2009 Parts Catalog

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R

2009 Parts Catalog

GEM e2 GEM e4 GEM e6 GEM eS GEM eL GEM eLXD

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GEM e2 - 2 Passenger

2009 Model Year Parts Catalog GEM ModelsGEM e2 - 2 Passenger


GEM e4 - 4 Passenger GEM e6 - 6 Passenger GEM eS - 2 Passenger Short-Back GEM eL - 2 Passenger Long-Back GEM eLXD - 2 Passenger Long-Back Extra Duty


GEM eS- 2 Passenger Short-Back

GEM eL - 2 Passenger Long-Back

GEM eL - 2 Passenger Long-Back Extra Duty760-321-2275 www.4GEMparts.com

P/N 1010-00328 [email protected]

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DisclaimerThis document is based on information available at the time of its publications. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations. Features may be described herein which are not present in all vehicles. Global electric Motorcars assumes no obligation of notice to holders of this document with respect to changes subsequently made. Global electric motorcars makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, or completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply. This catalog contains sections specifically separated into mechanical and electrical aspects as they relate to the GEM vehicle(s). This catalog is intended as a tool to locate and identify parts for replacement and part ordering. The catalog is written for both US/Domestic and International usage. A majority of the written materials are standard equipment for both US/Domestic and International vehicles, though there are also materials noted strictly for US/Domestic or International usage. These materials specific for International usage are identifiable by literature stating (Standard Component for European/International Homologated Vehicles). Section 12 European/International Components, identifies all other standard equipment for International vehicles that are not available as Standard or Optional Equipment for US/Domestic released vehicles.

Copyright 2009, Global Electric Motorcars. All rights reserved. Produced and printed in the USA.

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TABLE OF CONTENTSINTRODUCTION Parts Ordering Information ............................................................................................................................ 4 Replacement Parts.......................................................................................................................................... 4 V.I.N. Plate Location ....................................................................................................................................... 4 How to Use This Catalog and Locate Parts .................................................................................................. 5 Determining if this Part is for Your Model of Vehicle .................................................................................. 5 Parts Order Form ............................................................................................................................................ 6 Parts Return Authorization Form ................................................................................................................... 7 Dealer Return Policy ...................................................................................................................................... 8 SECTION 1 - FRAME ............................................................................................................................................ 9 SECTION 2 - FRONT AND REAR SUSPENSION ................................................................................................ 16 SECTION 3 - STEERING ..................................................................................................................................... 26 SECTION 4 - WHEEL END COMPONENTS ........................................................................................................ 41 SECTION 5 - BRAKES ........................................................................................................................................ 49 SECTION 6 - DRIVE LINE COMPONENTS ......................................................................................................... 70 SECTION 7 - ELECTRICAL ................................................................................................................................. 80 SECTION 8 - BODY ........................................................................................................................................... 124 SECTION 9 - MISCELLANEOUS....................................................................................................................... 201 SECTION 10 - DECALS ..................................................................................................................................... 217 SECTION 11 - OPTIONS ................................................................................................................................... 227 SECTION 12 - EUROPEAN COMPONENTS ...................................................................................................... 293 INDEX ................................................................................................................................................................ 314

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PARTS ORDERING INFORMATION If you need service or parts for your GEM vehicle:For service assistance or parts, contact your nearest authorized GEM dealer or the factory. Your nearest authorized GEM dealer will need to know the Vehicle Identification Number (V.I.N.) of your vehicle to provide the most efficient service. See below for information on how to identify and record the V.I.N. for your vehicle.

REPLACEMENT PARTSOnly genuine GEM replacement parts should be used to repair the vehicle. GEM replacement parts are available from your GEM Dealer. To obtain prompt, efficient service, remember to give the Dealer the correct part description and V.I.N. number of the vehicle.

When ordering parts for your GEM vehicle provide the following:1. The V.I.N. of your vehicle. 2. The PART NUMBER of the part. 3. The PART DESCRIPTION. 4. The QUANTITY needed.

WARNINGWe urge using only genuine replacement parts, which meet all the latest requirements. Replacement parts manufactured by others could present safety hazards, even though they may fit on this unit.

V.I.N. DECAL LOCATIONAlways give your authorized GEM dealer the V.I.N. of your vehicle when ordering parts, requesting service, or any other information. Remember to record the last six digits of your Vehicle Identification Number (V.I.N.) in the space provided below before calling. Use (Fig. # 1 & 2) to locate the V.I.N. decal.

Fig. # 2 use last six numbers

V.I.N.V.I.N. DECAL

Fig. # 1 V.I.N. decal locationPage 4760-321-2275

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HOW TO USE THIS CATALOG AND LOCATE PARTSThis catalog is divided into Item Class Groups in which illustrations for parts of a similar function and/or location are published. Option 1: From the contents page of the parts catalog, select the section which would most logically contain the part to be found. When the part is found, then determine if the part is for your model of vehicle by located the correct icon at the top of the page. (See illustration below Determining if the part is for your model of vehicle) If the part number is known but the applications and/or locations need to be determined, refer to the numerical index. This index shows the Part Number, Description, and Page Numbers that the item is listed.

Option 2:

DETERMINING IF THIS PART IS FOR YOUR MODEL OF VEHICLE

GEM e2 2 Passenger

GEM e4 4 Passenger

GEM e6 6 Passenger

GEM eS 2 Passenger

GEM eL 2 Passenger

GEM eL XD 2 Passenger

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Parts Catalog SECTION 1 - FRAME

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WELDMENT, FRAME - 2 PASSITEM 1 PART NO. 0201-00102 DESCRIPTION WELDMENT, FRAME - 2 PASS QTY. 1

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WELDMENT, FRAME - 4 PASSITEM 1 PART NO. 0201-00103 DESCRIPTION WELDMENT, FRAME - 4 PASS QTY. 1

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WELDMENT, FRAME - 4 PASSITEM PART NO. DESCRIPTION QTY. 1 1 0201-00188 WELDMENT, FRAME - 4 PASS *AVAILABLE FOR VEHICLES EQUIPPED WITH HARD DOOR OPTIONS ONLY.

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WELDMENT, FRAME - eL/eLXDITEM 1 PART NO. 0201-00244 DESCRIPTION WELDMENT, FRAME eL/eLXD QTY. 1

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WELDMENT, FRAME - e6ITEM 1 PART NO. 0201-00217 DESCRIPTION WELDMENT, FRAME e6 QTY. 1

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ASSY, SUPPORT FRAME - FRONT 46 IN WIDEITEM 1 2 3 4 5 6 7 PART NO. 0201-00187 0521-00100 0521-00120 0522-00063 0522-00076 0523-00032 0524-00009 DESCRIPTION WLD, SUPPORT FRAME - FRONT NUT, HEX FLANGE 3/8 - 16 UNC GR 6 TECH LOCK NUT, HEX FLANGE 1/2 - 13 SPIRALOCK BOLT, HEX - 3/8 - 16 UNC x 1.0 LG GR 5 ZINC PLATED BOLT, HEX - 1/2 - 13 UNC X 3.0 GR 8 ZN YL ZINC PLATED SCREW, HEX - WHSD 1/4 X .75 ZN WASHER HD SELF DRILLING WASHER, FLAT - 3/8 SAE 0.406 ID X 0.8125 OD X 0.080 THK ZN QTY. 1 4 2 4 2 2 4

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Parts Catalog SECTION 2 - FRONT AND REAR SUSPENSION

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ASSY, SUSPENSION - FRONT W/WHEEL ENDS 7.56 DIA DISCITEM PART NO. DESCRIPTION QTY.

1 2 3 4 *5 *6 *7 *8 9 10

0103-02548 0103-02549 0103-02550 0103-00289 0521-00023 0103-02551

ASSY, A-ARM - UPPER LH ASSY, A-ARM - UPPER RH ASSY, A-ARM - LOWER ASSY, SPRING OVER SHOCK REFER TO SECTION 3 - STEERING REFER TO SECTION 3 - STEERING REFER TO SECTION 5 - BRAKES REFER TO SECTION 4 - WHEEL END COMPONENTS NUT, HEX - NYLOCK M12 X 1.75 ASSY, BALL JOINT (NOT SHOWN)

1 1 2 2 1 1 2 2 4 4

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9 4 2 1 6 13 10 8 7

5 12 3

ASSY, SUSP - FRONT W/WHEEL ENDS 9.21 DISC W/OFF EXTITEM PART NO. DESCRIPTION QTY.

1 2 3 4 *5 *6 *7 *8 9 10 11 12 13 14

0103-02548 0103-02549 0103-02550 0103-00289 0521-00023 0521-00212 0522-00048 0522-00213 0522-00246 0103-02551

ASSY, A-ARM - UPPER LH ASSY, A-ARM - UPPER RH ASSY, A-ARM - LOWER ASSY, SPRING OVER SHOCK REFER TO SECTION 3 - STEERING REFER TO SECTION 3 - STEERING REFER TO SECTION 5 - BRAKES REFER TO SECTION 4 - WHEEL END COMPONENTS NUT, HEX - NYLOCK M10 X 1.75 NUT, HEX - NYLOCK M10 X 1.5 ZN BLK BOLT, HEX - M12 X 1.75 X 55 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M10 X 1.50 X 60 LG HHCS - GR 10.9 ZN BLK BOLT, HEX - M10 X 1.50 X 40 LG HHCS - GR 10.9 ZN ASSY, BALL JOINT (NOT SHOWN)

1 1 2 2 1 1 2 2 4 8 4 8 4 4

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6 12 3

ASSY, SUSP - FRONT W/WHEEL ENDS 9.21 DISCITEM PART NO. DESCRIPTION QTY.

1 2 3 4 *5 *6 *7 *8 9 10 11 12 13 14 15

0103-02548 0103-02549 0103-02550 0103-01606 0521-00023 0521-00212 0522-00048 0522-00213 0522-00246 0103-02551 0603-00149

ASSY, A-ARM - UPPER LH ASSY, A-ARM - UPPER RH ASSY, A-ARM - LOWER ASSY, SPRING OVER SHOCK REFER TO SECTION 3 - STEERING REFER TO SECTION 3 - STEERING REFER TO SECTION 5 - BRAKES REFER TO SECTION 4 - WHEEL END COMPONENTS NUT, HEX - NYLOCK M10 X 1.75 NUT, HEX - NYLOCK M10 X 1.5 ZN BLK BOLT, HEX - M12 X 1.75 X 55 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M10 X 1.50 X 60 LG HHCS - GR 10.9 ZN BLK BOLT, HEX - M10 X 1.50 X 40 LG HHCS - GR 10.9 ZN ASSY, BALL JOINT (NOT SHOWN) BUSHING, FRONT SUSPENSION QA1 (NOT SHOWN)

1 1 2 2 1 1 2 2 4 8 4 8 4 4 8

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ASSY, KING PIN - QA1ITEM PART NO. DESCRIPTION QTY.

0103-02551

ASSY, KING PIN - QA1

1

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ASSY, FRONT SUSPENSION BUSHING - FRONTITEM PART NO. DESCRIPTION QTY.

0603-00149

BUSHING, SUSPENSION - FRONT

8

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ASSY, SUSPENSION - REAR 2P/4P/SHTITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9

0102-01035 0103-01848 0202-00157 0521-00023 0522-00044 0522-00046 0522-00366 0524-00115 0302-00163

ASSY, ARM TRAILING ASSY, SHOCK SPRING OVER SHOCK WELD REAR AXLE TRAILING ARM NUT, HEX - NYLOCK M12 X 1.75 ZN BOLT, HEX M12 X 1.75 X 90 LG HHCS - GR 10.9 ZN YLW BOLT, HEX M12 X 1.75 X 65 LG HHCS - GR 10.9 ZN YLW BOLT, HEX M12 X 1.75 X 150 LG HHCS - GR 10.9 Z WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK BUSHING SUSPENSION - REAR

4 2 1 10 4 4 2 4 8

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6 2

511

1

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1

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ASSY, SUSPENSION - REAR e4 with 14 WHEEL OPTIONSITEM 1 2 3 4 5 6 7 8 9 PART NO. 0102-01035 0102-02525 0202-00157 0521-00023 0522-00044 0522-00046 0522-00366 0524-00115 0302-00163 DESCRIPTION ASSY, ARM-TRAILING ASSY, SPRING OVER SHOCK - REAR WELD REAR AXLE TRAILING ARM NUT, HEX - NYLOCK M12 X 1.75 BOLT, HEX - M12 X 1.75 X 90 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M12 X 1.75 X 65 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M12 X 1.75 X 65 LG HHCS - GR 10.9 ZN WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK BUSHING, SUSPENSION - REAR QTY. 4 2 1 10 4 4 2 4 8

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8

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3

2

7

4

1

ASSY, SUSPENSION - REAR eLITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9

0102-01035 0102-01441 0103-00289 0202-00157 0521-00023 0522-00044 0522-00046 0524-00115 0302-00163

ASSY, ARM-TRAILING ASSY, ARM-TRAILING ASSY, SPRING OVER SHOCK WELD REAR AXLE TRAILING ARM NUT, HEX - NYLOCK M12 X 1.75 BOLT, HEX - M12 X 1.75 X 90 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M12 X 1.75 X 65 LG HHCS - GR 10.9 ZN YLW WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK BUSHING SUSPENSION - REAR

2 2 2 1 12 8 4 12 8

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8

9

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3

2

7

4

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ASSY, SUSPENSION - REAR eLXDITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9

0102-01035 0102-01441 0103-01606 0202-00216 0521-00023 0522-00044 0522-00046 0524-00115 0302-00163

ASSY, ARM-TRAILING ASSY, ARM-TRAILING ASSY, SPRING OVER SHOCK WELD, AXLE-REAR 4 RAIL FRAME NUT, HEX - NYLOCK M12 X 1.75 BOLT, HEX - M12 X 1.75 X 90 LG HHCS - GR 10.9 ZN YLW BOLT, HEX - M12 X 1.75 X 65 LG HHCS - GR 10.9 ZN YLW WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK BUSHING SUSPENSION - REAR

2 2 2 1 12 8 4 12 8

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Parts Catalog SECTION 3 - STEERING

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5 4 7

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ASSY, STEERING GEAR - 46 IN WT 3.17 IN STRITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0312-01292 0521-00017 0522-00080 0522-00144 0522-00403 0524-00003 0612-00680

MOUNT, STEERING GEAR NUT, HEX - NYLOCK 5/16 - 18 UNC GR 5 BOLT, HEX - 5/16 - 18 UNC X 1.25 GR 5 ZINC PLATED BOLT, HEX - 5/16 - 18 UNC X 0.75 GR 5 BOLT, HEX - 5/16 - 18 UNC X 3.75 GR 5 ZN WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN GEAR, STEERING - 46 IN WT 3.17 IN STR

1 9 4 2 3 17 1

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ASSY, STEERING GEAR - 46 IN WT 3.17 IN STR with ADJUSTABLE TILT COLUMNITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0312-01292 0521-00017 0522-00080 0522-00144 0522-00403 0524-00003 0612-00741

MOUNT, STEERING GEAR NUT, HEX - NYLOCK 5/16 - 18 UNC GR 5 BOLT, HEX - 5/16 - 18 UNC X 1.25 GR 5 ZINC PLATED BOLT, HEX - 5/16 - 18 UNC X 0.75 GR 5 BOLT, HEX - 5/16 - 18 UNC X 3.75 GR 5 ZN WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN GEAR, STEERING - 46 IN WT 3.17 IN STR

1 9 4 2 3 17 1

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ASSY, TIE ROD ENDITEM PART NO. DESCRIPTION QTY.

0112-02946

TIE ROD END

2

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5 8

**

6

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1

*

7

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9

ASSY, KNUCKLE - RH 7.56 IN DIA DISCITEM PART NO. DESCRIPTION QTY.

*1 2 *3 *4 5 **6 **7 **8 9

0312-02360 0522-00508 0610-00455 0610-00456 0610-00457 0103-02142

KNUCKLE, MACHINED - RH EXTENSION, STR ARM - RH LOCKTITE, RED - 27140 (NOT SHOWN) ADHESIVE, FUSOR - #1088 / T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK BEARING, DOUBLE ROW - BALL BEARING SEAL, WHEEL RETAINER, SNAPRING - INTERNAL - 2.1 ASSY, KNUCKLE - RH 7.56 IN DIA DISC W/ OFFSET EXTENSION

1 1 0.02ML 2ML 1 1 2 1 1

* NOT SOLD SEPARATELY **AVAILABLE FOR ALL MODELS

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6

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8

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7

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ASSY, KNUCKLE - LH 7.56 IN DIA DISCITEM PART NO. DESCRIPTION QTY.

*1 2 *3 *4 5 **6 **7 **8 9

0312-02359 0522-00508 0610-00455 0610-00456 0610-00457 0103-02143

KNUCKLE, MACHINED - RH EXTENSION, STR ARM - LH LOCKTITE, RED - 27140 (NOT SHOWN) ADHESIVE, FUSOR - #1088 / T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK BEARING, DOUBLE ROW - BALL BEARING SEAL, WHEEL RETAINER, SNAPRING - INTERNAL - 2.1 ASSY, KNUCKLE - LH 7.56 IN DIA DISC

1 1 0.02ML 2ML 1 1 2 1 1

* NOT SOLD SEPARATELY **AVAILABLE FOR ALL MODELS

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ASSY, KNUCKLE - RH 9.21 IN DSC W/OFFSET EXTENSIONITEM PART NO. DESCRIPTION QTY.

1 2 *3 *4 5 6

0103-02323 0312-02360 0522-00508 0103-02320

ASSY, KNUCKLE - RH 9.21 IN DISC EXTENSION, STR ARM - RH LOCKTITE, RED - 21140 (NOT SHOWN) ADHESIVE, FUSOR - #1088/T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK ASSY, KNUCKLE - RH 9.21 IN DISC W/OFFSET EXTENSION

1 1 0.02ML 2ML 1 1

* NOT SOLD SEPARATELY

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ASSY, KNUCKLE - LH 9.21 IN DSC W/OFFSET EXTENSIONITEM PART NO. DESCRIPTION QTY.

1 2 *3 *4 5 6

0103-02324 0312-02359 0522-00508 0103-02321

ASSY, KNUCKLE - RH 9.21 IN DISC EXTENSION, STR ARM - RH LOCKTITE, RED - 21140 (NOT SHOWN) ADHESIVE, FUSOR - #1088/T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK ASSY, KNUCKLE - LH 9.21 IN DISC W/OFFSET EXTENSION

1 1 0.02ML 2ML 1 1


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ASSY, KNUCKLE - RH 12 INCHITEM PART NO. DESCRIPTION QTY.

1 2 *3 *4 5 6

0103-02323 0312-02211 0522-00508 0103-01997

ASSY, KNUCKLE - RH 9.21 IN DISC EXTENSION, STR ARM - RH LOCKTITE, RED - 21140 (NOT SHOWN) ADHESIVE, FUSOR - #1088/T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK ASSY, KNUCKLE - RH 9.21 IN DISC W/OFFSET EXTENSION

1 1 0.02ML 2ML 1 1


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ASSY, KNUCKLE - LH 12 INCHITEM PART NO. DESCRIPTION QTY.

1 2 *3 *4 5 6

0103-02324 0312-02211 0522-00508 0103-01996

ASSY, KNUCKLE - LH 9.21 IN DISC EXTENSION, STR ARM - RH LOCKTITE, RED - 21140 (NOT SHOWN) ADHESIVE, FUSOR - #1088/T30 LORD (NOT SHOWN) BOLT, HEX FLANGE - 1/2 - 13 UNC X 1.25 LG GR 8 BLACK ASSY, KNUCKLE - LH 9.21 IN, DISC WI/OFFSET EXTENSION

1 1 0.02ML 2ML 1 1


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ASSY, STEERING COLUMN - SPLINEDITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5

0112-01210 0521-00017 0522-00016 0522-00293 0524-00003

ASSY, STEERING COLUMN - SPLINED NUT, HEX - NYLOCK 5/16-18 UNC GR5 ZN BOLT, HEX - 5/16 - 18 UNC X 1.0 GR 5 ZINC PLATED BOLT, HEX - M8 X 1.25 X 30mm LG BLK OX WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN

1 3 3 1 6

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4 17 15 7

3 14 12 16 1 8 10

6

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9

12

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ASSY, COLUMN - TILT STEERINGITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

0112-02421 0148-02722 0212-00300 0312-02574 0312-02695 0312-02696 0510-00452 0521-00050 0521-00598 0522-00333 0522-00570 0524-00003 0524-00568 0524-00062 0524-00569 0524-00583 0610-00522 0612-00751

ASSY, STEERING SHAFT ASSY, LOCK - TILT STR COLUMN WLD, STEERING COLUMN TILT MOUNT, STEERING COLUMN SPRING, TILT COLUMN TUBE, SPACER RING, RETAINING - 19mm SHAFT, EXTERNAL NUT, HEX - NYLOCK 1/4 - 20 UNC GR 5 NUT, M8X1 .25, HFL, TL, C9, YZ BOLT, TORX - TRUSS HD - 1/4 - 20 X 1 - 18-8 S. S. BOLT, HEX - M8 X 1.25 X 115 MM LG GR 8.8 ZN WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.65 THK ZN WASHER, FLAT - 0.344 ID X 1.00 OD X 0.060 THK ZNC PLT WASHER, FLAT - 1/4 0.281 ID X 0.625 OD X 0.05 ZNC PLT BUSHING, SHOULDER - BRONZE WASHER, FLAT 0.758 ID X 1.00 OD X 0.060 THK ZNC PLT SPRING, CONICAL - 1.132 X 1.315 OD 2.175 LENGTH BEARING, ROLLER STEERING SHAFT

1 1 1 1 2 1 1 2 1 2 1 4 2 2 2 1 1 2

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10 11 5 8

7 3 4 13 12 2

1

9 6

ASSY, STEERING LOCK - MANUAL (STANDARD COMPONENT ON EUROPEAN HOMOLOGATED VEHICLES)ITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13

0212-00202 0212-00203 0419-00241 0410-00242 0312-01768 0510-00452 0521-00017 0521-00283 0522-00450 0523-00448 0523-00449 0524-00003 0610-00529

WLD, BRACKET - STEERING LOCK WLD, DISK - STEERING LOCK STRIP, WEAR - STEERING LOCK DETENT PAD, FOAM - STEERING LOCK DETENT ROD, LOCKING PIN - STEERING RING, RETAINING - 19mm SHAFT, EXTERNAL NUT, HEX - NYLOCK 5/16 - 18 UNC X 2.25 GR 5 NUT, 8-32 NYLOCK ZN PL BOLT, HEX - 5/16 - 18 UNC X 2.25 GR 5 ZINC PLATED SCREW, SHOULDER - 3/16 DIA X 1/8, 8-32 THREAD SCREW, SHOULDER - 3/16 DIA X 3/16, 8-32 THREAD WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.65 THK ZN ASSY, LOCKSET - STEERING LOCK

1 1 1 FT. 1 FT. 1 1 2 1 2 1 1 2 1

*NOT SOLD SEPARATELY

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3

1 2

4

ASSY, STEERING WHEEL - 4 SPOKE BLACK W/BLACK CENTERITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0521-00343 0612-00739 0612-00740 0350-03008

NUT, HEX - NYLOCK M14 X 1.5 ZP COVER, STEERING WHEEL - 4 SPOKE - BLACK WHEEL, STEERING - 4 SPOKE - BLACK DECAL, STEERING WHEEL

1 1 1 1

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ASSY, STEERING WHEELITEM 1 2 3 4 5 PART NO. 0350-03008 0612-00739 0523-00177 0612-00034 0612-00043 DESCRIPTION DECAL, STEERING WHEEL NUT, HEX - NYLOCK M14 X 1.52 P SCREW, HI-LOW - PHIL PAN # 10 X 1 BLANK ZINC WHEEL, STEERING COVER, STEERING WHEEL QTY. 1 1 2 1 1

2 3

1

CENTER - STEERING WHEEL WITH CLIPITEM PART NO. DESCRIPTION QTY.

1 2 3

0107-00527 * *

CENTER-STEERING WHEEL WITH CUP PENCIL SCORE CARD

1 1 1

*STARRED ITEMS ARE SHOWN FOR REFERENCE ONLY. STARRED ITEMS ARE NOT AVAILABLE SEPARATELY.

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Parts Catalog SECTION 4 - WHEEL END COMPONENTS

January 2009760-321-2275

GEM Parts Catalog Section 4 - Wheel End Componentswww.4GEMparts.com [email protected]

Page 41

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ASSY, WHEEL END - RH REAR - 12mmITEM *1 *2 3 4 5 *6 *7 *8 *9 10 11 *12 13 14 *15 PART NO. 0311-00833 0311-00834 0311-00884 0521-00035 0522-00038 0524-00036 0611-00203 DESCRIPTION ASSY, BRAKE - RH REAR ASSY, HUB SHOE, BRAKE RIGHT SHOE, BRAKE LEFT SPRING, E-BRAKE RELEASE LH SPINDLE DRUM SHAFT, AXLE TUBE, SPACER - BEARING NUT, HEX - TOP LOCK - M16 X 1.5 GRADE 12 BOLT, HEX - HHCS - M8 X 1.25 X 34.5 GR 8.8 SCREW, HEX SOCKET - CNTSK M5 X .8 X 12 LG GR 10.9 WASHER, FLAT - M16 NARROW 17.52 ID 32 OD KIT, CYLINDER - BRAKE - REAR BEARING, ROLLER QTY. 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1

16

0116-00166

ASSY, WHEEL END - RH REAR - 12mm (Includes all of the items above)

1

* STARRED ITEMS ARE NOT AVAILABLE SEPARATELY ITEMS ARE NOT INCLUDED WITH 0116-00166

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ASSY, WHEEL END - LH REAR - 12mmITEM PART NO. DESCRIPTION QTY.

*1 *2 3 4 5 *6 *7 *8 *9 10 11 *12 13 14 *15 16

0311-00833 0311-00834 0311-00883 0521-00035 0522-00038 0524-00036 0611-00203 0116-00167

ASSY, BRAKE - LH REAR ASSY, HUB SHOE, BRAKE RIGHT SHOE, BRAKE LEFT SPRING, E-BRAKE RELEASE RH SPINDLE DRUM SHAFT, AXLE TUBE, SPACER - BEARING NUT, HEX - TOP LOCK - M16 X 1.5 GRADE 1 BOLT, HEX - HHCS - M8 X 1.25 X 34.5 GR 8.8 SCREW, HEX SOCKET - CNTSK M5 X .8 X 12 LG GR 10.9 WASHER, FLAT - M16 NARROW 17.52 ID 32 OD KIT, CYLINDER - BRAKE - REAR BEARING, ROLLER ASSY, WHEEL END - LH REAR - 12mm (Includes all of the items above)

1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1

* STARRED ITEMS ARE NOT AVAILABLE SEPARATELY ITEMS ARE NOT INCLUDED WITH 0116-00166

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4

5

6

2

7

8 3

1

ASSY, WHEEL END - RH REARITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8

0111-01498 0116-01500 0316-01814 0316-01815 0316-01850 0521-00456 0522-00465 0524-00172

ASSY, BRAKE - RH REAR ASSY, HUB - REAR SPINDLE - REAR DRUM, 5 BOLT COVER, DUST NUT, HEX FLANGE NYLOCK - M20 X 1.50 GR 11 ZN BOLT, HEX - M12 X 1.50 X 30 LG HHCS GR 10.9 ZN WASHER, LOCK - M12 ZINC PLATED

1 1 1 1 1 1 4 4

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1 2 8 3 7 6

4

5

ASSY, WHEEL END - LH REARITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8

0111-01499 0116-01500 0316-01814 0316-01815 0316-01850 0521-00456 0522-00465 0524-00172

ASSY, BRAKE - LH REAR ASSY, HUB - REAR SPINDLE - REAR DRUM, 5 BOLT COVER, DUST NUT, HEX FLANGE NYLOCK - M20 X 1.50 GR 11 ZN BOLT, HEX - M12 X 1.50 X 30 LG HHCS GR 10.9 ZN WASHER, LOCK - M12 ZINC PLATED

1 1 1 1 1 1 4 4

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2 1 3

ASSY, WHEEL END - 10ITEM PART NO. DESCRIPTION QTY.

1 2 3

0116-00491 0311-01394 0522-00395

ASSY, HUB - DISC BRAKE DISC, BRAKE - 7.56 DIA BOLT, SHOULDER M6 X 1 - 6G X 17.8 LG CL 10.9 RD 33-39

1 1 4

*COMPONENTS ARE COMPATIBLE WITH LEFT HAND AND RIGHT HAND

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2 1

3


1 2 3

0116-00491 0311-01360 0522-00395

ASSY, HUB - DISC BRAKE DISC, BRAKE - 9.21 DIA BOLT, SHOULDER M6 X 1 - 6G X 17.8 LG CL 10.9 RD 33-39

1 1 4


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2 3

1


1 2 3

0116-01424 0311-01792 0522-00395

ASSY, HUB - 5-BOLT DISC, BRAKE - 9.21 DIA BOLT, SHOULDER M6 X 1 - 6G X 17.8 LG CL 10.9 RD 33-39

1 1 5


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Parts Catalog SECTION 5 - BRAKES

January 2009760-321-2275

GEM Parts Catalog Section 5 - Brakeswww.4GEMparts.com [email protected]

Page 49

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4 5 6 2

10

1

9

3

11

7 8

ASSY, CALIPER - LOADED AK150ITEM PART NO. DESCRIPTION QTY.

*1 *2 *3 *4 5 *6 *7 *8 9 *10 *11*NOT SOLD SEPARATELY

0522-00402 0611-00732

PISTON, BRAKE CALIPER CALIPER, MACHINED INNER CALIPER, MACHINED OUTER PIN, COTTER - 1/16 X 1.0 LG ZINC PLATED SCREW, SOCKET CAP HEAD - MB X 1.25 X 40 - ZINC PIN, CLEVIS - DISC BRAKE SCREW, BLEEDER CAP, BLEEDER PAD, BRAKE - DISC AK150 SEAL, BRAKE CALIPER RING, O - 9.5 mm OD X 6.0 mm ID

2 1 1 1 4 1 2 2 2 2 2

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12 14 13 9 10

5

2

6

8 16 17

4

7

3

11 1

15

ASSY, BRAKE PEDALITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

0211-00242 0311-00087 0311-00089 0311-00285 0311-02331 0510-00007 0521-00010 0521-00017 0521-00099 0521-00514 0522-00008 0522-00016 0522-00535 0524-00003 0524-00009 0524-00153 0611-00684

WLDMT, BRAKE PEDAL SHAFT, BRAKE PEDAL BUSHING, PUSH ROD MNT PAD, BRAKE PEDAL BRKT, BRAKE PEDAL PIN, COTTER 3/32 X 1.0 LONG NUT, HEX - NYLOCK 3/8 - 16 UNC GR5 NUT, HEX - NYLOCK 5/16 - 18 UNC GR5 NUT, HEX - 1/4 - 20 UNC GR5 ZN RIVNUT, 1/4 - 20 GRIP 0.027 - 0.165 P 0.3906 BOLT, HEX - 3/8-16 UNC X 1.5 LG GR5 BOLT, HEX - 5/16 - 18 UNC X 1.0 GR5 BOLT, HEX - 1/4 - 20 X 1.25 GR5 ZP WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN WASHER, FLAT - 3/8 SAE 0.406 ID X 0.8125 OD X 0.080 THK ZN WASHER, FLAT - 5/8 MACH BUSHING 5/8 ID X 1.0 OD X 0.080 ZN SPRING, TORSION BRAKE PEDAL

1 1 1 1 1 2 1 4 1 1 1 4 1 8 2 2 1

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ASSY, SPRING, TORSION BRAKE PEDALITEM PART NO. DESCRIPTION QTY.

1

0611-00684

SPRING, TORSION BRAKE PEDAL

1

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ASSY, MASTER CYLINDERITEM PART NO. DESCRIPTION QTY.

1 2 3 *4 *5 *6

0521-00017 0522-00084 0524-00003 *0611-00411 0606-00241 0611-00281

NUT, HEX - NYLOCK 5/16-18 UNC GR5 ZN BOLT, HEX - 5/16 - 18 UNC X 1.5 GR5 ZIN WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN CYLINDER, MASTER CYLINDER 11/16 BORE SWITCH, BRAKE LIGHT - PRESS SWITCH, BRAKE FLOAT

2 2 4 1 1 1

* ITEM NUMBERS 5 & 6 CAN BE PURCHASED SEPARATELY BUT ARE SUPPLIED WITH ITEM # 4

January 2009760-321-2275


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ASSY, BRAKE LINES - FRONTITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8

0111-01107 0111-01106 0111-01111 0111-01113 0510-00169 0522-00183 0524-00173 0611-00132

ASSY, BRAKE LINE LH FRONT ASSY, BRAKE LINE - RH FRONT ASSY, BRAKE LINE SLA - FRONT ASSY, BRAKE LINE - MC TO TEE CLIP, HORSE SHOE BOLT, BANJO WASHER, COPPER 0.408 ID X 0.670 OD X 0.050 THK FITTING, TEE UNION BRASS 3/8-24 THD

1 1 2 1 2 2 4 1

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ASSY, BRAKE LINES - MID - 2 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0111-00667 0319-00534 0510-00171 0523-00032

ASSY, BRAKE LINE REAR (2P) HOSE, COVER CLAMP, P - 3/16 WIRE STL/BLK VINYL COATED SCREW, HEX - WHSD 1/4 X 0.75 ZN

1 1 3 3

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1

4 3

2

ASSY, BRAKE LINES - MID - 4 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0111-00668 0319-00534 0510-00171 0523-00032

ASSY, BRAKE LINE REAR (4P) HOSE, COVER CLAMP, P - 3/16 WIRE STL/BLK VINYL COATED SCREW, HEX - WHSD 1/4 X 0.75 ZN

1 1 4 4

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1 3

5 2

4

ASSY, BRAKE LINES - MID - LONG BACKITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5

0111-01656 0111-02122 0510-00171 0520-00361 0611-00472

ASSY, BRAKE LINE MID REAR-e6 ASSY, BRAKE LINE - MID FRONT eL CLAMP, P - 3/16 WIRE STL/BLK VINYL COATED RIVET, BLND - 1/4 BDY DIA, 1/2 DMD HD, 1/16 - 1/4 GRP. FITTING, UNION - BRASS 3/8 - 24 THD FOR 3/16 TUBE DIA

1 1 5 5 1

January 2009760-321-2275


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1

ASSY, BRAKE LINE - MID FRONT e6ITEM PART NO. DESCRIPTION QTY.

1NOTES:

0111-02457

ASSY, BRAKE LINE - MID FRONT e6

1

THE 45 INVERTED FLARE WILL MEET SAE J5338 THE TUBE NUTS MUST MEET SAE J512

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1

ASSY, BRAKE LINE - MID REARITEM PART NO. DESCRIPTION QTY.

1

0111-01656

TUBE, BRAKE LINE - MID REAR

1

January 2009760-321-2275


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1

ASSY, BRAKE LINES - RH REARITEM PART NO. DESCRIPTION QTY.

1

0111-02943

ASSY, BRAKE LINES - RH REAR

1

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1

ASSY, BRAKE LINES - LH REARITEM PART NO. DESCRIPTION QTY.

1

0111-02944

ASSY, BRAKE LINES - LH REAR

1

January 2009760-321-2275


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2

7 3 6 5

1

4

ASSY, BRAKE LINES REARITEM PART NO. DESCRIPTION QTY.

1 2 3 *4 5 6 7

0111-01110 0111-01104 0111-01105 0510-00169 0510-00171 0523-00032 0611-00132

ASSY, BRAKE HOSE SLA - REAR ASSY, BRAKE LINE - RH REAR ASSY, BRAKE LINE - LH REAR CLIP, HORSESHOE CLAMP, P - 3/16 WIRE STL/BLK VINYL COATED SCREW, HEX - WHSD 1/4 X 0.75 ZN WASHER HD SELF-DRILLING FITTING, TEE UNION BRASS 3/8 - 24 THD

1 1 1 1 2 2 1

*AVAILABLE FOR eL MODELS ONLY

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1

7 6 5 2

3

4

ASSY, BRAKE LINES REARITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0111-02943 0111-02944 0111-01110 0510-00169 0510-00171 0523-00032 0611-00132

ASSY, BRAKE LINE - RH REAR ASSY, BRAKE LINE - LH REAR ASSY, BRAKE HOSE SLA - REAR CLIP, HORSESHOE CLAMP, P - 3/16 WIRE STL/BLK VINYL COATED SCREW, HEX - WHSD 1/4 X 0.75 ZN WASHER HD SELF-DRILLING FITTING, TEE UNION BRASS 3/8 - 24 THD

1 1 1 1 3 3 1

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11 13 14

5 16 10 7

1 3

6 12

9 4

8

2

15

ASSY, PARKING BRAKE LEVER 2-PASS & SHORT BACKITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

0111-02935 0211-00209 0311-00117 0311-01507 0311-01508 0510-00018 0510-00019 0510-00020 0521-00017 0521-00024 0521-00031 0522-00021 0522-00144 0524-00003 0532-00122 0611-00303

ASSY, PARKING BRAKE LEVER W/CABLE WLD, BRACKET -PARK BRAKE LEVER BRKT, EQUALIZER - PARKING BRAKE CABLE BRKT, BRAKE CABLE - LH PARKING BRAKE BRKT, BRAKE CABLE - RH PARKING BRAKE CLIP, E - 7/16 SHAFT ZINC PLATED PIN, CLEVIS - 3/16 ANSI B18.8.1-1972 R1983 PIN, COTTER - 1/16 X 1.0 LG ZINC PLATED NUT, HEX - NYLOCK 5/16-18 UNC GR5 ZN NUT, HEX FLANGE 1/2-13 UNC GR 6 TECH LOCK NUT, HEX - 5/16-18 UNC GR5 ZN BOLT, HEX - 1/2 - 13 UNC X 1.0 GR 8 ZN YL ZINC PLATED BOLT, HEX - 5/16 - 18 UNC X 0.75 GR5 ZINC PLATED WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN SCREW, HEX - WHSD 1/4 X 1.5 ZINC PLATED ASSY, CABLE PARKING BRAKE 2 PASS/SM UTILITY

1 1 1 1 1 4 2 2 2 2 2 2 2 5 4 2

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ASSY, PARKING BRAKE LEVER 4 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

0111-02935 0311-00117 0311-01507 0311-01508 0510-00018 0510-00019 0510-00020 0521-00017 0521-00024 0521-00031 0522-00021 0522-00084 0523-00190 0524-00003 0611-00131 0611-00304 0523-00122

ASSY, PARKING BRAKE LEVER BRKT, EQUALIZER - PARKING BRAKE CABLE BRKT, BRAKE CABLE - LH PARKING BRAKE BRKT, BRAKE CABLE - RH PARKING BRAKE CLIP, E - 7/16 SHAFT ZINC PLATED PIN, CLEVIS - 3/16 ANSI B18.8.1-1972 R1983 PIN, COTTER - 1/16 X 1.0 LG ZINC PLATED NUT, HEX - NYLOCK 5/16-18 UNC GR5 ZN NUT, HEX FLANGE 1/2-13 UNC GR 6 TECH LOCK NUT, HEX - 5/16-18 UNC GR5 ZN BOLT, HEX - 1/2 - 13 UNC X 1.0 GR 8 ZN YL ZINC PLATED BOLT, HEX - 5/16 - 18 UNC X 1.5 GR5 ZINC PLATED SCREW, TEK - PHIL PAN #8 - 18X1 #2PT, QTY. WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN BOOT, PARKING BRAKE LEVER ASSY, CABLE PARKING BRAKE 4 PASS / LG UTILITY SCREW, HEX - WASHER, HAND SELF-DRILL 1/4

1 1 1 1 4 2 2 2 2 2 2 2 2 5 1 2 4

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5 3 13 14 11 16 12

10 7

2 1 9 8 6

15

ASSY, PARKING BRAKE - eLITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 **NOT SHOWN

0111-02935 0211-00209 0311-00117 0311-01507 0311-01508 0510-00018 0510-00019 0510-00020 0521-00017 0521-00024 0521-00031 0522-00021 0522-00144 0524-00003 0532-00122 0611-00691 0311-00089

ASSY, PARKING BRAKE LEVER WLD, BRACKET - PARK BRAKE LEVER BRKT, EQUALIZER - PARKING BRAKE CABLE BRKT, BRAKE CABLE - LH PARKING BRAKE BRKT, BRAKE CABLE - RH PARKING BRAKE CLIP, E - 7/16 SHAFT ZINC PLATED PIN, CLEVIS - 3/16 ANSI B18.8.1-1972 R1983 PIN, COTTER - 1/16 X 1.0 LG ZINC PLATED NUT, HEX - NYLOCK 5/16-18 UNC GR5 ZN NUT, HEX FLANGE 1/2-13 UNC GR 6 TECH LOCK NUT, HEX - 5/16-18 UNC GR5 ZN BOLT, HEX - 1/2 - 13 UNC X 1.0 GR 8 ZN YL ZINC PLATED BOLT, HEX - 5/16 - 18 UNC X 1.25 GR5 ZINC PLATED WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN SCREW, HEX - WHSD 1/4 X 1.5 ZINC PLATED WASHER HD SELF DRILLING ASSY, CABLE PARKING BRAKE STD eL BUSHING, PUSH ROD MNT

1 1 1 1 1 4 2 2 2 2 2 2 2 2

2 1

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6

3

7

5

2 1 8 4

9

ASSY, PARKING BRAKE eLXDITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9

0111-02935 0211-00209 0311-00117 0521-00017 0521-00031 0522-00144 0524-00003 0532-00122 0611-00692

ASSY, PARKING BRAKE LEVER WLD, BRACKET - PARKING BRAKE BRKT, EQUALIZER - PARKING BRAKE CABLE NUT, HEX - NYLOCK 5/16 - 18 UNC GR5 NUT, HEX - 5/16 - 18 UNC GR5 ZN BOLT, HEX - 5/16 - 18 UNC X 0.75 GR5 WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN SCREW, HEX - WSHD 1/4 X 1.5 ZINC PLATED WASHER HD SELF-DRILLING ASSY, CABLE - PARKING BRAKE eLXD

1 1 1 2 4 2 2 4 2

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7

9

6 8 1 4 10

3

2 5

ASSY, PARKING BRAKE e6ITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10

0111-02935 0311-00117 0510-00154 0520-00361 0521-00031 0522-00084 0523-00177 0524-00003 0611-00131 0611-00524

ASSY, PARKING BRAKE LEVER BRKT, EQUALIZER - PARKING BRAKE CABLE CLAMP, P - 3/8 WIRE STL/BLK VINYL COATED RIVET, BLND - 1/4 BDY DIA, 1/2 DMD HD, 1/16 - 1/4 GRP. NUT, HEX - 5/16 - 18 UNC GR5 ZN BOLT, HEX - 5/16 - 18 UNC X 1.5 GR5 SCREW, HI-LOW - PHIL PAN # 10 X 1 BLANK ZINC

1 1 6 6 2 2 2

WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 X THK ZN 3 BOOT, PARKING BRAKE LEVER ASSY, CABLE - PARKING BRAKE e6 1 2

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ASSY, PARKING BRAKE LEVERITEM PART NO. DESCRIPTION QTY.

1 2

0111-02935 0306-00120

ASSY, PARKING BRAKE LEVER SWITCH, PARKING BRAKE LEVER

1 1

* STARRED ITEMS ARE NOT AVAILABLE SEPARATELY

January 2009760-321-2275


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Parts Catalog SECTION 6 - DRIVE LINE COMPONENTS

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8 9 3

6 4 7

2 10 1 11

ASSY, DRIVE LINE - 12.44, 46 IN WIDEITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11

0113-02685 0113-02686 0313-00417 0324-01480 0510-00137 0510-00409 0521-00401 0522-00016 0524-00081 0613-00643 0613-00645

ASSY, HALFSHAFT - LH TRIPOD ASSY, HALFSHAFT - RH (LONG) TRIPOD KEEPER, GEARBOX/DIFF WASHER, AXLE SHAFT TIE, CABLE W/#10 MOUNT HOLE 9 BLACK (NOT SHOWN) PIN, COTTER 1/8 X 1.25 LG ZC NUT, HEX - CASTLE - M16 X 2.0 - ZNC BOLT, HEX - 5/16 - 18 UNC X 1.0 GR 5 ZINC PLATED WASHER, LOCK - 5/15 ZINC PLATED ASSY, GEAR BOX/DIFFERENTIAL - W/BREATHER VENT 12.44 : 1 VENT, BREATHER - DIFFERENTIAL

1 1 2 2 1 2 2 8 8 1 1

January 2009760-321-2275

GEM Parts Catalog Section 6 - Drive Line Componentswww.4GEMparts.com [email protected]

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7 8 3

5 4 6

2 9 1

ASSY, DRIVE LINE - 14.76, 46 IN WIDEITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9

0113-02685 0113-02686 0313-00417 0324-01480 0510-00409 0521-00401 0522-00016 0524-00081 0613-00582

ASSY, HALFSHAFT - LH TRIPOD ASSY, HALFSHAFT - RH (LONG) TRIPOD KEEPER, GEARBOX/DIFF WASHER, AXLE SHAFT PIN, COTTER 1/8 X 1.25 LG ZC NUT, HEX - CASTLE - M16 X 2.0 - ZNC BOLT, HEX - 5/16 - 18 UNC X 1.0 GR 5 ZINC PLATED WASHER, LOCK - 5/15 ZINC PLATED ASSY, GEAR BOX/DIFFERENTIAL - 14.76:1

1 1 2 2 2 2 8 8 1

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5

4

3 1

ASSY, MOTOR - 5.0 HP HDITEM PART NO. DESCRIPTION QTY.

1 *2 3 4 5

0313-00168 0522-00056 0613-00541 0606-00272

BUMPER, RESILIENT - DIFF TO MOTOR LOCKTITE, RED - 27140 BOLT, HEX - 1/4 - 20 UNC X 1.0 GR 8 ZN YL MOTOR, ELECTRIC - HD 5 HP 72 V W/THERMAL PROTECTION ASSY, SENSOR - SPEED

1 0.03ML 3 1 1

*STARRED ITEMS ARE NOT AVAILABLE SEPARATELY

January 2009760-321-2275


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6

5 4

1

ASSY, MOTOR - 7.0 HP XDITEM PART NO. DESCRIPTION QTY.

1 **2 *3 4 5 6

0313-00168 0350-02793 0522-00056 0613-00724 0606-00272

BUMPER, RESILIENT - DIFF TO MOTOR DECAL, HORSEPOWER - 7.0 LOCKTITE, RED - 27140 BOLT, HEX - 1/4 - 20 UNC X 1.0 GR 8 ZN YL MOTOR, ELECTRIC VENTED 7 HP, W/THERMAL PROTECTION ASSY, SENSOR - SPEED

1 2 0.03 ML 3 1 1

*STARRED ITEMS ARE NOT AVAILABLE SEPARATELY**REFER TO SECTION 10 DECALS FOR ILLUSTRATION

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6 2 3

8

7

4

9

1

10

ASSY, COOLING PACKAGEITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10

0106-02112 0306-02221 0306-02222 0306-02237 0406-00259 0521-00071 0521-00317 0522-00049 0523-00163 0523-00432

ASSY, FAN HEATSINK, CONTROLLER - ALUMINUM PLATE, HEATSINK MOUNT BRACKET, FAN THERMAL GREASE, TYPE 120 SILICONE NUT, KEPS - 1/4 - 20 UNC ZINC PLATED NUT, KEPS - 8-32 ZINC PLATED BOLT, HEX - 1/4 - 20 UNC X 1.0 GRADE 2 SCREW, HEX - WHSD 10 - 16 X 1/2 #2 POINT STL BLK ZINC WASHER HD SELF-DRILLING SCREW, MACH GENERIC SST

1 1 2 1 1 6 4 6 4 4

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3 3

3

1 2

4

3

ASSY, SCOOP - DUALITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0305-02630 0305-02631 0523-00032 0524-00062

SCOOP, WIND - RH SCOOP, WIND - LH SCREW, HEX - WSD 1/2 X 0.75 ZN WASHER HD SELF-DRILLING WASHER, FLAT - 1/4 0.281 ID X 0.625 OD X 0.050 THK ZN

1 1 8 8

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3 6

7

4

1

5 2

ASSY, BRACKET - FAST CHARGE RECEPTACLEITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0310-02581 0251-00260 0520-00534 0522-00405 0610-00701 0610-00706 0310-02581

LID, FAST CHARGE WLD. BRACKET - FAST CHARGE RECEPTACLE RIVET, BLIND - 1/8 BDY DIA. 1/4 DOME HEAD DIA 1/16-1/8 GRIP ZINC PLATED STEEL BOLT, HEX - 1/4 - 20 UNSLT X 5/8 LG WSR HD ZN PLUG, HOLE - 9/16 BLACK PLASTIC HINGE, SPRING - SELF-CLOSING, 2 LENGTH X 1 WIDE SS FOAM, FAST CHARGE LID

1 1 4 3 4 1 1

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1

KIT, FAST CHARGE COMPONENTS - 0606-00702ITEM PART NO. DESCRIPTION QTY.

1

0606-00702

FAST CHARGE COMPONENTS

1

NOT SOLD SEPARATELY

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[email protected]

1

2

3

KIT, FAST CHARGE COMPONENTSITEM PART NO. DESCRIPTION QTY.

1 2 3

0106-02391 0106-02392 0106-02390

ASSY, CABLE - FAST CHARGE ASSY, WIRE HARNESS - TEMP SENSOR ASSY, WIRE HARNESS - FAST CHARGE

1 1 1

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Parts Catalog SECTION 7 - ELECTRICAL

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GEM Parts Catalog Section 7 - Electricalwww.4GEMparts.com


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[email protected]

ASSY, ACCELERATOR PEDALITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5

0148-01000 0521-00050 0522-00201 0522-00365 0524-00062

ASSY, PEDAL - ACCELERATOR NUT, HEX - NYLOCK 1/4-20 UNC GR5 ZN BOLT, HEX - 1/4 - 20 UNC X 2.25 GR5 ZN ZINC PLATED BOLT, HEX - 1/4 - 20 UNC X 3.75 LG GR 5 ZNC PLT WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN

1 3 1 2 6

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GEM Parts Catalog Section 7 - Electricalwww.4GEMparts.com [email protected]

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1

2

ASSY, CONVERTER - 72V/12V 30 AMP (SURE POWER)ITEM PART NO. DESCRIPTION QTY.

1 2

0521-00071 0606-00421

NUT, KEPS - 1/4 - 20 UNC ZINC PLATED GR 5 ZINC PLATED CONVERTER, 72V/12V - 30AMP

4 1

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2

3

1

ASSY, CHARGER - 72 V 12 AMP WITH SERIALITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0306-01135 0521-00071 0606-00678 0606-00681

CORD, EXTERIOR CHARGING INLET, TYPE B PLUG NUT, KEPS - 1/4 - 20 UNC ZINC PLATED CHARGER, 72 V - 12 AMP W/SERIAL SENSOR, BATTERY TEMPERATURE - DELTA Q (NOT SHOWN)

1 4 1 1

January 2009760-321-2275


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ASSY, EXTERIOR CHARGING INLET, 15A/125VAC, NEMA 5-15ITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0110-00832 0306-01135 0350-03008 0350-01134

ASSY, EXTERIOR CHARGING INLET HOUSING CORD, EXTERIOR CHARGING INLET, TYPE B PLUG DECAL, FRONT EMBLEM DECAL, EXTERIOR CHARGING INLET - FILLER

1 1 1 1

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*

ASSY, CONTROL - ELECTRIC MOTOR 5 HPITEM PART NO. DESCRIPTION QTY.

1 *2

0521-00071 0606-00628

NUT, KEPS - 1/4 - 20 UNC ZINC PLATED GR 5 ZINC PLATED CONTROL, ELECTRIC MOTOR - 72 V T4 *(When ordering a replacement controller, please specify the vehicles battery type, odometer reading and wheel/tire type and size.)

6

1

January 2009760-321-2275


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6 7

5

8

ASSY, CABLES - without COOLING PACKAGEITEM 1 2 3 4 5 6 7 8 PART NO. 0106-02948 0106-03200 0106-01040 0106-03113 0106-01047 0106-01048 0106-01049 0106-01050 DESCRIPTION ASSY, CABLE - MC+ TO DSW ASSY, CABLE MC- TO POS ASSY, CABLE NEG TO 72 GND ASSY, CABLE DSW - TO +72 ASSY, CABLE MA1 TO CA1 ASSY, CABLE MA2 TO CA2 ASSY, CABLE MF2 TO CF2 ASSY, CABLE MF1 TO CF1 QTY. 1 1 1 1 1 1 1 1

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ASSY, CABLES - with COOLING PACKAGEITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8

0106-02948 0106-03200 0106-01040 0106-01049 0106-01050 0106-03113 0106-02056 0106-02057

ASSY, CABLE TO DSW ASSY, CABLE MC- TO POS ASSY, CABLE NEG TO 72 GND ASSY, CABLE MF2 TO CF2 ASSY, CABLE MF1 TO CF1 ASSY, CABLE DSW TO +72 ASSY, CABLE MA1 TO CA1 ASSY, CABLE MA2 TO CA2

1 1 1 1 1 1 1 1

January 2009760-321-2275


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ASSY, WIRE HARNESS, MAIN REAR POWERITEM PART NO. DESCRIPTION QTY.

0106-03108

ASSY, WIRE HARNESS - REAR e2, eL, eLXD

1

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ASSY, WIRE HARNESS - e6SITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0106-02177 0106-01027 0106-02176 0106-03111

ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS REAR, e6S

1 1 1 1

January 2009760-321-2275


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ASSY, WIRE HARNESS - e6ITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0106-03110 0106-02177 0106-01027 0106-02176

ASSY, WIRE HARNESS - REAR, e6 ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER

1 1 1 1

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ITEM

PART NO.

DESCRIPTION

QTY.

6

0106-03109

ASSY, WIRE HARNESS - REAR - e4

1

January 2009760-321-2275


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1 2

3

ITEM

PART NO.

DESCRIPTION

QTY.

1 2 3

0106-02185 0606-00697 0106-02186

TURN SIGNAL REMINDER HARNESS RELAY, 12V, 1A - 45S DELAY ON MAKE ASSY, BUZZER, 12 VDC - 2500HZ

1 1 1

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ITEM

PART NO.

DESCRIPTION

QTY.

4

0106-01757

ASSY, WIRE HARNESS - TAILLIGHT

1

January 2009760-321-2275


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ASSY, WIRE HARNESS - TAIL LIGHTITEM PART NO. DESCRIPTION QTY.

1

0106-01617

ASSY, WIRE HARNESS - TAIL LIGHT

1

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ASSY, WIRE HARNESS - TAIL LIGHT LONG BACKITEM PART NO. DESCRIPTION QTY.

1

0106-01408

ASSY, WIRE HARNESS - TAIL LIGHT

1

January 2009760-321-2275


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ASSY, WIRE HARNESS - e2ITEM 1 2 3 EU 4 EU 5 6 7 8 * EU ITEM 1 2 3 EU 4 EU 5 6 7 8 * EU ITEM 1 1 2 3 4 EU 5 6 PART NO. 0106-02177 0106-01027 0106-02176 0106-03124 0106-01757 0106-01312 0106-03108 0106-02184 0106-02185 0106-01030 0106-02217 0106-01305 PART NO. 0106-02177 0106-01027 0106-02176 0106-03124 0106-01757 0106-01312 0106-03109 0106-02184 0106-02185 0106-01030 0106-02217 0106-01305 PART NO. 0106-03110 0106-03111 0106-02177 0106-01027 0106-02176 0106-03124 0106-02184 0106-01757 0106-01617 0106-02185 0106-01030 0106-02217 0106-01305 PART NO. 0106-02177 0106-01027 0106-02176 0106-03124 0106-03108 0106-01617 0106-02184 0106-02185 0106-01030 0106-02217 0106-01305 DESCRIPTION ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - TAILLIGHT ASSY, HARNESS - UNIVERSAL TAIL LIGHT ASSY, WIRE HARNESS - REAR, e2 eS ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN ASSY, WIRE HARNESS - HEADLIGHT - 07 ASSY, WIRE HARNESS - HEADLIGHT DESCRIPTION ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - TAIL LIGHT ASSY, HARNESS - UNIVERSAL TAIL LIGHT ASSY, WIRE HARNESS - REAR, e4 ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS - REMINDER - TIMER ASSY, WIRE HARNESS - STEERING COLUMN ASSY, WIRE HARNESS - HEADLIGHT - 07 ASSY, WIRE HARNESS - HEADLIGHT DESCRIPTION ASSY, WIRE HARNESS - REAR , e6 ASSY, WIRE HARNESS - REAR , e6S ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TAIL LIGHT ASSY WIRE HARNESS - TAIL LIGHT - e6S ASSY, WIRE HARNESS - TURN SIGNALS ALARM ASSY, WIRE HARNESS - STEERING COLUMN ASSY, WIRE HARNESS - HEADLIGHT - 07 ASSY, WIRE HARNESS - HEADLIGHT DESCRIPTION ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - MAIN REAR e2, eS ASSY, WIRE HARNESS - TAIL LIGHT EU ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN ASSY, WIRE HARNESS - HEADLIGHT - 07 ASSY, WIRE HARNESS - HEADLIGHT DESCRIPTION ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - REAR. eL ASSY, TAIL LIGHT HARNESS W/ GND - LNG BK ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN ASSY, WIRE HARNESS - HEADLIGHT - 07 ASSY, WIRE HARNESS - HEADLIGHT QTY. 1 1 1 1 1 1 1 1 1 1 1 1 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 QTY. 1 1 1 1 1 1 1 1 1 1 1 QTY. 1 1 1 1 1 1 1 1 1 1 1

ASSY, WIRE HARNESS - e4

ASSY, WIRE HARNESS - e6

7 8 * EUITEM 1 2 3 EU 4 5 6 7 8 * EU

ASSY, WIRE HARNESS - eS

ASSY, WIRE HARNESS - eL & eLXDITEM PART NO. 1 0106-02177 2 0106-01027 3 0106-02176 EU 0106-03124 4 0106-03108 5 0106-01408 6 0106-02184 7 0106-02185 8 0106-01030 * 0106-02217 EU 0106-01305 *NO PICTURE AVAILABLE

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ITEM

PART NO.

DESCRIPTION

QTY.

1 2 3

0106-02177 0106-01027 0106-02176

ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER

1 1 1

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1

2

ITEM

PART NO.

DESCRIPTION

QTY.

1 2

0106-02184 0606-00868

ASSY, WIRE HANRESS - PARK BRAKE RELAY, PARK BRAKE - SPDT 12 VDC

1 1

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ITEM 8

PART NO. 0106-01030

DESCRIPTION ASSY, WIRE HARNESS - STEERING COLUMN

QTY. 1

January 2009760-321-2275


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3 2

1

4

5

6

11

9

8

7

10

9

12

10 11

ASSY, PSDM TO DASH SUPPORTITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. 0151-01283 0521-00071 0606-00420 0606-00436 0606-00445 0610-00782 0650-00460 0606-00476 0606-00293 0606-00474 0606-00454 0606-00515 760-321-2275 DESCRIPTION ASSY, PSDM PLATE NUT, KEPS - 1/4 - 20 UNC ZINC PLATED CONTACTOR, MAIN - 100A MODULE, POWER & SIGNAL DISTRIBUTION PSDM SWITCH, DISCONNECT - 100A CAP, VINYL - 8/12 ID X 1: LENGTH, BLACK W/FLANGE DECAL, FUSE BLOCK - VIN37417 TO CURRENT FUSE, ATC-1 FUSE, ATC-10 FUSE, CARTRIDGE - 10 AMP SLO-BLO CAPS, FUSE HOLDER FUSE, CERAMIC TUBE - 30A SLO- BLO QTY. 1 6 1 1 1 2 1 2 4 3 3

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ASSY, BATTERY CABLE - 0106-01213ITEM 1 2 3 4 5 6 PART NO. 0106-01036 0106-01042 0106-01043 0106-01044 0106-01045 0106-01046 DESCRIPTION ASSY, CABLE B3+ TO FUSE ASSY, CABLE B1+ TO B2ASSY, CABLE B2+ TO B3ASSY, CABLE FUSE TO B4ASSY, CABLE B4+ TO B5ASSY, CABLE B5+ TO B6QTY. 1 1 1 1 1 1

January 2009760-321-2275


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[email protected]

NO PICTURE AVAILABLE PARTS LISTING ONLY

ASSY, BATTERY INTERCONNECTS - 0106-02234ITEM 1 2 3 4 5 6 7 8 PART NO. 0106-02244 0020-02245 0030-02246 0040-02247 0050-02248 0060-02249 0524-00478 0521-00335 DESCRIPTION ASSY, CABLE, 3/8 RING - B1+ TO B2 ASSY, CABLE, 3/8 RING - B2+ TO B3 ASSY, CABLE, 3/8 RING - B3+ TO FUSE ASSY, CABLE 3/8 RING - FUSE TO B4ASSY, CABLE, 3/8 RING - B4+ TO B5ASSY, CABLE 3/8 RING - B5+ TO B6WASHER, CONICAL ID 0.380, OD 0.750, H 0.059, T 0.040 NUT, 3/8-16 FIN. HEX NUT, 18-8 STAINLESS QTY. 1 1 1 1 1 1 12 12

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NO PICTURE AVAILABLE PARTS LISTING ONLY

ASSY, BATTERY INTERCONNECTS - 0106-02254ITEM 1 2 3 4 5 6 7 8 9 PART NO. 0106-02235 0106-02236 0106-02238 0106-02239 0106-02240 0106-02241 0106-00442 0106-02243 0524-00477 DESCRIPTION ASSY, CABLE, 5/16 RING - B1+ TO B2 ASSY CABLE, 5/16 RING - B2+ TO B3ASSY CABLE, 5/16 RING - FUSE TO B4ASSY, CABLE, 5/16 RING - B4+ TO B5ASSY, CABLE, 5/16 RING - B5+ TO B6ASSY, CABLE, 5/16 RING - B6+ TO B7ASSY, CABLE, 5/16 RING - B7+ TO B8ASSY, CABLE, 5/16 RING - B8+ TO B9WASHER, CONICAL ID 0.317, OD 0.625, H 0.059, T 0.047 QTY. 1 1 1 1 1 1 1 1 18

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ASSY, BATTERY INTERCONNECTS - eLXD 8V - 0106-02233ITEM 1 2 3 4 5 6 7 8 9 *10 *NOT SHOWN PART NO. 0106-02235 0106-02236 0106-02237 0106-02238 0106-02239 0106-02240 0106-02241 0106-02242 0106-02243 0524-00477 DESCRIPTION ASSY, CABLE 5/16 RING - B1+ TO B2ASSY, CABLE 5/16 RING - B2+ TO B3ASSY, CABLE 5/16 RING - B3+ TO FUSE ASSY, CABLE 5/16 RING -FUSE TO B4ASSY, CABLE 5/16 RING - B4+ TO B5ASSY, CABLE 5/16 RING - B5+ TO B6ASSY, CABLE 5/16 RING - B6+ TO B7ASSY, CABLE 5/16 RING - B7+ TO B8ASSY, CABLE 5/16 RING - B8+ TO B9WASHER, CONICAL ID. 0.317, OD. 0.625, H. 0.059, T. 0.047 QTY. 1 1 1 1 1 1 1 1 1 18

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2

3 10 1 2 5 9

6 8

4

11

ASSY, BATTERY LEAD ACID FLOODED EV31 HOLD DOWNITEM 1 2 3 4 5 6 7 8 9 10 11 PART NO. 0306-01944 0306-02124 0506-00481 0510-00336 0510-00479 0521-00050 0521-00335 0524-00062 0524-00478 0524-00482 0606-00584 DESCRIPTION BRACKET, BATTER HOLD DOWN BRKT, BATTERY HOLD DOWN KNOB, 3/8 - 16 3 PRONG HOOK, J THREADED 1/4 - 20 UNC X 4" HOOK, J THREADED 3/8 - 16 UNC X 5-1/2" NUT, HEX - NYLOCK 1/4-20 UNC GR5 NUT, 3/8-16 FIN. HEX NUT, 18-8 STAINLESS WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN WASHER, CONICAL - ID 0.380, OD .750, H 0.059, T 0.040, ZN WASHER, LOCK - 3/8 EXTERNAL/INTERNAL STAR ZP BATTERY, 12 VOLT DEKA FLOODED EV31 QTY. 2 1 2 2 2 2 12 2 12 2 6

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ASSY, BATTERY VRLA GEL HOLD DOWN (STANDARD COMPONENT FOR EUROPEAN HOMOLOGATED VEHICLES)ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. 0201-00138 0306-00996 0306-02124 0510-00286 0510-00287 0510-00336 0510-00342 0521-00050 0521-00335 0524-00062 0524-00478 0606-00364 DESCRIPTION WELDMENT, REAR BATTERY HANDLE KNOB, 1/4 - 20 3 PRONG BRKT, BATTERY HOLD DOWN HOOK, J REAR PIVOT TUBE HOLD DOWN ZINC PLATED PIN, LYNCH 3/16" ZINC PLATED HOOK, J THREADED 1/4 - 20 UNC X 4" O-RING, 3/32 C/S X 7/32 ID X 13/32 OD NUT, HEX - NYLOCK 1/4 - 20 UNC GR5 ZN NUT, 3/8 - 16 FIN. HEX NUT, 18 - 8 STAINLESS WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN WASHER, CONICAL BATTERY, 12 VOLT-GEL DEEP CYCLE QTY. 1 1 1 2 2 3 1 2 12 2 12 6

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1

OPTIONS, BATTERIES 8V, GELITEM PART NO. DESCRIPTION QTY.

1

0606-00587

BATTERIES, GEL 8V

9

January 2009760-321-2275



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www.4GEMparts.com

[email protected]

1 4 2

3

ASSY, BATTERY HOLD DOWN 8-VOLTITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0306-00996 0306-01892 0510-00472 0524-00062

KNOB, 1/4 - 20 3 PRONG CHANNEL, HOLD DOWN - BATTERY HOOK, J THREADED 1/4 - 20 UNC WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN

6 6 6 6

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REAR

1

6 2

5

3FRONT

4

ASSY, BATTERY HOLD DOWN e6 - 8 VOLTITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6

0306-00996 0306-01892 0351-01811 0351-01939 0510-00472 0524-00062

KNOB, 1/4 - 20 3 PRONG CHANNEL, HOLD DOWN - BATTERY SPACER, BATTERY - e6 SPACER, BATTERY HOOK, J THREADED 1/4 20 UNC WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN

6 6 1 3 6 6

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www.4GEMparts.com

[email protected]

1 4 2

3

ASSY BATTERY HOLD DOWN e6 12 VOLTITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0306-00996 0306-01892 0510-00472 0524-00602

KNOB, 1/4 - 20 3 PRONG CHANNEL, HOLD DOWN - BATTERY HOOK, J THREADED 1/4 - 20 UNC WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN

4 4 4 4

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1 8 2 5 7

3

4 6

ASSY BATTERY HOLD DOWN eL 12 VOLTITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8

0306-00996 0306-01892 0351-02296 0510-00472 0521-00010 0522-00001 0524-00009 0524-00062

KNOB, 1/4 - 20 3 PRONG CHANNEL, HOLD DOWN - BATTERY ANGLE, SUPPORT - BATT TRAY HOOK, J THREADED 1/4 - 20 UNC NUT, HEX - NYLOCK 3/8 - 16 UNC GR5

4 4 1 4 2

BOLT, CARRIAGE - 3/8 - 16 UNC X 1.0 LG GRADE 5 ZINC PLATTED 2 WASHER, FLAT - 3/8 SAE 0.406 ID X 0.8125 OD X 0.080 THK ZN WASHER, FLAT - 1/4 0.282 ID X 0.715 OD X 0.063 THK ZN 2 4

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ASSY, COLUMN STEERING 2&4 PASSITEM 1 2 3 4 5 6 7 8 9 PART NO. DESCRIPTION 0106-01030 HARNESS, INSTRUMENT PANEL 0305-01271 COWL, RH 0305-01272 COWL, LH 0305-01273 COWL, FRONT 0523-00590 SCREW, PLASTITE - - 6 - 19 x 1/2 RF BLK ZC, WAX 0523-00544 SCREW, MACHINE-TORX PAN HD M4 X 0.7 X 16 0606-00415 SWITCH, DRIVE MODE 0606-00416 SWITCH, TURN SIGNAL 0606-00417 SWITCH, LIGHT 0306-01822 SWITCH,ROCKER, 3-POS - LIGHTS 0606-00418 SWITCH, TRIP 0606-00419 DISPLAY LCD DRIVER 0617-00471 PLUG, SCREW COVER 0110-02338 KEY SW KIT W/T-HANDLE SERVICED WITH 0110-02338 REFER TO SECTION 9 - MISCELLANEOUS QTY. 1 1 1 1 10 2 1 1 1 1 1 1 2 1

10 11 12 *13 * ONLY

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ASSY, COLUMN STEERING L&S BACKITEM 1 2 3 4 5 6 7 8 9 PART NO. 0106-01030 0305-01271 0305-01272 0305-01273 0523-00590 0523-00544 0606-00415 0606-00416 0606-00417 0306-01822 0606-00418 0606-00419 0617-00471 0906-00016 DESCRIPTION HARNESS, INSTRUMENT PANEL COWL, RH COWL, LH COWL, FRONT SCREW, PLASTITE - - 6 - 19 x 1/2 RF BLK ZC, WAX SCREW, MACHINE-TORX PAN HD M4 X 0.7 X 16 SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, LIGHT SWITCH,ROCKER, 3-POS - LIGHTS SWITCH, TRIP DISPLAY LCD DRIVER PLUG, SCREW COVER KEY SW KIT QTY. 1 1 1 1 10 2 1 1 1 1 1 1 2 1

10 11 12 13

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4

7 9 5 6 1

17 16 10 13 2 8 11 3 14 15 19 12PART NO. 0106-01030 0305-01273 0305-01271 0305-01272 0305-02821 0312-02573 0312-02836 0510-00137 0523-00166 0523-00544 0523-00590 DESCRIPTION ASSY, HARNESS - INSTRUMENT PANEL COWL, FRONT COWL, RH COWL, LH SUPPORT, INST POD BELLOWS, STEERING COLUMN STRIP, GORILLA TAPE TIE, CABLE W/#10 MOUNT HOLE 9 BLACK SCREW, PHIL PAN HEAD - #4 X 1/2 PH PAN T/S A 18-8 SCREW, MACHINE TORX PAN HEAD M4 X 0.7 X 16mm LG SCREW, PLASTITE - 619 X 1/2 RF, T15 TAMPER PROOF, BLACK ZINC & WAX SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, LIGHT SWITCH, TOGGLE, 3-POS - DRIVE MODE SWITCH, ROCKER, 3-POS - LIGHTS SWITCH, TRIP DISPLAY LCD DRIVER SLEAVING, HARNESS - TILT COLUMN PLUG, SCREW COVER REFER TO SECTION 9 MISCELLANEOUS QTY. 1 1 1 1 1 1 3 1 2 2

11 18

11

ASSY, INSTRUMENT POD - ADJUSTABLE TILT STEERINGITEM 1 2 3 4 5 6 7 8 9 10 11

12 13 14

15 16 17 18 19 NOTES: A. HEADLIGHT SWITCH IS SUPPLIED WITHIN HEADLIGHT OPTION. B. IGNITION SWITCH IS SUPPLIED WITH LOCK SET. C. CABLE TIE IS USED TO SECURE HARNESS TO FRAME.

0606-00415 0606-00416 0606-00417 0606-00415 0306-01822 0606-00418 0606-00419 0606-00784 0617-00471

8 1 1 1

1 1 1 2 1

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ASSY, COLUMN STEERING W/LOCKITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23NOTES:

0106-01030 0112-01210 0305-01273 0305-01818 0305-01937 0305-01272 0307-02109 0408-00263 0408-00274 0510-00137 0521-00017 0522-00016 0522-00293 0523-00349 0523-00544 0523-00590 0524-00003 0606-00415 0606-00416 0606-00418 0606-00419 0617-00471

ASSY, HARNESS - INSTRUMENT PANEL ASSY, STEERING COLUMN-SPLINED ASSY, STEERING LOCK - MANUAL COWL, FRONT COVER, STEERING LOCK COWL, RH W/LOCK COWL, LH W/LOCK PAD, WEAR ADHESIVE, METHACRYLATE - LOCTITE H3300 LOCTITE 416 TIE, CABLE W/#10 MOUNT HOLE 9" BLACK NUT, HEX - NYLOCK 5/16-18 UNC GR5 BOLT, HEX - 5/16 - 18 UNC X 1.0 GR 5 BOLT, HEX - M8 x 1.25 x 30mm LG BLK OX HHCS - GR 10.9 -

1 1 1 1 1 1 1 1 12.5 ML 0.01 OZ 1 3 3 1

SCREW, HEX - WHSD 10-16 X 3/4 ZINC PLATED WASHER HD SELF DRILLING 4 SCREW, MACHINE-TORX PAN HD M4 X 0.7 X 16mm LG 2

SCREW, PLASTITE - 6-19 X 1/2 RF, T15 TAMPER PROOF, BLACK ZINC & WAX10 WASHER, FLAT - 5/16 SAE 0.344 ID X 0.688 OD X 0.065 THK ZN SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, TRIP DISPLAY LCD DRIVER PLUG, SCREW COVER 6 1 1 1 1 2

A. LOCK AND HEADLIGHT SWITCH SHOWN FOR REFERENCE ONLY. B. CABLE TIE IS USED TO SECURE HARNESS TO FRAME.

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14

2

13

18

12 7

3

1 11 17

17 20 16 22 4 6

5

23

15

21

19

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ASSY, HORNITEM PART NO. DESCRIPTION QTY.

1 2

0523-00032 0606-00507

SCREW, HEX - WHSD 1/4 X 0.75 ZN HORN, ECE

1 1

3

1

2

4

ASSY, FUSE -BATTERYITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0606-00443 0606-00442 0524-00477 0523-00408

ASSY, FUSE HOLDER FUSE, BATTERY - 250A WASHER CONICAL ID 0.317, OD 0.625, H 0.059, T 0.047 SCREW PHILLIPS FLAT HEAD 12-24 X 1.0

1 1 2 2

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ASSY, TAIL LIGHTS - CARITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0510-00137 0523-00032 0523-00168 0606-00141

TIE, CABLE W/#10 MOUNT HOLE 9" BLACK SCREW, HEX - WHSD 1/4 X 0.75 ZN

2 8

SCREW, PHIL TRUSS HEAD-#10 X 1 3/4 LG STEEL ZINC PHIL TRUSS 4 KIT, TAIL LIGHT 2

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1

ASSY, TAIL LIGHT UTILITY BEDITEM 1 PART NO. 0606-00147 DESCRIPTION ASSY, TAIL LIGHT BED QTY. 1

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1

KIT, REVERSE LAMPITEM PART NO. DESCRIPTION QTY.

1

0606-00207

REVERSE LAMP

1

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5

3

6

4

1 2

ASSY, CHMSLITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6

0510-00342 0521-00240 0523-00241 0606-00117 0606-00349 0619-00359

O-RING, 3/32 C/S X 7/32 ID X 13/32 OD NUT, BINDING POST # 8-32 GRAY SCREW, BINDING POST #8-32 X 0.375 WHITE TERMINAL, SPADE - MALE INSULATED 1/4 22 - 18 GA WIRE LAMP, CHMSL BUSHING, OPEN/CLOSE - 0.50 INCH HOLE

2 2 2 2 1 2

NOTE: APPLY THREAD SEALANT TO SCREW PRIOR TO ASSEMBLY.

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A 2 4 1 3

ASSY, LICENSE PLATE LAMPITEM PART NO. DESCRIPTION QTY.

1 2 3 4

0521-00317 0523-00282 0606-00117 0606-00206 0606-00760

NUT, KEPS - 8-32 ZINC PLATED SCREW, MACH PAN HEAD PHIL 8-32 X 3/4 ZN TERMINAL, SPADE - MALE INSULATED 1/4 22 - 18 GA WIRE KIT, LICENSE PLATE LAMP CHROME OPTION

2 2 1 1 1

NOTE: LENS AND SCREW ARE PART OF ITEM #4

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ASSY, WIPER MOTOR WINDSHIELD WIPERITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5

0518-00085 0519-00230 0523-00032 0610-00254 0618-00434

BUSHING, RUBBER - 1.06245 OD X 0.625 ID X SPACER, SPECIAL NYLON SCREW, HEX - WASHER HEAD SELF DRILL 1/4 MOTOR, WIPER - DIN 8 GROMMET, SBR RUBBER - 5/8" ID X 1/8" GROOVE FOR 7/8" HOLE

1 1 1 1 1

* STARRED PARTS ARE SUPPLIED WITH ITEM #4

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Parts Catalog SECTION 8 - BODY

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ASSY, LICENSE PLATE MOUNT - FRONTITEM PART NO. DESCRIPTION QTY.

1 2 3

0521-00014 0523-00134 0305-01228

NUT, KEPS - 12 - 24 UNC ZINC PLATED GR 5 ZINC PLATED SCREW, MACHINE #12-24 x 1 HEX SLOT HEAD BRACKET, LICENSE PLATE - FRONT

2 2 1

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3

1

2

ASSY, BRACKET, LICENSE PLATE - REARITEM PART NO. DESCRIPTION QTY.

1 2 3

0305-00928 0521-00050 0522-00333

BRACKET, LICENSE PLATE NUT, HEX - NYLOCK 1/4 - 20 UNC GR5 BOLT, TORX - TRUSS HD - 1/4 - 20 X 1 - 18-8 S.S

1 2 2

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2

1

3

ASSY, BRACKET LICENSE W/LIGHT - REAR UTILITYITEM PART NO. DESCRIPTION QTY.

1 2 3

0251-00250 0521-00071 0522-00333

BRACKET, PLATE LICENSE REAR NUT, KEPS - 1/4 - 20 UNC ZINC PLATED BOLT, TORX - TRUSS HD - 1/4 - 20 X 1 - 18-8 S.S

1 2 2

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2

1 3

ASSY, LICENSE PLATE BRACKET - UTILITY W/REVERSE LAMPITEM PART NO. DESCRIPTION QTY.

1 2 3

0251-00322 0521-00071 0522-00333

WLD, BRACKET - REAR LICENSE PLATE W/REVERSE LAMP NUT, KEPS - 1/4 - 20 UNC ZINC PLATED BOLT, TORX - TRUSS HD - 1/4 - 20 X 1 - 18-8 S.S

1 2 2

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ASSY, ROOF RAILS - 2 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6

0204-00086 0204-00087 0521-00024 0522-00021 0522-00059 0524-00115

WELDMENT, ROOF RAIL 2 PASS LH - PAINTED WELDMENT, ROOF RAIL 2 PASS RH - PAINTED NUT, HEX FLANGE 1/2-13 UNC GR 6 TECH LOCK BOLT, HEX - 1/2 - 13 UNC X 1.0 GR 8 ZN YL ZINC PLATED BOLT, HEX - 1/2 - 13 UNC X 2.5 LG GR 8 ZINC PLATED WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK

1 1 4 2 2 2

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ASSY, ROOF SUPPORTS - 2 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5

0304-00146 0304-01683 0304-00149 0523-00032 0523-00057

SUPPORT, WINDSHIELD - UPPER FR SUPPORT, ROOF - REAR - 2 PASS SUPPORT, WINDSHIELD - LOWER FR SCREW, HEX - WASHER HEAD SELF DRILL 1/4 SCREW, CSNK PHIL FLAT - #6 X 3/4 STAINL

1 1 1 4 8

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ASSY, ROOF PANEL - 2 PASSITEM PART NO. DESCRIPTION QTY.

1 *2 3 4

0304-00157 0417-00065 0408-00126 0408-00257

PANEL, ROOF 2 PASS FOAM, VINYL-PVC VF-5600 SERIES 0.250 X 0.250 X 50 FT ROLL (Formerly 0304-00184 - STRIP. WEATHER UPPER WINDSHIELD) ADHESIVE, ESSEX U400 (NOT SHOWN) PRIMER, ABS BETA PRIME (NOT SHOWN)

1 1 1 1

* FOR ANY OF ALL OF ITEM 2, use 0417-00065 FOAM, VINYL-PVC VF-5600 SERIES 0.250 X 0.250 X 50 FT ROLL (SOLD AS ENTIRE ROLL ONLY P/N 0417-00065)

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ASSY, ROOF RAILS - 4 PASSITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6

0204-00312 0204-00313 0521-00024 0522-00021 0522-00059 0524-00115

WELDMENT, ROOF RAIL - LH 4 PASS WELDMENT , ROOF RAIL - RH 4 PASS NUT, HEX FLANGE 1/2-13 UNC GR 6 TECH LOCK BOLT, HEX - HHCS 1/2 - 13 UNC X 1.0 GR 8 ZN YL ZINC PLATED BOLT, HEX - HHCS 1/2 - 13 UNC X 2.5 LG GR 8 ZINC PLATED WASHER, FLAT - M12 13mm ID X 24mm OD X 2.5mm THK

1 1 4 2 2 2

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ASSY, ROOF SUPPORTS - 4 PASSITEM PART NO. DESCRIPTION QTY.

1 2 *3 *4 5 6 7

0304-00146 0304-00149 0304-00152 0304-01682 0304-01683 0523-00032 0523-00057

SUPPORT WINDSHIELD UPPER FRONT SUPPORT, WINDSHIELD LOWER FRONT SUPPORT, SUNROOF FRONT SUPPORT, SUNROOF REAR SUPPORT, ROOF - REAR 4 PASS SCREW, HEX - WHSD 1/4 X 0.75 ZN SCREW, CSNK PHIL FLAT - #6 X 3/4 LG STAINLESS STEEL

1 1 1 1 1 4 16

* ONLY USED ON MODELS WITH A SUN ROOF OPTION - e4

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6

3

4

2

1

5

7

ASSY, ROOF RAILS e6ITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0204-00329 0204-00330 0328-02125 0521-00129 0522-00164 0522-00502 0524-00115

WLD, ROOF RAIL LH 6 PASS WLD, ROOF RAIL RH 6 PASS SPACER, SAFETY BELT NUT, HEX FLANGE 7/16 - 14 UNC GR 5 ZN TECH LOCK BOLT, HEX - 7/16 - 14 UNC X 1.25 GR 8 BOLT, HEX - 7/16 - 14 X 2.0 GRADE 8 ZINC PLATED YELLOW WASHER, FLAT - M12 13mm 1D X 24mm OD X 2.5mm THK

1 1 2 8 6 2 8

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3

4

5

7

1

2

6

ASSY, ROOF SUPPORTS - e6ITEM PART NO. DESCRIPTION QTY.

1 2 3 4 5 6 7

0304-02527 0304-00149 0304-02530 0304-02529 0304-02528 0523-00032 0523-00057

SUPPORT WINDSHIELD UPPER FRONT SUPPORT, WINDSHIELD LOWER FRONT SUPPORT, ROOF - REAR 4 PASS SUPPORT, SUNROOF REAR SUPPORT, SUNROOF FRONT SCREW, HEX WSHD 1/4 X 0.75 ZN WASHER HD SELF-DRILLING SCREW, CSNK PHIL FLAT - #6 X 3/4 LG STAINLESS STEEL

1 1 1 1 1 4 16

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ASSY, WINDSHIELDITEM PART NO. DESCRIPTION QTY.

1 *2 3 4

0304-00170 0417-00065 0408-00126 0408-00257

WINDSHIELD STRIP, WEATHER LOWER WINDSHIELD (Formerly 0304-00183) ADHESIVE, ESSEX U400 (NOT SHOWN) PRIMER, ABS BETA PRIME

1 1 1 1

* FOR ANY OR ALL OF ITEM 2, USE 0417-00065 FOAM, VINYL - PVC VF-5600 SERIES 0.250 X 0.250 X 50 FT ROLL (SOLD ONLY AS ENTIRE ROLL)

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2009 Parts Catalog

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