Pantone 419C 2013 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information.
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The following are registered trademarks of POLARIS Industries Inc.: POLARIS® RANGER® VICTORY® INDIAN® Global Electric Motorcars® GEM® e6® Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Maintenance . . . . . . . . . . . . . . . . . . . .
WELCOME Thank you for purchasing a GEM by POLARIS, and welcome to our world-wide POLARIS family of recreational and utility vehicle owners. We believe POLARIS sets a standard of excellence for all recreational and utility vehicles manufactured in the world today.
WELCOME For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the GEM Service Manual and should be performed only by an authorized GEM dealer technician. If questions arise after reading the manual, please contact GEM customer service. Be prepared to provide your Vehicle Identification Number (VIN) and date of purchase.
INTRODUCTION This vehicle complies with the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA) low-speed vehicle regulations and can be operated on many streets posted with low speed limits. Please familiarize yourself with all laws and regulations concerning the operation of the vehicle in your area.
INTRODUCTION Safety Signal Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. NOTICE A NOTICE indicates a situation that may result in property damage.
INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. Special precautions must be followed when owning and operating a battery-powered vehicle. This vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. • Read this owner’s manual.
INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Record your vehicle's identification numbers and key number in the spaces provided on page 11. The Vehicle Identification Number (VIN) is on the manufacturer’s label, located on the left rear section of the roof panel. The VIN indicates the model year, model type and serial number of your vehicle. The manufacturer’s label also contains the Gross Vehicle Weight Rating (GVWR) and Gross Axle Weight Rating (GAWR) information for your vehicle.
INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Manufacturer’s Label Tire / Wheel Information GAWR Information Date of Manufacture USA Label EU Label VIN 10 GVWR Information
INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Vehicle Identification Number (VIN): |___|___|___|___|___|___|___|___|___|___|___|___|___|___|___|___|___| Vehicle Model Number: _______________________________________________________________________ Motor Serial Number (on case of motor): __________________________________________________________ Key Number (stamped on key): _________________________________________________________________ Optional Rear Accessory # (stamped on key): _________
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If any label becomes illegible or comes off, contact your authorized GEM dealer to purchase a replacement. Replacement safety labels are provided at no charge.
SAFETY Safety Labels and Locations General Warning • Although most states prohibit this vehicle from operating on streets having posted speed limits of more than 35 MPH (56 km/h), state and local rules may vary. Check with your local law enforcement (city and state officials) for variations in your area. • Never exceed the passenger and cargo limits of this vehicle. • Do not start or operate vehicle until all occupants are seated with seat belts fastened.
SAFETY Safety Labels and Locations Door/Seat Belt Warning This label is located near the lower edge of the window on the driver’s side door on models equipped with doors. WARNING The doors on this vehicle are designed only for protection against the elements. Do not rely on the doors to contain occupants within the vehicle or to protect against injury during an accident. WEAR SEAT BELTS AT ALL TIMES.
SAFETY Safety Labels and Locations High Voltage Warning High voltage warning labels are located in two places on your vehicle: near the battery compartment and under the hood near the motor controller. WARNING HIGH VOLTAGE You could be seriously or fatally injured by electric shock if you attempt to open, repair, test, inspect or adjust. Only qualified technicians should open and service. Consult service manual.
SAFETY Safety Labels and Locations Cargo Warnings Cargo warning labels are located in the beds of GEM eL and GEM eL XD models. CARGO WARNING (eL) • Maximum cargo capacity of this bed should never exceed 700 lbs. (317.5 kg). • Distribute weight equally over axle. • No passengers permitted. • Abuse or noncompliance will void warranty. CARGO WARNING (eL XD) • Maximum cargo capacity of this bed should never exceed 1100 lbs. (499 kg). • Distribute weight equally over axle. • No passengers permitted.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY Operator Safety • Never exceed the gross vehicle weight rating (GVWR) of your vehicle. • The cab frame is not designed or intended to provide rollover protection. Avoid situations that could result in a rollover. • Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.
SAFETY Operator Safety • Never carry loads on the roof of the vehicle. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions on cargo warning labels for hauling cargo. Allow a greater distance for braking. • Always set the park brake and remove the key when leaving the vehicle unattended. • The voltage in the battery pack is sufficient to cause death by electrocution.
SAFETY Operator Safety • Do not carry a passenger until you have at least two hours of driving experience with this vehicle. • Always keep arms and legs inside the cab frame while the vehicle is in motion. • Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation. • Never consume alcohol or drugs before or while operating this vehicle. 20 • Never operate at excessive speeds.
SAFETY Operator Safety • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized GEM dealer if it has been involved in an accident. • Always be alert for obstacles when operating this vehicle. Never attempt to operate over obstacles. • Always be careful of skidding or sliding.
SAFETY Operator Safety Gross Vehicle Weight Rating (GVWR) WARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling and could cause loss of control. NEVER exceed the GVWR of your vehicle. The maximum payload capacity of your vehicle is the maximum weight you may add to your vehicle without exceeding the GVWR. This capacity is determined by calculating the difference between your vehicle’s GVWR and wet weight.
SAFETY Operator Safety Gross Vehicle Weight Rating (GVWR) When determining the weight you will be adding to your vehicle, and to ensure you do not exceed the maximum payload capacity, include the following: • operator body weight • passenger body weight • weight of all occupants’ apparel and items in or on apparel • weight of any options or accessories and their contents • weight of any additional cargo on the vehicle 23
SAFETY Operator Safety Equipment Modifications Never install any equipment or make vehicle modifications to increase the speed or power of the vehicle. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury. The warranty on your vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
SAFETY Operator Safety WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions Seat Belts This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license.
SAFETY Operator Safety Operating Without Instruction Ventilation When Charging Batteries Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle.
SAFETY Operator Safety Failure to Inspect Before Operating Using Alcohol or Drugs Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.
SAFETY Operator Safety Operating a Damaged Vehicle Exhibition Driving Operating a damaged vehicle can result in an accident. After any overturn or accident, have your authorized GEM dealer inspect the entire machine for possible damage, including (but not limited to) brakes, accelerator, steering system and electrical system. Exhibition driving increases the risk of an accident or overturn. Never attempt wheelies, jumps, doughnuts or other stunts. Avoid exhibition driving.
SAFETY Operator Safety Turning Improperly Carrying Cargo Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds. Carrying loads on the roof could damage the roof and affect vehicle handling, which could result in an accident or overturn. Never carry loads on the roof of the vehicle.
SAFETY Operator Safety Improper Tire Maintenance Hot Drive Systems Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. The motor and controller are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot drive system components.
SAFETY Operator Safety Precautions During Maintenance WARNING! The voltage in the battery pack is sufficient to cause death by electrocution. With the exception of battery inspections and refilling the water in flooded type batteries, never attempt to perform service on the electric drive system, including the battery pack, unless you are properly trained to work on electrical systems.
FEATURES AND CONTROLS Console Cup Holders LCD Display Instrument Pod Storage Tray Glove Box Lock Key Switch Turn Signal Windshield Wiper Horn Lever 32 Headlight Switch Trip/Odometer Switch Direction Switch
FEATURES AND CONTROLS Console Headlight Switch Press the top of the switch to turn the headlights to high beam. Press the bottom of the switch to turn the headlights to low beam. Move the switch to the center position to turn the headlights off. Electrical Components Electrical wiring, circuit boards and components are located under and behind the upper and lower console. HIGH OFF LOW Optional Accessory Switches NOTICE: Liquids can damage electrical components and the circuit board.
FEATURES AND CONTROLS Console Key Switch When the key is turned to the ON position (clockwise), the display will light up and all electrical accessories can be used. Leaving the key in the ON position will discharge the batteries. Always turn the key to the OFF position when not operating. Remove the key from the ignition to prevent unauthorized use. When the key is turned to the OFF position, the vehicle will not accelerate, but accessories and lights will remain on for approximately 30 seconds.
FEATURES AND CONTROLS Console Zero Speed Detection Feature To prevent the vehicle from rolling away, the electric motor will resist vehicle motion if the accelerator pedal is released while the key is on and the vehicle is moving. Horn Press the turn signal wand inward toward the instrument pod to sound the horn. Horn Glove Box The glove box is equipped with a lock to protect items from theft or damage. Use the ignition key to lock and unlock the glove box door.
FEATURES AND CONTROLS Console Turn Signal The turn signal lever contains the controls for the turn signals, horn, windshield wiper and windshield washer (if equipped). Check turn signal lamps before each ride. When driving, activate a turn signal before turning to alert others of your intentions. Tip: The key must be in the ON position to activate the turn signals. Move the turn signal lever downward to signal a left turn. The left turn signal lamp below the front headlight will flash.
FEATURES AND CONTROLS Console Windshield Wiper Push the turn signal lever toward the console and release it to turn the windshield wipers on. Push the lever toward the console again to activate the washer momentarily (if equipped, see page 85). Pull the lever toward the steering wheel to turn the wiper off. If the wiper fails to work, check for a blown fuse at the fuse block. See page 102. Wiper ON Wiper OFF CAUTION! A worn or damaged wiper blade could impair operator vision and result in an accident.
FEATURES AND CONTROLS Console Trip Meter/Odometer/E-Meter The trip switch has four functions: • Toggle between the odometer and trip meter. • Reset the trip meter. • Change the function of the speedometer and odometer from miles per hour (MPH) to kilometers per hour (km/h) and miles to kilometers. • Toggle between odometer/trip meter and e-meter to display accumulated power consumed from grid, shown in kilowatt hours (kWh).
FEATURES AND CONTROLS Console Trip Meter/Odometer/E-Meter Trip Switch Operation Desired Result Toggle between the odometer and trip meter modes on the display Reset the trip meter to zero Press Trip Switch Press and hold for less than 2 seconds Press and hold for 3-9 seconds while display is in trip mode (“TRIP” is illuminated, see page 42) Change the display from standard to metric (MPH Press and hold for 10-12 seconds while display is to km/h and miles to kilometers) in odometer mode Display consumed po
FEATURES AND CONTROLS Console Direction Switch NOTICE: Always bring the vehicle to a complete stop before changing the position of the direction switch. Drive High 1. With the key in the ON position, apply the brakes. 2. Move the direction switch to the desired mode. 3. Release the brakes and gradually depress the accelerator pedal to increase speed.
FEATURES AND CONTROLS Console Direction Switch Drive High The HIGH mode allows operation of the vehicle at speeds of 0-25 MPH (0-40 km/h). Drive Low The LOW mode allows operation of the vehicle at speeds of 0-15 MPH (0-24 km/h). When LOW mode is selected, the rate of acceleration is also limited. Reverse A reverse warning alert will automatically sound when the key is on and reverse mode is selected. Vehicle speed is limited when operating in reverse. See page 90 for safe reverse operation procedures.
FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Left Turn Right Turn Brake Warning High Motor Temperature Warning Odometer/Trip Meter Charger Connected BRAKE km/h MPH km MILES TRIP Service Required State of Charge/ Battery Discharge High Beam Headlight Current Limiting Mode Low Beam Headlight Seat Belt Warning Reverse Selected 42 Drive Low Selected Drive High Selected
FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Indicator When driving, the speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). The display can be changed to display either standard or metric units of measurement. See page 38. When the batteries are charging, this area displays the percent of charge. When the service indicator illuminates, a service code displays in this area.
FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Indicator Common service codes are detailed below. Code 06 11 Condition Accelerator pedal is depressed, no direction is selected. 15 Accelerator pedal was depressed before key was turned on. Low state of charge on batteries. 16 High state of charge on batteries. Remedy Release pedal, apply brakes, make sure direction switch is locked into a position. Turn key off, release accelerator pedal, then turn key on.
FEATURES AND CONTROLS Console LCD Display Indicators Turn Indicators The corresponding turn signal indicator flashes when a signal is activated. Brake Warning Indicator The brake warning illuminates when the park brake is engaged or when a brake system failure has occurred. If the brake warning illuminates, check the following items before operating the vehicle. Brake System Item Park brake Brake fluid level Brake system Solution Release the park brake. If low, add brake fluid. See page 98.
FEATURES AND CONTROLS Console LCD Display Indicators High Motor Temperature Warning Indicator If the motor temperature warning illuminates, or if service code “41” displays in the speedometer/service code display, the motor or motor controller may be overheating. Continued operation could result in motor damage. Stop the vehicle promptly, preferably in a cool or shaded location, and wait for the motor to cool down. Do not operate the vehicle until the warning indicator turns off.
FEATURES AND CONTROLS Console LCD Display Indicators Odometer/Trip Meter Indicator The odometer indicator logs the total distance the vehicle has been driven since it was manufactured. The trip meter is useful for logging distances traveled on separate trips. See page 38 for trip meter instructions. The display can be changed to display either standard or metric units of measurement. See page 38.
FEATURES AND CONTROLS Console LCD Display Indicators State of Charge/Battery Discharge Indicator (BDI) This indicator contains 8 green bars, a yellow bar and a red bar. It shows available battery capacity by illuminating one or more bars. The indicator illuminates when the key is turned on. It also illuminates 8-10 seconds after the charging cord is connected, turning off when the batteries are 100% charged. To verify a full charge or to check the state of charge, turn the key on.
FEATURES AND CONTROLS Console LCD Display Indicators State of Charge/Battery Discharge Indicator (BDI) State of Charge/Battery Discharge Indicator Bars 1 2 3 4 5 6 7 8 9 10 Color Red (Far Left) Yellow Green Green Green Green Green Green Green Green (Far Right) % Of Charge Less Than 10 10-20 20-30 30-40 40-50 50-60 60-70 70-80 80-90 90-100 NOTICE: Batteries can be permanently damaged (and the warranty voided) if allowed to remain 30 days or more with low charge. Fully charge batteries before storing.
FEATURES AND CONTROLS Console LCD Display Indicators Current Limiting Mode Indicator This indicator illuminates if the system limits the amount of current available due to extremely low battery voltage. The state-of-charge/battery-discharge indicator will also indicate low voltage. If you continue to drive, acceleration and power will begin to decrease. The controller will eventually shut down the vehicle to protect the batteries and motor from damage.
FEATURES AND CONTROLS Console LCD Display Indicators Direction Indicators When the key is on, one of the three direction indicators illuminate to indicate the selected position of the direction switch (REVERSE, DRIVE LOW or DRIVE HIGH). See page 40. Headlight Beam Indicators Either the high beam or low beam headlight indicator illuminates to indicate which headlight beam is selected. See page 33.
FEATURES AND CONTROLS Console Main Disconnect Switch WARNING! The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals. HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY TERMINALS. The main disconnect switch is located inside the fuse access panel on the lower console. The main disconnect switch must be turned on for operation and for charging.
FEATURES AND CONTROLS Console Main Disconnect Switch Move the switch to the left (OFF) to disconnect the battery pack from the motor. After the switch is turned off, some power may remain in the system until all capacitors have discharged. NOTICE: Do not turn off the disconnect switch while the vehicle is in motion or undergoing recharge except in emergency situations. NOTICE: Damage to electrical connections and components will occur if they are unplugged before the main disconnect switch is turned off.
FEATURES AND CONTROLS Brake Pedal The brake pedal is located on the floor to the left of the accelerator pedal. Push the brake pedal toward the floor to slow or stop the vehicle. Apply the brakes before turning the key on. WARNING! Constant brake use (riding the brakes) can cause brakes to overheat and fail, which could lead to an accident resulting in serious injury or death. Do not drive with your foot resting or riding on the brake pedal.
FEATURES AND CONTROLS Accelerator Pedal The accelerator pedal is located on the floor to the right of the brake pedal. To begin moving or to increase vehicle speed, gradually push the accelerator pedal toward the floor. Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed. The accelerator pedal will function only if the key is on. To slow the vehicle, release the accelerator pedal. Electric motor braking provides braking when the pedal is released.
FEATURES AND CONTROLS Park Brake Lever WARNING! A rolling vehicle can cause serious injury. Always set the park brake when leaving the vehicle unattended. Remove the key from the ignition to prevent unauthorized use. NOTICE: Be sure the park brake is fully disengaged before driving. Failure to do so can lead to overheating of the rear brakes.
FEATURES AND CONTROLS Park Brake Lever The park brake lever is located to the lower right of the driver seat. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, the vehicle will not move. Always apply the brakes before setting or releasing the park brake. The park brake is adjustable and should be checked periodically as outlined in the Periodic Maintenance Chart beginning on page 96.
FEATURES AND CONTROLS Batteries Battery Pack Your vehicle is equipped with a battery pack containing either six 12-volt gel batteries, six 12-volt flooded batteries or nine 8-volt gel batteries that supply the power needed to operate the vehicle. These batteries perform best when recharged fully and often. Recharge the batteries daily, or after each use of the vehicle. NOTICE: Each vehicle is programmed at the factory for a particular battery type.
FEATURES AND CONTROLS Batteries Battery Performance Tips • New batteries will not perform to their fullest capacity until they have been discharged and recharged 20 to 30 times. • Batteries should be fully charged before the first use. • Recharge the batteries daily, or after each use of the vehicle. • Always maintain a full charge on the batteries. For best battery life, avoid discharging the batteries more than 80%. See page 48. • Batteries should be at room temperature when recharging.
FEATURES AND CONTROLS Batteries On-Board Charger The on-board battery charger is located under the hood and can be Green Indicates 100% Charge viewed through the left front wheel well. When batteries are 100% charged, a green light on the charger will illuminate. When the vehicle will not be used for 10 or more days, leave the main disconnect switch on and connect the charger.
FEATURES AND CONTROLS Batteries Battery Charging WARNING! Using a non-recommended extension cord could result in fire, heat damage or charger failure, which could result in serious injury or death. Always use the recommended type of cord to charge the batteries. Tip: Do not use a ground fault interrupt (GFI) type cord on a GFCI-protected outlet.
FEATURES AND CONTROLS Batteries Battery Charging The battery charge receptacle is located on the hood. When charging the vehicle, always use a standard 3-wire grounded extension cord of one of the following types: • 12-gauge wire with 3-wire grounded, 50 feet (15.25 m) or shorter. • 14-gauge wire with 3-wire grounded, 25 feet (7.6 m) or shorter.
FEATURES AND CONTROLS Batteries Battery Charging Always follow these precautions when charging: • Position the vehicle on a level surface. Make sure the charging area is well ventilated. • Make sure the key is off. • Always use the recommended extension cord type. • Inspect the extension cord for cracks, loose connections and frayed wiring. Never use a damaged extension cord. • Always connect the charging cord to the vehicle’s charge receptacle first, then plug the cord into a wall receptacle.
FEATURES AND CONTROLS Batteries Battery Charging Tip: Always use a 110-volt AC, 15 amp breaker outlet. A GFI (Ground Fault Interrupt) receptacle is recommended. See your authorized GEM dealer if you do not have a GFI receptacle at your regular recharge site. • Make sure the charger uses a dedicated circuit to prevent overloading. If charging multiple vehicles, each vehicle should use a dedicated circuit.
FEATURES AND CONTROLS Batteries Alternate Battery Charging Method If the combined voltage of all batteries reaches 68 volts or less, a safety feature in the onboard charger will not allow the charger to activate. Use the alternate charging method to add a small charge to each battery separately. The on-board charger will then activate properly to recharge all batteries to a full charge. Use a 12-volt battery charger to charge 12-volt batteries. Charge each battery individually.
FEATURES AND CONTROLS Batteries Alternate Battery Charging Method 1. Turn the main disconnect switch off. 2. Set the battery charger to the medium amp setting (10 to 30 amps). 3. Charge each battery for 10-20 minutes. 4. Move quickly from battery to battery, as this is only a residual charge and it will dissipate in a short period of time. 5. After charging the last battery, remove the off-board charger leads, turn the main disconnect switch on and plug the vehicle in. 6.
FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals.
FEATURES AND CONTROLS Batteries Battery Handling Precautions • Never connect jumper cables to any of the batteries of this vehicle. • Always wear safety glasses or approved eye protection when servicing the vehicle. Wear a full-face shield and gloves when working with or around batteries and electrical connectors. • Use only insulated tools when working in the battery compartment. • Always keep battery terminals and connections clean and free of corrosion at all times. See page 122.
FEATURES AND CONTROLS Accessory Outlet The optional accessory outlet is located on the lower console, to the right of the fuse access panel. This outlet will accept a standard automotive 12-volt accessory and is intended for moderately powered accessories, such as a cellular phone. It will not operate large current items, such as cigarette lighters. Accessory Outlet The fuse for the power outlet plug is located in the fuse block under the access panel in the center of the lower console.
FEATURES AND CONTROLS Bench Seat Removal Pull up on the front of the seat to disengage the front latches. Slide the seat forward and lift it away from the seat base. To reinstall the seat, align the rear plunger to the socket at the rear of the seat base. Slide the seat fully rearward, then push down firmly along the front edge of the seat to secure the latches. Seat Adjustment The front seats on the GEM e4 and GEM e6® models are equipped with manual seat adjustments.
FEATURES AND CONTROLS Seat Belts WARNING Failure to properly use seat belts and child restraints can result in serious injury or death. Always follow all legal requirements for seat belt and child restraint use in on-road vehicles. • Always make sure the seat belts are secured for operator and all passengers before operating. • Pregnant women should wear the lap part of the belt across the thighs and as snug across the hips as possible. Keep the belt low so that it does not come across the abdomen.
FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use This vehicle is equipped with three-point lap and diagonal seat belts for all occupants. Always make sure the seat belts are secured for operator and all passengers before operating. To wear the seat belt properly, follow this procedure: 1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. Slide the buckle up the webbing as far as needed for the belt to reach across your hips.
FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use 2. Push the latch plate into the buckle until it clicks. 3. Release the strap, it will self tighten. 4. To remove slack in the lap belt portion of the belt, pull upward on the shoulder belt. To loosen the lap belt if it is too tight, tilt the buckle and pull the lap belt slightly longer. 5. To release the seat belt, press the square red button in the buckle's center. If necessary, slide the buckle down the webbing to allow it to retract fully.
FEATURES AND CONTROLS Seat Belts Seat Belt Safety Tips • In a rear seat, you may have trouble tightening the lap/shoulder belt on the child restraint because the buckle or latch plate is too close to the belt path opening on the restraint. Disconnect the latch plate from the buckle and twist the short buckle-end belt several times to shorten it. Insert the latch plate into the buckle with the release button facing outward.
FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness.
FEATURES AND CONTROLS Stereo System (Option) The optional stereo system is mounted in an overhead console and features speakers, FM radio, CD player and MP3 capabilities. Refer to your stereo system’s user manual for detailed operating instructions.
FEATURES AND CONTROLS Rear Accessory Backs (Option) Rear accessory back options are available. These rear accessory backs are interchangeable.
FEATURES AND CONTROLS Rear Accessory Backs (Option) WARNING! Never carry a passenger on a rear accessory back. Do not overload an accessory back. Overloading the vehicle can reduce stability and handling and could cause loss of control. Never exceed the GVWR or the GAWR. See page 22. NOTICE: Use only GEM-approved rear accessories. Others may cause damage to the locking system or vehicle, and will void warranty. 1. Remove the contents of the installed rear accessory back. 2.
FEATURES AND CONTROLS Rear Accessory Backs (Option) 5. 6. 7. 8. 9. Rotate the release handle to release the dual latches. Remove the safety strap and carefully remove the existing accessory back. Install the desired accessory back onto the mounting brackets. Secure the safety strap. Push the accessory back forward to engage the dual latches. Make sure you hear two clicks, one for each latch engagement. Test to make sure the latches are secure. If not secure, repeat this step.
FEATURES AND CONTROLS Chrome Bumpers/Rugged Bumpers (Option) Front bumpers are for appearance only and will protect the body panels only from minor dents and scratches. They will not provide protection to the vehicle in front collisions. NOTICE: Never use your GEM vehicle for pushing. Damage to the vehicle may result.
FEATURES AND CONTROLS Doors (Option) WARNING! Doors do not offer structural protection in the event of an accident and do not change the open body characteristics of the vehicle. The doors provide protection from the weather only. Always use seat belts. Failure to use the seat belts puts the driver and passengers at greater risk of serious injury or death in the event of an accident. Soft Doors: From either inside or outside the vehicle, locate the zipper at the bottom front or mid rear of each door.
FEATURES AND CONTROLS Grab Handle Package (Option) Grab handles can be added at each seat position to assist riders in entering and exiting the vehicle. Interior grab handles are not intended to retain passengers in the vehicle. Always make sure the seat belts are secured for operator and all passengers before operating. Enclosed Cargo Carrier (Option) To open the cargo carrier door, insert the key and turn the lock. Pull the handle outward and rotate it to open the door.
FEATURES AND CONTROLS Steering Column Lock (Option) To lock the steering column, insert the key into the steering column lock and turn it clockwise while turning the steering wheel. The wheel may need to turn up to one full revolution. When you feel the lock engage, remove the key. WARNING! Do not leave the key in the column lock while driving as the lock may inadvertently activate and cause loss of steering control, which could result in serious injury or death.
FEATURES AND CONTROLS Adjustable Tilt Steering Column (Option) To adjust the tilt steering column, pull the lever at the left of the column rearward toward the driver’s seat to release the latch. Adjust the steering column to the desired position, then push the lever toward the console to lock the steering column. Tilt Lever Heater/Defogger (Option) The heater/defogger unit can be used to provide heat inside the vehicle and to assist in defogging the windshield. The switch is located on the console.
FEATURES AND CONTROLS Windshield Washer (Option) Push the turn signal lever toward the console to turn the windshield wipers on. Push the lever toward the console again to activate the washer momentarily. Check the washer reservoir fluid level frequently. When the level is low, remove the cap and add windshield antifreeze (not radiator antifreeze) rated for -25°F (-31°C). Operate the system for a few seconds to flush out any residual water. WARNING! Commercial windshield washer solvents are flammable.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
OPERATION Pre-Ride Inspection Item Turn signals Mirrors Horn Seat belts Steering Tires Latches (hood/seat) Batteries Battery cables Wheels/fasteners Remarks Page Ensure operation of all signal lamps Adjust mirrors for proper side and rear view Ensure operation Check length of belt for damage, check latches for proper operation Ensure free operation Check tire condition and pressure Ensure all latches are secure Ensure full charges, proper water levels, clean terminals Inspect for proper cable routing, se
OPERATION Driving Procedure 1. Disconnect the charging cable. Make sure the main disconnect switch is on. 2. Sit in the driver's seat and fasten the seat belt. Make sure passengers are seated with seat belts secured. 3. Adjust mirrors as needed. 4. Turn the key clockwise to the ON position. 5. Apply the brakes. 6. Release the park brake. 7. Move the direction switch to the desired position. See page 40. 8. Check your surroundings and determine your path of travel. 9.
OPERATION Driving Procedure 11. Before turning, activate a turn signal to alert others of your intentions. See page 36. 12. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. Allow a passenger to ride only in a designated passenger seat with seat belt secured. 13. To stop the vehicle, release the accelerator pedal completely and brake to a complete stop. NOTICE: Always bring the vehicle to a complete stop before changing the position of the direction switch.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never accelerate suddenly.
OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever driving on slippery surfaces Sideways Turn in direction such as wet or icy pavement or loose skid of skid gravel, follow these precautions: 1.
OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3. Place the direction switch on either forward position. 4. Set the park brake. 5. Turn the key off. Remove the key from the ignition to prevent unauthorized use.
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: • If parking in an open area, block the wheels on the downhill side of the vehicle after turning the key off. • If parking parallel to a curb, stop the vehicle close to the curb. If the vehicle is facing downhill, turn the steering wheel toward the curb. The forward part of the front tire should be turned into the curb.
OPERATION Transporting the Vehicle NOTICE: Towing your GEM vehicle could result in severe damage to the vehicle. Vehicle failures resulting from dolly towing will void warranty. When transporting the GEM vehicle on a trailer, always use a trailer with an approved load rating greater than the GEM vehicle’s curb weight plus any installed accessories or cargo. Refer to the specifications section beginning on page 134.
OPERATION Transporting the Vehicle Transport the vehicle in a closed trailer if possible. Use the following guidelines when transporting the vehicle on an open trailer. 1. Always transport the GEM vehicle facing forward on the trailer. 2. Set the park brake. 3. Remove the key to prevent loss. 4. Secure the seats, hood and any items that could be damaged or dislodged by strong winds. If equipped with hard doors, put all windows down. 5. Never allow passengers on a trailer or in a trailered vehicle. 6.
MAINTENANCE Periodic Maintenance Chart WARNING! Always wear safety glasses or approved eye protection when servicing the vehicle. Wear a full-face shield and gloves when working with or around batteries and electrical connectors. Always use insulated tools when working with or near batteries. Failure to follow these instructions could result in serious injury or death. NOTICE: Damage to electrical connections and components will occur if they are unplugged before the main disconnect switch is turned off.
MAINTENANCE Periodic Maintenance Chart Monthly Maintenance Check battery fluid level (flooded only) Wash tops and terminals of batteries and allow to dry Check cables and terminal connections Check for worn insulation or frayed wires Check battery hold-down bar to ensure batteries are tightly secured Check tires for correct air pressure and wear Check brake fluid reservoir for proper brake fluid level. Check brake lines for leaks.
MAINTENANCE Brakes Brake Fluid Inspect the brake system routinely. Inspect the brake fluid level before each operation. If the level drops between fluid checks, add brake fluid as needed. See your authorized GEM dealer for service. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Brakes Brake Fluid Maximum Minimum 1. Position the vehicle on a level surface. 2. Open the hood. The brake fluid reservoir is located on the driver’s side of the vehicle, above and to the rear of the front tire. 3. View the brake fluid level in the reservoir. The level should be between the upper (MAX) and lower (MIN) level lines. 4. If the fluid level is lower than the upper level line, add brake fluid to the upper (MAX) line. 5.
MAINTENANCE Brakes Brake Inspection The front and rear brakes are hydraulic disc type brakes. 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when worn to 3/64" (1 mm).
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. There should be 0.8-1.0 inch (20-25 mm) of freeplay at the outer rim of the steering wheel. 3. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by your authorized GEM dealer.
MAINTENANCE Fuse Replacement NOTICE: Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. If you experience electrical failures not related to the batteries, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. See your Access Panel authorized GEM dealer if you suspect a relay or Fuse Block diode needs replacement.
MAINTENANCE Fuse Replacement Fuse Label Fuse Recommendations Fuse Application Heater Coil (fuse used for accessory) Turn Signals / Brake Lamps Windshield Wiper Accessories Radio Tail Lamp/Headlamps / Horn / License Plate Lamp Heater Radio / Public Address System Odometer Switch Turn Signals Brake Lamps Fuse Size 30 amp 10A Spare Wiper 30A 10 amp Accessories 10A Display 1A 10A 72V System 10A Heater 10A Heater Coil Tail/Headlamps Horn License P.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.
MAINTENANCE Tires Tire Tread Depth Any accelerated wear of tires may be an indicator of improper alignment or poor driving habits. See your authorized GEM dealer for service. Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Nut Torque Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Aluminum (14-inch) 95 ft. lbs. (128 Nm) 1/8" (3 mm) Turf (12-inch) 95 ft. lbs.
MAINTENANCE Tires Wheel Removal WARNING! A falling vehicle can cause serious injury or death. Never place any part of your body under an elevated vehicle. If you need access to the bottom of the vehicle, use automotive jack stands to support the vehicle on a firm, level surface, or see your authorized GEM dealer for service. Frame viewed from bottom 1. Position the vehicle on a dry, firm, level surface. 2. Set the park brake. 3. Turn the key off.
MAINTENANCE Tires Wheel Removal 4. Block both the front and rear of the tire that is located diagonally opposite the jacking position. For example, if the right front tire is being changed, block the left rear wheel. 5. Use a small floor style jack or low profile scissors jack only. Jack the vehicle only from the side of the vehicle, on the main frame rail, at the point where the tub or floor panel support and the main frame rail are welded.
MAINTENANCE Tires Wheel Installation WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your authorized GEM dealer for service. 1. Set the park brake. 2. Place the wheel in the correct position on the wheel hub.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Replacement If a headlight fails to work properly, an expired lamp may need replacement.
MAINTENANCE Lights Rear Turn Signal Light Replacement 1. Remove the rear turn signal lens. 2. Remove the expired lamp. 3. Apply dielectric grease to the socket before installing the new lamp. 4. Test the light for proper operation. Brake Lights 1. Remove the brake light lens. 2. Remove the expired lamp. 3. Apply dielectric grease to the socket before installing the new lamp. 4. Test the light for proper operation.
MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. Mark 8" (20 cm) X 25 ft. (7.
MAINTENANCE Lights Headlight Beam Adjustment 3. Apply the brakes. Turn the key on. Turn the headlights to high beam. Tip: Include the weight of a rider on the seat while performing the following step. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall. 5. If a headlight needs adjustment, access the adjustment screw under the hood or through the wheel well. 6. Loosen the screw, adjust the headlight, and tighten the screw. 7.
MAINTENANCE Batteries WARNING The voltage in the battery pack is sufficient to cause death by electrocution. With the exception of battery inspections and refilling the water in flooded type batteries, never attempt to perform service on the electric drive system, including the battery pack, unless you are properly trained to work on electrical systems. Always see your authorized GEM dealer for battery-related service.
MAINTENANCE Batteries WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
MAINTENANCE Batteries Battery Configurations NOTICE: Before removing the seat to access the batteries, make sure any wire or metal items (including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system. Two battery pack configurations exist for GEM vehicles. The standard configuration consists of six 12-volt batteries. An optional configuration consists of nine 8-volt batteries. See pages 116-117 for battery locations and access instructions.
MAINTENANCE Batteries Battery Locations Standard 12-Volt Battery Configurations Model GEM e2 GEM e4 GEM e6® GEM eS GEM e4 (short-bed option) GEM e6® (short-bed option) GEM eL GEM eL XD Quantity 6 6 6 6 6 6 6 6 Locations 4 under bench seat, 2 in rear spat 4 under bench seat, 2 in rear spat 3 under bench seat, 3 in rear spat 4 under bench seat, 2 in rear bed 4 under bench seat, 2 in rear bed 3 under rear bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed Optional
MAINTENANCE Batteries Battery Access Batteries located in the rear spat or rear bed can be accessed through the battery access covers. Remove the four cover screws to remove a cover. Spat Access Cover Tip: Remove any rear accessory options that may obstruct the rear spat access cover. Batteries located under a middle seat (optional configuration) can be accessed through the panel on the front of the pedestal.
MAINTENANCE Batteries Battery Inspections/Maintenance Perform the following battery inspections and maintenance procedures monthly as outlined in the Periodic Maintenance Chart beginning on page 96. Perform these operations more often for vehicles subjected to heavy use. WARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components.
MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Fluid (Flooded Batteries) Gel batteries are maintenance-free batteries. They do not have fill wells. On flooded batteries, check the fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a battery. NOTICE: Never charge batteries if plates are exposed above the water level. Unless the plates are exposed before charging, distilled water should be added to a battery after charging.
MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Fluid (Flooded Batteries) Maintain the fluid level between the battery plates and the bottom of the fill well. Do not overfill. WARNING! The fluid in an overfilled battery may boil over and cause electrolyte to spill. Inspect the fluid level of each battery. 1. Remove one of the fill well caps. Tip: The battery plates should be visible when looking into the fill well. Use a flashlight if necessary. 2. View the fluid level.
MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Fluid (Flooded Batteries) 3. Maintain the fluid level between the battery plates and the bottom of the fill well. Add distilled water as needed. Do not overfill. Reinstall the fill well cap securely.
MAINTENANCE Batteries Battery Inspections/Maintenance Clean the Batteries NOTICE: Do not allow cleaning solution or tap water to enter the batteries. Before cleaning, make sure all battery fill well caps are installed securely. 1. Remove corrosion with a stiff wire brush. 2. Wash the terminals and tops of the batteries with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. 3. Make sure battery terminals are tight.
MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Connections WARNING! Improper handling of high voltage wiring, batteries or control systems could result in serious injury or death by electric shock. Only qualified technicians should repair or access high voltage wiring, battery packs and associated systems. Check Battery Cables and Wiring Check the battery compartment for any signs of worn insulation, frayed cables or damaged cable ends.
MAINTENANCE Batteries Battery Replacement With proper care and maintenance, battery life could be extended up to four years or longer, depending on the amount of use. When battery replacement is necessary, please see your authorized GEM dealer. NOTICE: Always install batteries of the exact type and make originally supplied with the vehicle to prevent damage to the vehicle’s electrical system. WARNING! Handling batteries and electrical components improperly can result in serious injury or death.
MAINTENANCE Batteries Battery Disposal Lead-acid batteries are recyclable. Return whole scrap batteries to a distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.
MAINTENANCE Batteries Battery Care During Storage WARNING! Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals. HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY TERMINALS.
MAINTENANCE Batteries Battery Care During Storage When the vehicle will not be used for a period of 10 days or longer, check battery water levels (flooded type batteries) and perform one of the battery storage procedures listed in the chart below. Battery Storage Options Storage Period Less than 10 days 10 days to 24 weeks Indefinitely or Unknown Charging Procedure Fully charge the batteries, park the vehicle and turn the ignition key off. The battery will lose some of its charge during this period.
MAINTENANCE Cleaning and Storage Cleaning the Windshield and Sunroof We recommend using GEM Windshield Cleaner and Protectant to remove normal dust and dirt. A liquid household glass cleaner can also be used. Do not use abrasive cleaners on the windshield and sunroof, as they will cause scratches. To remove oil, grease or road tar use isopropyl alcohol, then wash the windows with water. Dry gently with a soft cloth or chamois.
MAINTENANCE Cleaning and Storage Cleaning Seats Use GEM Foaming All Surface Cleaner to clean the seats. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt and other soils will stain if not removed quickly. Use a clean cloth and solvent type vinyl cleaner, then wash the area thoroughly with a damp cloth and mild liquid detergent. Rinse with cool water. Cleaning the Interior Use mild liquid detergent and warm water to clean the interior.
MAINTENANCE Cleaning and Storage Cleaning the Exterior The best way to preserve your vehicle’s finish is to wash the vehicle regularly. Use GEM Fiberglass Plastic and Rubber Restorer or mild liquid detergents. Do not use strong soaps or chemical detergents. Rinse promptly. Dry the finish with a soft, clean chamois or towel to avoid surface scratches and water spotting. Tip: To prevent spotting, avoid washing the vehicle in direct sunlight.
MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 96. Check Fluid Levels Inspect the fluid levels. Add or change fluids as recommended. Change brake fluid every two years and any time the fluid looks dark or contaminated.
MAINTENANCE Cleaning and Storage Storing the Vehicle Any time the vehicle will be parked for more than 10 days, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 128. 2. Clean the batteries. See page 122. 3. Prepare the batteries for storage. See page 126. NOTICE: Batteries can be permanently damaged (and the warranty voided) if allowed to remain 30 days or more with low charge. Fully charge batteries before storing.
MAINTENANCE Cleaning and Storage Storing the Vehicle 7. Verify that tire pressure is at specification. 8. Block the wheels to prevent rolling. WARNING! Do not cover the vehicle while the charger is connected. Dangerous levels of hydrogen gas could accumulate. 9. If the vehicle is not connected to the charger, turn off the main disconnect switch. Cover the vehicle with a genuine GEM vehicle cover. Do not use plastic or coated materials.
SPECIFICATIONS GEM e2 GEM e4 GEM eS Dimensions Curb Weight 1120 lbs. (508 kg) 1270 lbs. (576 kg) 1150 lbs. (521.6 kg) Length 99 in. (251.5 cm) 128 in. (325 cm) 108 in. (274.3 cm) Width 55 in. (139.7 cm) 55 in. (139.7 cm) 55 in. (139.7 cm) Height 70 in. (177.8 cm) 70 in. (177.8 cm) 70 in. (177.8 cm) Wheelbase 72 in. (183 cm) 102 in. (259 cm) 72 in. (183 cm) Turning Circle/Radius 11.5 feet (3.5 m) 15 feet (4.6 m) 11.5 feet (3.
SPECIFICATIONS GEM e2 GEM e4 GEM eS Performance Motor Motor peak Controller Battery pack Maximum speed Range Drive System On-board charger 5 HP (7 HP optional), shunt DC electric 23 HP Peak (17kw) Flight Systems, T4, 350 amp DC Controller Six 12-volt flooded lead acid batteries (12-volt gel optional) 25 MPH (40 km/h) 30 miles (48.3 km) (will vary with conditions) 12.
SPECIFICATIONS GEM e2 GEM e4 GEM eS Suspension Front suspension Rear suspension Tires Tire pressure Independent wishbone w/coil over shock Solid rear axle w/coil over shock Street rated 12-inch 165/70R-12 (Options: 12-inch aluminum turf, 14-inch aluminum) 12-inch: 32 psi (221 kPa) / 14-inch: 36 psi (248 kPa) Features Gauge Auxiliary power Seat belts Direction switch Headlights LCD Display 12-volt accessory outlet Automotive-style 3-point seat belts High/Low/Reverse Hi/Low Beam 35W/35W Taillights/brak
SPECIFICATIONS GEM eL GEM eL XD GEM e6® Dimensions Curb Weight 1235 lbs. (560 kg) 1550 lbs. (703 kg) 1620 lbs. (735 kg) Length 144 in. (365.8 cm) 144 in. (365.8 cm) 162 in. (411.5 cm) Width 55 in. (139.7 cm) 55 in. (139.7 cm) 55 in. (139.7 cm) Height 70 in. (177.8 cm) 70 in. (177.8 cm) 70 in. (177.8 cm) Wheelbase 114 in. (289.6 cm) 114 in. (289.6 cm) 133 in. (337.8 cm) 17 feet (5.2 m) 17 feet (5.2 m) 19 feet (5.
SPECIFICATIONS GEM eL GEM e6® GEM eL XD Performance Motor 5 HP (7 HP optional), shunt DC electric Motor peak Controller Battery pack Maximum speed Range Drive System On-board charger 7 HP vented, shunt DC electric 23 HP Peak (17kw) Flight Systems, T4, 350 amp DC Controller Six 12-volt flooded lead acid batteries (12-volt gel optional) Nine 8-volt gel batteries Six 12-volt gel batteries (e6®) Nine 8-volt gel batteries (e6® w/S option) 25 MPH (40 km/h) 30 miles (48.
SPECIFICATIONS GEM eL GEM eL XD GEM e6® Suspension Front suspension Independent wishbone w/coil over shock Rear suspension Solid rear axle w/coil over shock Tires Tire pressure Street rated 12-inch 165/70R-12 (Options: 12-inch aluminum turf, 14-inch aluminum) 12-inch: 32 psi (221 kPa) / 14-inch: 36 psi (248 kPa) Features Gauge Auxiliary power Seat belts Direction switch Headlights Taillights/brake lights LCD Display 12-volt accessory outlet Automotive-style 3-point seat belts High/Low/Reverse Hi/L
WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR or 8,000 MILE (12,900 km), whichever comes first, LIMITED WARRANTY on all components of your GEM vehicle against defects in material or workmanship. Mileage is unlimited for the first 6 months of the vehicle warranty. Any time after month 6, the vehicle warranty expires at 8,000 miles (12,900 km) or at the end of the two-year period, whichever comes first.
WARRANTY BATTERY WARRANTY EXCLUSIONS • Batteries that fail due to lack of battery maintenance, over-charging, under-charging, abuse or neglect is excluded from coverage • Batteries that fail due to fire, wreckage, explosion, or freezing • Broken batteries • Batteries ruined by defective chargers • Batteries to which an additive is added • Batteries which have been improperly stored and allowed to discharge • Any battery pack with a mixture of code dates or with other manufacturer’s products • Any battery im
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES The GEM limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to GEM within three days. Upon receipt of this registration, GEM will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy, please contact your dealer immediately.
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a GEM Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY. GEM suggests that you use your original selling dealer; however, you may use any GEM Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues.
WARRANTY How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized GEM dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized GEM dealer.
WARRANTY How to Get Service If Purchased From A Private Party: If you purchase a GEM product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE 148 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 149
MAINTENANCE LOG DATE 150 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A B D Accelerator Pedal . . . . . . . . . . . . . 55 Accessory Backs . . . . . . . . . . . . 77-79 Accessory Outlet, 12-Volt . . . . . . 69 Battery Discharge Indicator . . . 48-49 Brake Lever, Park . . . . . . . . . . 56-57 Brake Lights. . . . . . . . . . . . . . . . . 110 Brake Pedal . . . . . . . . . . . . . . . . . . 54 Brakes . . . . . . . . . . . . . . . . . . 98-100 Brake Fluid . . . . . . . . . . . . . 98-99 Brake Inspection . . . . . . . . . . . 100 Bumpers, Optional . . . . . . . . . . .
INDEX G L P Glove Box . . . . . . . . . . . . . . . . . . . 35 Grab Handle Package . . . . . . . . . . . 82 Gross Vehicle Weight Rating. . 22-23 LCD Display Indicators. . . . . . 42-51 Lights . . . . . . . . . . . . . . . . . 109-112 Brake Lights. . . . . . . . . . . . . . 110 Dome Light . . . . . . . . . . . . . . . 68 Front Turn Signal . . . . . . . . . . 109 Headlight Adjustment . . 111-112 Headlight Replacement . . . . . 109 Rear Turn Signal . . . . . . . . . . 110 Park Brake Lever . . . . . . . .
INDEX S T W Seat Removal, Bench . . . . . . . . . . 70 Signal Words. . . . . . . . . . . . . . . . . . 7 State of Charge Indicator . . . . . 48-49 Steering Column Lock . . . . . . . . . 83 Steering Column, Adjustable Tilt . 84 Steering Wheel Inspection . . . . . 101 Stereo System . . . . . . . . . . . . . . . . 76 Storage . . . . . . . . . . . . . . . . . 128-133 Storage Tips . . . . . . . . . . . . . . . . 131 Storage, Removal . . . . . . . . . . . . 133 Storing the Vehicle . . . . . . . .
For your nearest GEM dealer, call 855-RIDEGEM (855-743-3436) or visit www.gemcar.com Polaris Sales Inc. 2100 Hwy. 55 Medina, MN 55340 Part No.
