eLXD) pattern, and tires in three different sizes as shown in the charts below: WHEEL CHART Two Passenger Two Passenger, Four Six Passenger &...
Page 143: Tires
6 - 3 WHEELS & TIRES TIRES TIRE INFLATION PRESSURES DESCRIPTION Proper tire inflation pressure is essential to the safe Tires are designed and engineered for each and satisfactory operation of the vehicle. Under specific vehicle. They provide the best overall inflation will cause rapid shoulder wear, tire flexing, performance for normal operation.
Page 144: Replacement Tires
WHEELS & TIRES 6 - 4 REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: • Ride • Noise • Handling • Durability • Tread life • Traction • Rolling resistance • Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed.
Page 145: Diagnosis And Testing - Pressure Gauges
6 - 5 WHEELS & TIRES DIAGNOSIS AND TESTING - Tire replacement is necessary when indicators appear in two or more grooves or if localized PRESSURE GAUGES balding occurs. A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight.
Page 146: Diagnosis And Testing - Tire Noise Or Vibration
WHEELS & TIRES 6 - 6 DIAGNOSIS AND TESTING - ROTATION TIRE NOISE OR VIBRATION Tires on the front and rear operate at different loads and perform different steering, driving, and braking functions. For these reasons they wear at unequal Radial-ply tires are sensitive to force impulses rates and tend to develop irregular wear patterns.
Page 147: Diagnosis And Testing - Wheel Inspection
6 - 7 WHEELS & TIRES DIAGNOSIS AND TESTING – To install the wheel, first position it properly on the WHEEL INSPECTION mounting surface. All wheel nuts should then be tightened just snug. Gradually tighten them, in sequence, to the proper torque specification (see Inspect wheels for: Figure 4).
Page 148 7 - 1 BODY CONTENTS SEAT BELTS....................................7 – 2 THREE-POINT SEAT BELT................................7 - 3 BODY PANELS ....................................7 - 4 BODY SIDE PANEL ..................................7 - 4 BODY SIDE PANEL (6 PASSENGER ONLY)..........................7 - 5 INSTALLATION OF SCUFF GUARDS............................7 - 6 INSTALLATION OF SCUFF GUARDS (CONTINUED)........................
Page 149: Seat Belts
BODY 7 - 2 SEAT BELTS Seat belts should be inspected monthly for the following signs of wear: DESCRIPTION 1. Frayed edges on web. 2. Scores across web. The GEM vehicles use automotive type seatbelts at 3. Obvious signs of wear on web at buckle. all locations.
Page 150: Three-Point Seat Belt
7 - 3 BODY THREE-POINT SEAT BELT REMOVAL 1. Remove the lower seat cushion. See Bench DESCRIPTION Seats in this section. 2. Turn the master disconnect switch OFF. Three-point automotive shoulder/lap belts are used 3. Remove the seat back assembly. See Bench with bench and bucket seats.
Page 151: Body Panels
BODY 7 - 4 BODY PANELS REMOVAL 1. Remove the upper and lower dash. DESCRIPTION See Dash in this section. 2. Remove mudguards. See Mudguards in this The GEM body panels are molded of white plastic. section. The hood, mudguards and spat come in a variety of 3.
Page 152: Body Side Panel (6 Passenger Only)
7 - 5 BODY BODY SIDE PANEL MIDDLE (6 PASSENGER ONLY) 1. Remove the scuff guard (sill plate), (if equipped). 2. Remove the (10) body side rivets. 3. Remove the center side panels. 4. To install reverse this procedure. REAR 1.
Page 153: Installation Of Scuff Guards
BODY 7 - 6 INSTALLATION OF SCUFF GUARDS • Once all the panel bolts are tightened then the scuff guard can be assembled. • Measure down from bolt number three on the front side panel 3-1/2 inches. 1. 2 Pass •...
Page 154: Installation Of Scuff Guards (Continued)
7 - 7 BODY INSTALLATION OF SCUFF GUARDS (CONTINUED) • Drill out the back hole. • Insert the bolt. • Put on the nuts • Tighten the fasteners just tight enough to not deform the scuff guards. 4. Finishing the scuff guard 5.
Page 155 BODY 7 - 8 INSTALLATION OF SCUFF GUARDS (CONTINUED) • Measure ½ inch from the seam of the panel to get your front hole location. • Drill out the hole to accommodate the bolt. 7. Mark the hole location • Insert the front bolt to locate the scuff guard.
Page 156: Installation Of Scuff Guards (Continued)
7 - 9 BODY INSTALLATION OF SCUFF GUARDS (CONTINUED) 10. Finish e4 GEM Service Manual November 2007...
Page 157: Body Back Panel
BODY 7 - 10 BODY BACK PANEL DESCRIPTION REMOVAL The body back panel is made of molded plastic. The two, four and six passenger models have a cut out to accommodate the Trunkback/Golfback/Clip- 1. Remove the spat or utility bed. See Spat or In Stake Bed latch assembly.
Page 158: Floor Panels (6 Passenger Only)
7 - 11 BODY FLOOR PANELS MIDDLE REAR (6 PASSENGER ONLY) 1. Remove the center side panels. 2. Remove the middle and rear floor mats. 3. Remove the bolt from the seat belt D-ring. 4. Remove the front seats. See Bucket Seat in this section.
Page 159: Bench Seats
BODY 7 - 12 BENCH SEATS REMOVAL 1. Pull up on front edge of seat cushion until DESCRIPTION friction latch is disengaged. 2. Lift seat cushion up and away to remove. The GEM vehicles use bench seats in all models. 3.
Page 160: Bucket Seat
7 - 13 BODY BUCKET SEAT REMOVAL DESCRIPTION 4 PASSENGER The driver and passenger front and middle seats in 1. From beneath vehicle, remove nuts from the 4- the four and six passenger models are bucket bucket seat anchoring bolts. seats.
Page 161: Mudguard
BODY 7 - 14 MUDGUARD INSTALLATION 1. If installing a new mudguard, drill four 1/4" DESCRIPTION holes through mudguard, if necessary. (Use old mudguard to determine hole locations). The mudguards are color keyed to match the hood. 2. With hood closed, position mudguard against They are attached to the body side panel to form body side panel so that the mudguard forms a the trailing portion of the front fenders.
Page 162: Mudflap
7 - 15 BODY MUDFLAP INSTALLATION 1. Check the fit of the mud flap to the vehicle. DESCRIPTION • The mud flap should fit with no gaps larger then 1/8”. Trim as necessary for proper fit. The mudflaps are attached to the mudguards that 2.
Page 163: Hood
BODY 7 - 16 HOOD DESCRIPTION The hood assembly forms the hood and upper part of the front fenders. The headlamps and turn signal lamps are mounted in the hood. Hinges to the front suspension support frame attach the hood. On newer models, a latch at the center of the upper edge of the hood holds it secured when hood is closed.
Page 164: Hood Latch Assembly
7 - 17 BODY HOOD LATCH ASSEMBLY OPERATION To unlatch the hood, pull up on leading end of latch handle to release tension on the striker plate, DESCRIPTION allowing disengagement of the striker. To latch the The hood latch assembly consists of an adjustable hood, engage handle on striker plate, then press bracket, mounted to the center of the lower down on leading end of handle to lock in place.
Page 165: Dash
BODY 7 - 18 DASH INSTALLATION 1. Connect heater ducts at heater assembly (if DESCRIPTION equipped). 2. Connect electrical connections, if any. The dash consists of an upper panel assembly and 3. Position upper dash assembly on lower dash a lower panel assembly. Inside the dash is located assembly.
Page 166: Dash Lower Panel
7 - 19 BODY DASH LOWER PANEL INSTALLATION 1. Insert panel lower tabs into slots in floor pan. DESCRIPTION 2. Connect any electrical connections then slowly lower and rock lower panel forward into place. The lower dash panel is constructed of molded plastic.
Page 167: Pod Covers
BODY 7 - 20 POD COVERS REMOVAL 1. Remove the upper and lower dash assemblies. DESCRIPTION See upper and lower dash in this section. 2. Remove the 2 screw covers on front of the The Pod Covers are used to protect and house the instrument Pod.
Page 168: Spat
7 - 21 BODY SPAT REMOVAL 1. Remove the Trunkback/Golfback (if equipped). DESCRIPTION See Trunkback/Golfback in this section. 2. If equipped with license plate light and tail A Spat is an assembly that acts as fenders over the lights, rear wheels of the 2, 4 and 6 passenger (e2, e4, a) remove bench seat cushion.
Page 169: Utility Bed
BODY 7 - 22 UTILITY BED DESCRIPTION (eS, eL, e6S) The Utility Bed is an assembly designed to transport various objects from one location to another. It consists of 3 retaining rails, flat bed and a rear wiring harness assembly. Fig.
Page 170: Trunkback/Golfback/ Clip-In Stake Bed
7 - 23 BODY TRUNKBACK/GOLFBACK/ CLIP-IN STAKE BED FIG. 23 CLIP-IN STAKE BED DESCRIPTION The Golfback is a unit designed to carry two sets of golf clubs. The Trunkback is a molded plastic box with a hinged locking lid. The Clip-In Stake bed is a versatile bed unit designed with a hinged rear Fig.
Page 171: Pack Latch Assembly
BODY 7 - 24 PACK LATCH ASSEMBLY DESCRIPTION The pack latch assembly consists of a locking handle connected to a latch by threaded rods and a turnbuckle. The handle is mounted to the back of the body back panel. The latch is mounted to a plate that, in turn, is mounted to the bench seat back/body back panel support frame.
Page 172 7 - 25 BODY ADJUSTMENT INSTALLATION When turning the latch handle, there should be little 1. Position latch mounting plate on seat back/body or no play detected before the latching mechanism back panel support frame and install the 2 self- disengages the latch bar.
Page 173: Trunkback/Golfback/ Clip-In Stake Bed Leg Pocket
BODY 7 - 26 TRUNKBACK/GOLFBACK/ MIRROR - CENTER REAR CLIP-IN STAKE BED LEG VIEW POCKET DESCRIPTION The center rear view mirror assembly is mounted in DESCRIPTION the center of the upper windshield support. It is not The Trunkback/Golfback has two legs that fit into serviceable and is replaced as a unit.
Page 174: Mirror - Side Rear View
7 - 27 BODY MIRROR - SIDE REAR VIEW INSTALLATION 1. Install mirror assembly and mounting gasket. 2. Install the 2 Phillips head screws attaching the mirror to roof rail/door. 3. Reposition the rubber boot to original position. 4. Install lower screw cover on mirror base. Fig.

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Polaris GEM E Series Service Manual

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