2013 GEM Service Manual Polaris e2 e4 e6 eS eL eLXD Electric Vehicle PDF

Description

2013 GEM Service Manual – Polaris e2 e4 e6 eS eL eLXD Electric Vehicle PDF DOWNLOAD

DESCRIPTION

2013 GEM Electric Vehicle Factory Service Manual – Complete Technical Documentation

This official 2013 GEM electric vehicle service manual provides comprehensive repair and maintenance procedures for the complete lineup of Polaris GEM e2 e4 e6 repair guide models and variants. Published by Polaris Sales Inc. (Publication PN 9924112, August 2012), this manual is the authoritative technical reference for certified technicians servicing GEM neighborhood electric vehicles.

Models Covered – 2013 GEM Electric Vehicle Lineup

This service manual covers all 2013 GEM (Global Electric Motorcars) models:

Two-Passenger Models:

• GEM e2 – Two-seat electric utility vehicle

Four-Passenger Models:

• GEM e4 – Four-seat electric utility vehicle

Six-Passenger Models:

• GEM e6® – Six-seat electric people mover

Utility/Cargo Models:

• GEM eS – Short bed cargo utility vehicle
• GEM eL – Long bed cargo utility vehicle
• GEM eLXD – Heavy-duty long bed cargo vehicle

Vehicle Specifications – GEM Electric Vehicles

Power System: 72-Volt DC Electric Motor
Vehicle Type: Low-Speed Electric Vehicle (LEV) / Neighborhood Electric Vehicle (NEV)
Manufacturer: Polaris Industries Inc.
Publication Number: 9924112
Publication Date: August 2012
Model Year: 2013
Manual Pages: 204 pages

Complete Service Manual Chapters

CHAPTER 1 – INTRODUCTION

Vehicle Identification:

• Model number designation system
• Vehicle Identification Number (VIN) structure
• VIN location and safety certification label
• Model year coding (D = 2013)
• Gross Vehicle Weight Rating (GVWR)
• Gross Axle Weight Rating (GAWR)
• Wheel and tire specifications

General Information:

• Service manual introduction and use
• General safety warnings and precautions
• 72-volt master disconnect safety procedures
• Battery hydrogen gas safety
• Electrical shock hazard warnings
• Proper service procedures
• Reference to left-hand (LH) and right-hand (RH) terminology

Fastener Usage:

• SAE fastener identification
• Torque specifications
• Fastener salvage and replacement
• Nylon lock nut replacement requirements

Parts and Lubricants:

• Recommended GEM replacement parts
• Lubricants and grease specifications
• Society for Automotive Engineers (SAE) standards
• National Lubricating Grease Institute (NLGI) ratings
• Differential service – Full Synthetic AGL Plus (PN 2878068)
• Brake fluid – DOT 4 specification

Maintenance Schedule:

• Monthly inspection items:
  • Six-battery water level checks (if applicable)
  • Battery terminal connections and corrosion
  • Tire pressure (PSI) and wear inspection
  • Hand brake operation check
  • Master cylinder brake fluid levels
  • Brake line leak inspection
  • Seat belt operation
  • Lights, horn, turn signals, wipers, brake lights
  • Battery hold-down security
  • Wire insulation and fraying inspection

Hoisting and Jacking:

• Single-post frame-contact hoist procedures
• Twin-post chassis hoist usage
• Ramp-type drive-on hoist procedures
• Floor jack positioning guidelines
• Jack stand placement locations
• Center of gravity considerations

CHAPTER 2 – SUSPENSION AND STEERING

Wheel Alignment:

• Inspection procedures for alignment
• Toe-in/Toe-out adjustment (+1/16-inch toe-in specification)
• Front wheel alignment specifications
• Adjusting front toe procedures

Front Suspension System:

• Front suspension component diagrams
• Control arm assembly service
• Bushing replacement procedures
• Ball joint service and replacement
• Front shock assembly
  • Description and operation
  • Diagnosis and testing
  • Removal and installation procedures
  • Inspection procedures
• Shock absorber testing

Rear Suspension System:

• Rear suspension component diagrams
• Rear shock assembly service
  • Removal procedures
  • Inspection guidelines
  • Installation procedures
• Rear hub and bearing/spindle service:
  • E6, E6S, eLXD models
  • E2, E4, eS, eL models
• Suspension troubleshooting

Steering System:

• Steering wheel removal and installation
• Steering column assembly service
• Locking steering column procedures
• Steering wheel tilt adjustment
• Steering gear (rack and pinion)
  • Description and operation
  • Diagnosis and testing procedures
  • Removal and installation
  • Torque specifications

Steering Components:

• Steering knuckle service
  • Description and operation
  • Removal and installation procedures
• Outer tie rod end replacement
• Bearing and retaining ring service
• Steering system troubleshooting

CHAPTER 3 – DRIVETRAIN

Electric Motor Drivetrain:

• 72-volt DC electric motor system
• Motor mounting and service
• Differential service and fluid specifications
• Drive axle service
• CV joint service
• Axle shaft replacement
• Drivetrain troubleshooting
• Torque specifications

CHAPTER 4 – BRAKES

Hydraulic Brake System:

• Master cylinder service
• Brake fluid specifications (DOT 4)
• Brake line inspection and replacement
• Disc brake system service
  • Caliper service
  • Brake pad replacement
  • Rotor inspection and replacement
• Parking brake (hand brake)
  • Operation check
  • Adjustment procedures
  • Cable replacement
• Brake system bleeding procedures
• Brake troubleshooting

CHAPTER 5 – ELECTRICAL

72-Volt Electrical System:

• Battery system (six-battery configuration)
  • Battery water level maintenance
  • Terminal cleaning and corrosion prevention
  • Battery hold-down security
  • Hydrogen gas safety precautions
• 72-volt master disconnect switch
  • Safety procedures
  • Service protocols
• Wiring harness inspection
• Wire insulation checking
• Electrical troubleshooting

Lighting and Accessories:

• Headlight service
• Turn signal system
• Brake light testing
• Horn operation
• Windshield wiper service
• Electrical component testing

CHAPTER 6 – WHEELS AND TIRES

Wheel and Tire Service:

• Tire size specifications
• Cold tire pressure specifications
• Tire wear inspection
• Wheel bearing service
• Tire mounting and balancing
• Wheel alignment impact
• Tire rotation patterns

CHAPTER 7 – BODY

Body Components:

• Body panel removal and installation
• Windshield service
• Seat and seat belt service
• Roof panel access procedures
• VIN label location (above bench seat, rear roof panel driver side)
• Body hardware and fasteners
• Trim and accessory installation

Applications and Uses

GEM electric vehicles are designed for:

• Campus transportation – Universities and corporate campuses
• Resort and hospitality – Hotels, resorts, golf courses
• Industrial facilities – Manufacturing plants, warehouses
• Municipal use – Parks, maintenance departments
• Gated communities – Residential neighborhood transport
• Airport operations – Terminal and tarmac transport
• Security and patrol – Campus and facility security
• Golf cart replacement – Enhanced utility vehicles
• Fleet operations – Multi-vehicle commercial use

Safety and Compliance

Critical Safety Warnings:

• 72-volt electrical system – Potentially lethal voltage
• Master disconnect must be OFF during service
• Hydrogen gas from batteries – extremely flammable
• Key switch must be OFF and key removed
• Parking brake set with wheel chocks during service
• Safety glasses required for all service work
• No smoking near batteries or vehicle

Recommended Safety Equipment:

• Safety stands for lifting
• Proper jack and jack stands
• Eye protection
• Insulated tools for electrical work
• Battery service equipment

Why This Manual is Essential

This GEM eS eL eLXD maintenance manual provides:

✓ Factory-authorized procedures – Official Polaris documentation
✓ Complete model coverage – All six 2013 GEM models
✓ Electrical system safety – Critical 72-volt system procedures
✓ Battery maintenance – Proper service for six-battery system
✓ Suspension and steering – Alignment and component service
✓ Brake system service – Complete hydraulic brake procedures
✓ Monthly maintenance – Scheduled inspection checklist

Perfect For

• Certified GEM technicians performing warranty and service repairs
• Golf cart and electric vehicle mechanics expanding service capabilities
• Fleet maintenance departments with GEM electric vehicles
• Municipal maintenance shops servicing city-owned GEM fleets
• Resort and campus maintenance teams maintaining GEM vehicles
• Independent repair shops specializing in electric vehicles
• Technical training schools teaching electric vehicle service
• Parts departments identifying correct replacement components

Official Polaris Documentation

This service manual is published by Polaris Industries Inc., the parent company of GEM electric vehicles. It represents the most current technical information available at the time of publication and is the same manual used by authorized GEM dealers.

Publisher Information:

• Polaris Industries Inc.
• Service Publications Department
• 2100 Hwy 55, Medina, MN 55340

Trademark Acknowledgments

The manual acknowledges the following products:

• Loctite® – Registered Trademark of Henkel Corporation
• Torx® – Registered Trademark of Textron
• Velcro® – Registered Trademark of Velcro Industries, B.V.
• Optimol Olistamoly™ – Trademark of Castrol Limited

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