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1. Fuse Replacement Fuse Label Fuse Recommendations Turn Signals ane Fuse Application Fuse Size 10 40A Heater Coil fuse used for accessory 30 amp m os Turn Signals Brake Lamps 10A 10A Windshield Wiper Accessories Radio PA Accessories i 10A 10 Radio 10 amp Display Odometer Switch Tail Lamp Headlamps Horn License Plate 1A 1A Lamp Radio Display Heater 10A 1 Radio Public Address System Odometer Switch 1 amp NOTICE Always install fuses with the recommended amperage to avoid damage to the electrical System Tip See the label attached to the inside of the fuse access panel for the function and amp rating of each fuse The spare and heater coil fuses are used for accessories 105 MAINTENANCE Tires A 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 Tire Pressure WARNING Improper tire pressure can cause loss of control resulting in severe injury or death Proper tire pressure is essential to the safe and comfortable operation of your vehicle Check tire pressure daily or before each use of the vehicle For recommended tire pressures s
2. Direction switch High Low Reverse Headlights Single beam 40 watt Taillights brake lights LED Horn Turn Signals Standard Mirrors Rear view interior left side view 141 WARRANTV LIMITED WARRANTV POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 givesa TWO YEAR or 8 000 MILE 12 900 km whichever comes first LIMITED WARRANTY on all components of your GEM vehicle against defects in mate rial or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a GEM dealer The warranty coverage ends two years or 8 000 miles 12 900 km whichever comes first from the date of purchase BATTERY WARRANTY Battery coverage begins on the retail purchase date and continues for twenty four months or 8 000 miles 12 900 km whichever comes first During this time period GEM warrants your vehicle s batteries due to defects in materials or workmanship After the first six months in service a defective battery will be replaced on a manufac turer customer shared basis provided that the warranty limit of 8 000 miles 12 900 km has not yet occurred Review the table below for guidelines TERM FOR VEHICLES WITH LESS WARRANTY COVERAGE THAN 8 000 MILES 12 900 km FOR BATTER
3. 4 Allow battery terminals to dry then coat the terminals with dielectric grease or petro leum jelly or spray them with battery anti corrosion spray 124 MAINTENANCE Batteries Batterv Inspections Maintenance Check Batterv Connections WARNINGI Improper handling of high voltage wiring batteries or control svstems could result in serious injury or death by electric shock Only qualified technicians should repair or access high voltage wiring batterv packs and associated svstems Check Batterv Cables and Wiring Check the batterv compartment for anv signs of worn insulation fraved cables or damaged cable ends If found see vour authorized GEM dealer for service before operating WARNING If battery cable ends are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation possibly leading to fire which may result in serious injury or death Check Battery Hold Down Bars Battery hold down bars should be snug to keep batteries from moving while the vehicle is in motion but not so tight as to crack or buckle the battery case 125 MAINTENANCE Batteries Batterv Replacement With proper care and maintenance batterv life could be extended up to four vears or longer depending on the amount of use When batterv replacement is necessarv please see vour authorized GEM dealer NOTICE Alwavs install batteries of the exact tvpe and make originallv supplied w
4. OPERATION Parking the Vehicle 1 2 94 Apply the brakes Stop the vehicle on a level surface When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights Place the direction switch on either forward position Set the park brake 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 e If parking in an open area block the wheels on the downhill side of the vehicle after turn ing 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 If the vehicle is facing uphill turn the steering wheel away from the curb The rear part of the front tire should be turned into the curb Set the park brake 95 OPERATION Transporting the Vehicle NOTICE Towing vour 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 F rM i rame vehicle s curb weight plus any installed accessories or cargo
5. 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 Applv the brakes before turning the kev 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 Brake Accelerator Pedal Pedal 54 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 graduallv 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 For additional speed control or to stop the vehicle apply the brakes 55 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 Park Brake Release Park Brake Lever Park Brake Lever GEM 2 eS
6. 60 Operator Safetv 17 31 P Park Brake Lever 56 57 Parking on an Incline 95 Parking the Vehicle 94 Periodic Maintenance Chart 98 99 Pre Ride Inspection 88 89 Public Address Svstem 76 R Rear Accessorv Backs 77 79 Removing Vehicle from Storage 135 Reverse Operaton 92 S Safety Labels 12 16 Safety 7 Seat Adjustment 70 Seat Belt Inspection 75 Seat Belt Safetv Tips 74 Seat Belt Proper Use 72 73 Seat Belts 71 75 Seat Heaters 69 Seat Removal Bench 70 Signal 8 7 State of Charge Indicator 48 49 Steering Column Lock 83 Steering Column Adjustable Tilt 84 5 Steering Wheel Inspection 103 Stereo System 76 Stofag sie 130 135 Storage 133 Storage Removal 135 Storing the Vehicle 134 135 Switches Direction Switch 40 41 Headlight Switch 33 Key 34 Main Disconnect Switch 52 53 T THOS 525 4d vene IUS 106 110 Tire Pressure 106 Tread Depth 107 Wheel Installation 110 Wheel Nut Torque 107 Wheel Removal 108 109 T Transporting the Vehicle 96 97 Trip Meters ovo 38 39 T
7. FEATURES AND CONTROLS Seat Belts A 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 The operator and all passengers are subject to the same legal requirements for seat belt use as occupants in other on road vehicles Always make sure children are properly restrained Children ages 12 and under should ride in a rear seat Infants must always be restrained in a rear seat Use the type of restraint that is correct for your child When using child safety seats always follow the manufacturer s instructions for proper installation and use in a vehicle containing only a shoulder lap belt restraint system Visit www seatcheck org or call 1 866 SEATCHECK for more information about child restraints 71 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use This vehicle is equipped with three point lap and diago nal 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 dow
8. SAFETV Operator Safetv e 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 Always travel at a speed proper for the traffic visibility and operating conditions and your experience Never attempt jumps doughnuts or other stunts Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Operator Safetv Never operate on excessivelv rough slip perv or loose terrain Alwavs follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Alwavs have this vehicle checked bv an authorized GEM dealer if it has been involved in an accident SAFETV e Always be alert for obstacles when oper ating this vehicle Never attempt to oper ate over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of con trol Never
9. 24 weeks If the combined voltage of all batteries reaches 68 volts or less a safety feature in the on board charger will not allow the charger to activate If this occurs use the alternate charging method See page 65 60 FEATURES AND CONTROLS Batteries Batterv 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 WARNING Charging from a circuit of lesser capacity and or using a cord from the outlet to the vehicle that is not sufficient in wire gauge could create a fire hazard WARNING Failure to provide adequate ventilation while charging batteries can result in an explosion Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling Always ensure a minimum of five 5 air changes per hour in the charging area Never charge the batteries in an area subject to a flame or spark including areas containing gas or propane water heaters and furnaces Do not smoke in the charging area 61 FEATURES AND CONTROLS Batteries Batterv Charging The batterv charge receptacle is located on the hood When Charge charging the vehicle always use a standard 3 wire grounded Receptacle extension cord of one of the following tvpes 12 gauge wire with 3 wire gro
10. 53 Customer Service 5 148 D Direction Switch 40 41 Dome 84 DOTS n 5522 81 Driving in Reverse 92 Driving on Slippery Surfaces 93 Driving Procedure 90 91 153 INDEX E Electrical Components 33 ie canes tests 38 39 Equipment Modifications 24 F Fluid Levels During Storage 133 Fluid 121 123 Fluid Brake 100 101 Fuse Recommendations 105 Fuse Replacement 104 105 G Glove Boks 35 Grab Handle Package 82 Gross Vehicle Weight Rating 22 23 GVWR 22 23 154 H Hazard Signals 76 Headlight Beam Adjustment 113 114 Headlight Beam High Low 83 Headlight Replacement 111 Headlight Switch 33 Heater Defogger 85 taa i ee ay an 35 K Key Switch 34 L LCD Display Indicators 42 51 Lights Brake Lights 112 Dome Light 84 Front Turn Signal 111 Headlight Adjustment 113 114 Headlight Replacement 111 Rear Turn Signal 112 M Main Disconnect Switch 52 53 Maintenance Precautions 21 Maintenance Periodic 98 99 Manufacturer s Label 9 11 Modifications 24 Odometer 38 39 On Board Charger
11. NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from GEM Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or ser vice bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls 146 WARRANTV How to Get Service In the Countrv where vour vehicle was purchased Warrantv or Service Bulletin repairs must be done bv an authorized GEM dealer If vou move or are traveling within the countrv where vour vehicle was purchased Warrantv or Service Bulletin repairs mav be requested from anv authorized GEM dealer Outside the Countrv where vour vehicle was purchased If vou are traveling temporarilv outside the countrv where vour vehicle was purchased vou should take vour vehicle to an authorized GEM dealer You must show the dealer photo identification from the country of the sell ing dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If vou move to another countrv be sure to contact GE
12. and maintenance procedures monthiv as outlined in the Periodic Maintenance Chart beginning on page 98 Perform these operations more often for vehicles subjected to heavv 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 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 120 MAINTENANCE Batteries Batterv Inspections Maintenance Check Batterv Fluid Flooded Batteries Gel batteries are maintenance free batteries Thev do not have fill wells On flooded batter ies 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 If the plates are exposed add just enough water to cover the plates Fully charge the batteries then recheck the fluid level continued on next page 121 MAINTENANCE Batteries Batterv Inspections Maintenance Check Batterv Fluid Flooded Batteries Main
13. eL eL XD GEM e4 e6 56 FEATURES AND CONTROLS Park Brake Lever The park brake lever is located to the lower right of the driver seat To help prevent the vehi cle 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 Alwavs applv the brakes before setting or releasing the park brake The park brake is adjustable and should be checked periodicallv as outlined in the Periodic Maintenance Chart beginning on page 98 See your authorized GEM dealer for service 1 set the park brake apply the brakes Pull the park brake lever upward as far as possi ble 2 release the park brake apply the brakes Press the park brake release inward and move the lever downward as far as possible 57 FEATURES AND CONTROLS Batteries Batterv Pack 8 Volt Gel 12 Volt Gel Batterv Batterv Your vehicle is equipped with a battery pack con taining 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 Switching battery types should be done only by an authorized GEM service technician 12 Volt Flooded Battery 58 Batteries Batterv Perfo
14. electric motor Motor peak 23 HP Peak 17kw Controller Flight Systems T4 350 amp DC Controller Battery pack 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 Maximum speed 25 MPH 40 km h Range 30 mil es 48 3 km will vary with conditions Drive System 12 44 1 Single speed 14 76 1 Single speed 14 76 1 Single speed On board charger 120 volt 15 amp 60 Hz AC input 72 100 volt 12 amp DC output Accessory power supply Brakes 12 volt 30 amp DC DC converter Brake System 4 Wheel hydraulic brakes disc front drum rear Park Brake Console mounted lever activated mechanical park brake 140 SPECIFICATIONS GEM eL GEM eL XD GEM e6 Front suspension Independent wishbone w coil over shock Rear suspension Solid rear axle w coil over shock Tires 2 ply street rated tires TR13 185 70 13 86H 2 ply street rated tires 2 ply street rated tires TR13 P185 70R13 86H 12 inch 165 70R 12 aluminum turf available Tire pressure Gauge 10 inch 30 psi 207 kPa 12 inch 32 psi 221 kPa 13 inch 36 psi 248 kPa 1 4 inch 36 psi 248 kPa LCD Display Auxiliary power option 12 volt accessory outlet Seat belts Automotive style 3 point seat belts
15. 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 Usea 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 Alternative locations include the rear frame rail and the center of the front crossmember NOTICE Jacking at any location other than the recommended jacking points may cause significant damage to the vehicle frame and body 6 Remove the wheel nuts and washers 7 Remove the wheel 109 MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injurv or death Alwavs ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See vour authorized GEM dealer for service 1 Set the park brake 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Attach the wheel nuts and washers and finger F tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page e 107 110 MAINTENANCE Lights Poor lighting can result i
16. park brake WARNING A rolling vehicle can cause serious injury or death Always set the park brake when leaving the vehicle unattended 15 Turn the key off 16 Recharge the batteries daily or after each use of the vehicle 91 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 Avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Aw Pw Never accelerate suddenly 92 OPERATION Driving On Slipperv Surfaces A 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 AZ 2 1 Do not operate on excessively slip Sak SS Six l pery surfaces l b NA D 2 Slow down before driving onto a slippery surface 3 Avoid quick sharp turns which can cause skids 4 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid 93
17. viewed Refer to the specifications section beginning on page 136 VLA Always tie the frame of the GEM vehicle to the transporting unit securely with suitable straps Use the designated tie down points Never place tie straps across any plastic body or floor panel components continued on next page Tie Down Points 96 OPERATION Transporting the Vehicle Transport the vehicle in a closed trailer if possible Use the following guidelines when trans porting the vehicle on an open trailer 1 2 3 4 Alwavs transport the GEM vehicle facing forward on the trailer Set the park brake Remove the key to prevent loss 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 Never allow passengers on a trailer or in a trailered vehicle Reduce speed and drive with caution 97 MAINTENANCE Periodic Maintenance Chart WARNINGI Alwavs wear safetv glasses or approved eve protection when servicing the vehicle Wear a full face shield and gloves when working with or around batteries and electrical connectors Alwavs use insulated tools when working with or near batteries Failure to follow these instructions could result in serious injurv or death NOTICE Damage to electrical connections and components will occur if thev are unplugged before the main disconnect switch is turned off Alwavs turn off the main disconnect switch before servic
18. 5 Besure the storage area is well ventilated 6 Turn the key off Do not set the park brake 134 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 Cover the vehicle with a genuine GEM vehicle cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Removal from Storage 1 Inspect all battery connections Verify that batteries are fully charged 2 Verify that tire pressure is at specification 3 Perform the pre ride inspection See page 88 4 Inspect and verify the tightness of the bolts nuts and other fasteners 135 SPECIFICATIONS GEM e2 GEM e4 GEM eS Curb Weight 1120 Ibs 508 kg 1280 Ibs 580 6 kg 1160 Ibs 526 2 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 Payload Capacity occupants cargo options 24 feet 7 3 m 32 feet 9 75 m Load Capacity 730 Ibs 331 kg 920 Ibs 417 3 kg 24 feet 7 3 m 690 Ibs 313 kg Gross Vehicle Weight Rating
19. Backs Option 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 LI ON 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 CAUTION Keep the rear latch in a locked position when operating or transporting the vehicle The rear accessory could fall and cause injury if the safety strap is not used 10 Always lock the release handle with the ignition key after changing accessory backs 79 FEATURES AND CONTROLS Chrome Bumpers Option Chrome 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 or rear collisions Rugged Bumpers Option The rugged bumpers will protect the body panels only from minor dents and scratches They will not provide protection to the vehicle in front or rear collisions NOTICE Never use your GEM vehicle for pushing or towing Damage to the vehicle may result 80 IU FEATURES AND CONTROLS Doors Option WARNINGI Doors do not offer structural protection in the event of an accident and do not change the open bodv characteristics of the vehicle The doors provide prote
20. GVWR page 22 1850 Ibs 839 kg 2200 Ibs 998 kg 1850 Ibs 839 kg Gross Axle Weight Rating GAWR Front 1023 Ibs 464 kg Rear 1317 597 4 kg Front 1023 165 464 kg Rear 1317 597 4 kg Front 1023 165 464 kg Rear 1317 597 4 kg Seating 2 4 2 136 SPECIFICATIONS GEM e2 GEM e4 GEM eS Performance Motor GE Heavy Duty 5 HP shunt DC electric motor Motor peak 23 HP Peak 17kw Controller Flight Systems T4 350 amp DC Controller Battery pack Six 12 volt flooded lead acid batteries 12 volt gel optional Maximum speed 25 MPH 40 km h Range 30 miles 48 3 km will vary with conditions Drive System 12 44 1 Single speed On board charger 120 volt 15 amp 60 Hz AC input 72 100 volt 12 amp DC output Accessory power supply Brakes 12 volt 30 amp DC DC converter Brake System 4 Wheel hydraulic brakes disc front drum rear Park Brake Console mounted lever activated mechanical park brake 137 SPECIFICATIONS GEM e2 GEM e4 GEM eS Front suspension Independent wishbone w coil over shock Rear suspension Solid rear axle w coil over shock Tires 2 ply street rated tires 12 inch 165 70R 12 12 inch aluminum turf available Tire pressure 10 inch 30 psi 207 kPa 12 inch 32 psi 221 kPa 13 inch 36 psi 248 kPa 14 inch 36 psi 248 kPa Gauge LCD Display Auxili
21. IES DEEMED DEFECTIVE BY GEM Purchase Date 6th Month of Service 100 of the cost of an approved GEM battery at a GEM dealer 7th 12th Month of Service 75 of the cost of an approved GEM battery at a GEM dealer 13th 18th Month of Service 50 of the cost of an approved GEM battery at a GEM dealer 19th 24th Month of Service 25 of the cost of an approved GEM battery at a GEM dealer 142 WARRANTV BATTERV WARRANTV 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 improperly installed or with loose or corroded hardware 143 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES The GEM limited warrantv excludes anv failures that are not caused bv a defect in material or workmanship This warrantv does not cover accidental damage normal wear and tear abuse or improper handling This warrantv also does not cover any vehicle that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was manufactured or for any damages which occur during tr
22. L ATT Vow GEM Global Electric Motorcars byP amp sLARIS 2012 Owner s Manual for Maintenance and Safetv Read this manual carefuliv It contains important safetv information A WARNING Read understand and follow all of the instructions and safetv precautions in this manual and on all product labels Failure to follow the safetv precautions could result in serious injurv or death WENTALLY y Qe A S Q S Q s O ienun The text is printed on 100 recycled with 40 post consumer waste PCW ST Vos GEM Global Electric Motorcars by P amp SLARIS 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 9923940 Rev 01 Printed in USA LAT R ER GEM Global Electric Motorcars by P amp LARIS The following are registered trademarks of POLARIS Industries Inc POLARIS VICTORY Global Electric Motorcars GEM THE WAY OUT RANGER INDIAN e6 Copyright 2011 POLARIS Sales Inc All information contained within this publication is based on the latest prod uct 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 Depictions and or procedures in this publication are intended for reference use only No l
23. M Customer Assistance and the customs department of the destination country before you move Vehicle importation rules vary considerably from country to country You may be required to present documentation of your move to GEM in order to continue your warranty coverage You may also be required to obtain documentation from GEM in order to register your vehicle in your new coun try 147 WARRANTV How to Get Service If Purchased From A Private Partv If vou purchase a GEM product from a private citizen outside of the countrv in which the vehicle was originallv purchased all warrantv coverage will be denied Notice If vour vehicle is registered outside of the countrv where it was purchased and vou have not followed the proce dure set out above vour vehicle will no longer be eligible for warrantv or service bulletin coverage of anv kind Vehicles registered to Government officials or militarv personnel on assignment outside of the countrv where the vehicle was purchased will continue to be covered by the basic warranty GEM Customer Service Phone 855 RIDEGEM 855 743 3436 Web www gemcar com 148 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 149 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 150 MAI
24. NTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 151 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 152 A Accelerator Pedal 55 Accessory Backs 77 79 Accessory Outlet 12 Volt 87 B Batteries 58 68 115 129 ACCESS onse aga bunt VERTES E 119 Battery Pack 58 Care During Storage 128 129 Charging 61 64 Charging Alternate Method 65 66 Cleaning EREURESY 124 Configurations 117 127 Fluid fos eee ba 121 123 Handling Precautions 67 68 B Batteries 58 68 115 129 Inspections 120 125 Locations 118 Monthly Maintenance 120 125 On Board Charger 60 Performance Tips 59 Replacement 126 Batterv Discharge Indicator 48 49 Brake Lever Park 56 57 Brake Lights 112 Brake 22 2 2252552 54 Brake Fluid 100 101 Brake Inspection 102 Bumpers Chrome 80 Bumpers Rugged 80 Cargo Carrier Enclosed 82 Cleaning Exterior ure us 132 Interior uisi ss 131 SEAS ves sro 131 Windshield and Sunroof 130 Cleaning and Storage 130 135 Console oce Re 32
25. ROLS 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 kev WARNINGI Do not leave the kev 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 To unlock the steering column insert the key and turn the steering wheel to remove any pres sure on the lock Turn key counter clockwise High Low Headlight Beam Option 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 83 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 Dome Light Option Turn the dome light on or off by pressing the switch on the side of the light The dome light is powered by four AA batter ies To replace the batteries remove the light cover and install the new batteries Instructions are located inside the battery compartment 84 FEAT
26. URES AND CONTROLS 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 Move the switch to the ON position then adjust airflow to the windshield as needed using the deflectors located on the top of the console Deflector 85 FEATURES AND CONTROLS Windshield Washer Option Push the turn signal lever toward the console to turn the wind shield wipers on Push the lever toward the console again to activate the washer momentarilv 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 Keep sparks flames and cigarettes away Handle with caution 86 FEATURES AND CONTROLS Accessorv Outlet Option The optional accessorv outlet is located on the lower con sole to the right of the fuse access panel This outlet will accept a standard automotive 12 volt accessorv and is intended for moderatelv powered accessories such as a cellular phone It will not operate large current items such as cigarette lighters e The fuse for the power outlet plug is located in the fuse e block under the access panel in the center of the lower con sole Always u
27. ailed operating instructions Public Address System Option The optional public address PA system features a heavy duty micro phone speaker and four tone siren Refer to your PA system s user manual for detailed operating instructions 76 FEATURES AND CONTROLS Rear Accessorv Backs Option Rear accessorv back options are available These rear accessorv backs are interchangeable Trunk Cover Lock Latch Release Handle TrunkBack LinksBack Clip In StakeBack 77 FEATURES AND CONTROLS Rear Accessorv 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 Ensure that the safety strap is secured CAUTION Before releasing the rear latch always make sure the safety strap is secure The rear back can fall suddenly and cause injury or damage to the vehicle if the safety strap is not secured 3 Firmly grasp the installed back to prevent it from tipping or falling 4 Use the ignition key to unlock the latch release handle Tip There is a separate key for the TrunkBack cover lock 78 FEATURES AND CONTROLS Rear Accessorv
28. ailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond GEM control The exclusive remedy for breach of this warranty shall be at GEM s exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY GEM SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 144 WARRANTV REGISTRATION At the time of sale the Warrantv Registration Form must be completed bv vour dealer and submitted to GEM within three davs Upon receipt of this registration GEM will record the registration for war
29. an be used OFF ON 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 acceler ate but accessories and lights will remain on for approximately 30 sec onds Turn the key to the OFF position to disable all electrical circuits The key can be removed from the switch when it is in the OFF position WARNING Never turn the key to the OFF position while the vehicle is in motion This could lead to loss of speed control and loss of vehicle control which could result in serious injury or death 34 FEATURES AND CONTROLS Console Zero Speed Detection Feature To prevent the vehicle from rolling awav the electric motor will resist vehicle motion if the accelerator pedal is released while the kev is on and the vehicle is moving Horn Press the turn signal wand inward toward the instrument pod to sound the 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 Turn the key 1 4 turn counter clockwise to unlock the door 35 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 act
30. ary power option 12 volt accessory outlet Seat belts Automotive style 3 point seat belts Direction switch High Low Reverse Headlights Single beam 40 watt Taillights brake lights LED Horn Turn Signals Standard Hazard Signals Optional Mirrors Rear view interior left side view 138 SPECIFICATIONS GEM eL GEM eL XD GEM e69 Curb Weight 1230 Ibs 558 kg 1570 Ibs 712 kg 1560 Ibs 707 6 kg e6 1860 Ibs 843 7 kg e6 w S option 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 71 in 180 3 cm 71 in 180 3 cm Wheelbase 114 in 289 6 cm 114 in 289 6 cm 133 in 337 8 cm Turning Circle Radius Payload Capacity occupants cargo options 35 feet 10 7 m 35 feet 10 7 m Load Capacity 1070 165 485 3 kg 1430 Ibs 648 6 kg 39 feet 11 9 m 1440 lbs 653 2 kg Gross Vehicle Weight Rating GVWR page 22 2300 Ibs 1043 kg 3000 Ibs 1360 8 kg 3000 Ibs 1360 8 kg Gross Axle Weight Rating GAWR Front 1023 Ibs 464 kg Rear 1317 597 4 kg Front 1380 626 kg Rear 1820 825 5 kg Front 1380 626 kg Rear 1820 825 5 kg Seating 2 2 6 139 SPECIFICATIONS GEM eL GEM eL XD Performance GEM e6 Motor GE Heavy Duty 5 HP GE Heavy Duty 7 HP vented shunt DC electric motor shunt DC
31. atents U S 0 000 USA Label EU Label GVWR VIN Information INTRODUCTION Manufacturer s Label Vehicle Information Label Vehicle Identification Number VIN ene mde de Oe Ue Vehicle Model Number Motor Serial Number on case of motor Key Number stamped on key Optional Rear Accessory stamped on key Date Purchased SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour 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 The part number is printed on the label General Warning General Warning WARNING Read your owner s manual before operating this vehicle Do not operate this vehicle under the influence of alcohol drugs or medication This vehicle is not intended to be driven at speeds exceeding 25 MPH 40 km h continued on next page 4 12 SAFETV Safetv 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 ma
32. ce Code Charge Displav Indicator Common service codes are detailed below Code Condition Remedv 06 Accelerator pedal is depressed Release pedal applv brakes no direction is selected make sure direction switch is locked into a position 11 Accelerator pedal was depressed Turn key off release accelerator before key was turned on pedal then turn key on 15 Low state of charge on batteries Charge batteries before operating 16 High state of charge on batteries Turn headlights on for several minutes then turn the key switch off and on Tip If any other codes display contact your authorized GEM dealer or call GEM customer service FEATURES AND CONTROLS Console LCD Displav Indicators G 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 sys tem failure has occurred If the brake warning illuminates check the following items before operating the vehicle Brake System Solution Park brake Release the park brake Brake fluid level If low add brake fluid See page 100 Brake system Check hoses for cracks scuffs and worn spots If you discover signs of wear or damage do not operate the vehicle See your authorized GEM dealer for service WARNING Worn or damaged brake hoses can cause brake failure Always have w
33. ct 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 Always make sure that all electrical accessories are grounded directly to the negative post on the terminal board Never use the chassis or body as a ground connection Make sure vent caps are installed properly and securely during vehicle operation and bat tery charging Never connect 12 volt accessory directly to the batteries Always connect any powered accessory to a 12 volt auxiliary outlet or terminal board continued on next page 67 FEATURES AND CONTROLS Batteries Batterv Handling Precautions Never connect jumper cables to any of the batteries of this vehicle e 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 connec tors 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 124 68 FEATURES AND CONTROLS Seat Heaters Option Heater Switch For 2 passenger vehicles the front driver and passenger seats are heated For 4 passenger and 6 passenger vehicles both front and second row seats are heated WARNING Use care
34. ction from the weather oniv Alwavs use seat belts Failure to use the seat belts puts the driver and passengers at greater risk of serious injurv 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 Unzip the door to open it The door can be held in the open position using the straps and snaps located on the pillars or door supports Framed Canvas Doors To open the doors from outside the vehi cle locate the door knob and slide it in the direction of the arrows To open doors from inside the vehicle locate the nylon strap at the center of the door and pull it toward the front of the vehicle To open windows locate the zipper and unzip it to the desired posi tion The window can be stored in the open position by securing it with the nylon straps and snaps 81 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 l Enclosed Cargo Carrier Option To open the cargo carrier door insert the kev and turn the lock Pull the handle outward and rotate it to open the door Reverse the process to close and lock the door 82 FEATURES AND CONT
35. cupants GEM eL XD 2 occupants GEM e6 6 occupants 17 SAFETV Operator Safetv Never exceed the gross vehicle weight Always use the proper size and type of rating GVWR of your vehicle tires and always maintain proper tire The cab frame is not designed or intended pressure as specified in this manual and to provide rollover protection Avoid situ on safety labels ations that could result in a rollover Never modify this vehicle through Always be sure there are no obstacles improper installation or use of accesso people behind your vehicle when operat ries ing in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse 18 SAFETV Operator Safetv Never carry loads on the roof of the vehi The voltage in the battery pack is suffi cle 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 cient to cause death by electrocution With the exception of battery inspections and refilling the water in flooded type batteries never attempt to perform ser vice on the electric drive system includ ing the battery pack unless you are properly trained to work on electrical sys tems
36. d surface scratches and water spotting Tip To prevent spotting avoid washing the vehicle in direct sunlight Protection From the Elements Prolonged exposure to sunlight mav deteriorate the exterior and interior finish Park the vehi cle in a garage or similar structure or cover the vehicle with a GEM vehicle cover 132 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 Main tenance Chart beginning on page 98 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 133 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 130 2 Clean the batteries See page 124 3 Prepare the batteries for storage See page 128 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 In hot climates battery self discharge will increase In cold climates batteries could freeze if not properly charged 4 Store the vehicle out of the sun in a cool dry place
37. dows sunroof side and rear windows as they can be scratched or damaged Do not use a cleaner with an abrasive a combination cleaner and wax or any solvent that contains ethyl or methyl alcohol Do not use products containing ammonia soaps or abrasives Never use gasoline or cleaning solvent These products scratch or destroy the surface of the windows 130 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 Remove detergent or deposits with a clean damp cloth NOTICE Do not spray the interior of your vehicle Liquids can damage electrical components and the circuit board Handle liquids with care Do not spray water directly into the upper or lower console 131 MAINTENANCE Cleaning and Storage Cleaning the Exterior The best wav to preserve vour vehicle s finish is to wash the vehicle regulariv Use GEM Fiberglass Plastic and Rubber Restorer or mild liquid detergents Do not use strong soaps or chemical detergents Rinse promptiv Drv the finish with a soft clean chamois or towel to avoi
38. e 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 92 for safe reverse operation procedures 41 FEATURES AND CONTROLS Console LCD Displav Indicators Left Turn Code Charge Display Brake Warning Lp Turn High Motor 0 Temperature ant j 4 km h _ MPH LLLI I km Se 5858985 8 j MILES Service Charger FE Required State of Charge xe High Beam Battery Discharge lt gt 20 Headlight Current Limiting Mode zm Low Beam DL DH 80 Headlight Seat Belt Warning Reverse Drive Low Drive High Selected Selected Selected 42 FEATURES AND CONTROLS Console LCD Displav Indicators Speedometer Service Code Charge Displav Indicator When driving the speedometer displavs vehicle speed in either miles per hour MPH or kilometers per hour km h The display can be changed to displav either standard or metric units of measurement See page 38 When the batteries are charging this area displavs the percent of charge When the service indicator illuminates a service code displavs in this area 74 Charge 43 FEATURES AND CONTROLS Console LCD Displav Indicators Speedometer Servi
39. e roads where speed limits are appropriate for low speed vehicles Be familiar with motor vehicle laws in your area of operation Do not operate this vehicle in situations where it could become an obstacle or an annoyance for faster moving traffic INTRODUCTION Manufacturer s Label Vehicle Information Label Record vour vehicle s identification numbers and kev 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 vear model tvpe and serial num ber of vour vehicle The manufacturer s label also contains the Gross Vehicle Weight Rating GVWR and Gross Axle Weight Rating GAWR information for vour vehicle Never exceed the GVWR or the GAWR See page 22 To order an extra or replacement kev for vour vehicle please contact GEM customer service See page 5 Be prepared to provide vour kev number and VIN INTRODUCTION Manufacturer s Label Vehicle Information Label Date of Manufacture Manufacturer s Label Tire Wheel Information GAWR Information DATE OF MFR ommi MFD BV RIS INDUSTRIES VWR 000 KG 0000 LB GA TIRES RI COLD FRONT 000 KG 0000 ae xo KPA 00 PSI REAR 00 KG 0000 L8 000 0080 00X0 000 PSI THIS ner CONFORMS TO ALL APPLICABLE GAWR TIRES E UTE vw SASAAAAODOADODODO Pat P
40. e used Become familiar with their meanings before reading the manual A NOTICE The safety alert symbol indicates a potential 2 personal hazard WARNING The Prohibition Safetv Sign indicates A WARNING indicates a hazardous situation an action NOT to take in order to avoid which if not avoided may result in death or a hazard serious injury CAUTION The Mandatory Action Sign indicates A CAUTION indicates a hazardous situation an action that NEEDS to be taken to which if not avoided may result in minor or avoid a hazard moderate injury INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injurv or death Special precautions must be followed when owning and operating a batterv powered vehicle This vehicle is not a tov and can be hazardous to operate This vehicle handles differentiv 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 Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle 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 Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Operate this vehicle only on public or privat
41. ead and understand the Owner s Manual and all warning and instruction labels before operating the vehicle 26 Ventilation When Charging Batteries Failure to provide adequate ventilation while charging batteries can result in an explosion Volatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling Always ensure a minimum of 5 air changes per hour in the charging area Always remove any storage covers from the vehicle and open any cab doors if equipped before charging Operator Safetv Failure to Inspect Before Operating Failure to inspect and verifv that the vehicle is in safe operating condition before operating increases the risk of an accident Alwavs inspect the vehicle before each use to make sure it s in safe operating condition Alwavs follow all inspection and maintenance procedures and schedules described in the owner s manual SAFETY Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while operating this vehicle as 27 SAFETV Operator Safetv Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After anv overturn or accident have your authorized GEM dealer inspect the entire machine for possible damage including but not limited to brakes accelerator ste
42. ee the manufacturer s label on your vehicle or the specifications section beginning on page 136 NOTICE After inspecting or adjusting the tire pressure always reinstall the valve stem cap if equipped This will prevent moisture and dirt from entering the valve stem which could cause damage 106 Tires Tire Tread Depth Any accelerated wear of tires may be an indica tor of improper alignment or poor driving hab its 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 MAINTENANCE Y 1 8 3 mm gt Aluminum Wheel 12 inch 14 inch 95 ft Ibs 128 Nm Steel Wheel 12 inch 13 inch 65 ft Ibs 88 Nm 107 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 1 Position the vehicle on a dry firm level surface 2 Set the park brake 3 Turn the key off Frame viewed from bottom VA an fii Jack Points 108 MAINTENANCE Tires Wheel Removal 4 Block both the
43. el drops between fluid checks add brake fluid as needed See vour authorized GEM dealer for service WARNINGI After opening a bottle of brake fluid alwavs discard anv unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown Always use DOT3 brake fluid 100 MAINTENANCE Brakes Brake Fluid Maximum Minimum 1 Position the vehicle on a level surface 2 Open the hood The brake fluid reservoir is located above and to the rear of the left 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 Apply the brake forcefully for a few seconds and check for fluid leakage around the fit tings NOTICE Brake fluid may cause damage to painted and finished surfaces Use caution when refilling the brake fluid reservoir 101 MAINTENANCE Brakes Brake Inspection The front and rear brakes are hvdraulic disc tvpe brakes 1 Check the brake system fo
44. empt to open repair test inspect or adjust Onlv qualified technicians should open and service Consult service manual SAFETV Safetv 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 Ibs 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 Ibs 499 kg Distribute weight equally over axle No passengers permitted Abuse or noncompliance will void warranty 16 SAFETV Operator Safetv A 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 e Read this manual and all labels carefully Always make sure the seat belts are Follow the operating procedures secured for operator and all passengers described before operating e Never allow anyone under age 16 to oper Never exceed the maximum occupant ate this vehicle and never allow anyone capacity of your vehicle without a valid driver s license to operate this vehicle GEM e2 2 occupants e Never permit a guest to operate this vehi AENEA cle unless the guest has read this manual GEM eS 2 occupants and all product labels GEM eL 2 oc
45. ering system and electrical system Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the traffic the visibility and operating conditions your skills and your passengers skills 28 Exhibition Driving Exhibition driving increases the risk of an accident or overturn Never attempt wheelies jumps doughnuts or other stunts Avoid exhibition driving Operator Safetv Turning Improperly 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 Vehicle Rollover Vehicle rollover could cause serious injury or death The cab frame is not designed or intended to provide rollover protection Always make sure the seat belts are secured for operator and all passengers before operating Avoid situations that could result in a rollover Avoid sharp turns and abrupt steering maneuvers SAFETY Carrying Cargo 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 29 SAFETV Operator Safetv Improper Tire Maintenance Operating this vehicle with improper tires or with improper o
46. ghts Headlight Beam Adjustment 1 2 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 8 20 25 ft 7 6 113 MAINTENANCE Lights Headlight Beam Adjustment 3 Apply the brakes Turn the key on Turn the headlights on 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 If the vehicle is equipped with both high and low beam headlights place the headlights on high beam for this step 5 Ifaheadlight 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 Repeat steps 4 6 until the lamp is properly adjusted 114 MAINTENANCE Batteries A 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 A WARNING Battery posts terminals and re
47. iability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is expressly prohibited Printed in U S A 2012 GEM Owner s Manual P N 9923940 2 TABLE OF CONTENTS IntrodLictik i xi i fa ania l de Ra eg tal ee Seer uL 6 eee qx REPE id wee edi Vea ne eed are qs 12 Features and 32 ODER AU OM ix doo ag nen jj C e DO a 88 M int liallGe oco rk he be ree uar d a 98 Specifications a sa ue xk i ee oe 136 Warranty iu kai wx 142 Maintenance Log 149 Index RR RR eR ee eee ee is 153 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 With our many years of experience in design and manufacturing we proudly bring you only the finest of vehicles e Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles e Low emission vehicles LEVs VICTORY motorcycles NDIAN motorcycles GEM vehicles WELCOME For safe and enjovable operation of vour vehicle be sure to follow the instructions and rec ommendations in th
48. ing or unplugging anv electrical components Careful periodic maintenance will help keep vour vehicle in the safest most reliable condi tion Inspect clean lubricate adjust and replace parts as necessarv When inspection reveals the need for replacement parts alwavs use genuine GEM parts available from vour autho rized GEM dealer Record maintenance and service in the Maintenance Log beginning on page 149 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have your authorized GEM dealer perform these operations 98 MAINTENANCE Periodic Maintenance Chart Monthiv Maintenance See Page Check batterv fluid level flooded oniv 121 Wash tops and terminals of batteries and allow to drv 124 Check cables and terminal connections 125 Check for worn insulation or fraved wires 125 Check battery hold down bar to ensure batteries are tightly secured 125 Check tires for correct air pressure and wear 106 Check brake fluid reservoir for proper brake fluid level 100 Check brake lines for leaks Check seat belts for proper operation 75 Check headlights horn turn signals windshield wiper and brake lights for proper operation Check steering wheel freeplav 103 99 MAINTENANCE Brakes Brake Fluid Inspect the brake svstem routinelv Inspect the brake fluid level before each operation If the lev
49. is owner s manual Xour manual contains instructions for minor mainte nance 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 pre pared to provide your Vehicle Identification Number VIN and date of purchase Your authorized GEM dealer knows your vehicle best and is interested in your total satisfac tion Be sure to return to your dealership for all of your service needs during and after the warranty period GEM Customer Service Phone 855 RIDEGEM 855 743 3436 Web www gemcar com 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 This manual applies to the following GEM vehicles GEM e2 two passenger GEM e4 four passenger GEM eS two passenger short bed GEM eL two passenger long bed GEM eL XD two passenger extra duty long bed GEM six passenger INTRODUCTION Safetv Signal Words and Svmbols The following signal words and svmbols appear throughout this manual and on vour vehicle Your safety is involved when these words and symbols ar
50. ith the vehicle to prevent damage to the vehicle s electrical svstem WARNING Handling batteries and electrical components improperly can result in serious injury or death Do not attempt to remove batteries or battery cables It is essential when replacing the cables on the batteries that the positive cable is attached to the positive post and the negative cable is attached to the negative post Battery posts are identified on the battery case as positive and negative Always see your authorized GEM dealer for battery related service 126 MAINTENANCE Batteries Batterv Disposal Lead acid batteries are recyclable Return whole scrap batteries to a distributor manufac turer or lead smelter for recvcling For neutralized spills place residue in acid resistant con tainers 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 environmen tal officials regarding disposal information You can also contact GEM Customer Service for information See page 5 127 MAINTENANCE Batteries Batterv Care During Storage WARNINGI Alwavs turn off the main disconnect switch before servicing or unplugging anv electrical components See page 52 The main disconnect switch will disable the vehicle bv disconnecting the battery pack from the motor It does not disable the battery pack HIGH VOLTAGE will be present at the battery
51. ivate 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 The left turn indicator in the LCD display will also flash Move the lever upward to signal a right turn The right signal lamp and indicator will flash Return the lever to the center position to end the signal If the operator does not end the signal within 45 seconds an alert will sound i N Left Turn 36 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 con sole again to activate the washer momentarilv if equipped see page 86 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 104 CAUTION A worn or damaged wiper blade could impair operator vision and result in an accident A worn wiper blade could also damage windshield glass Always replace worn or damaged wiper blades promptly 37 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 kilo
52. lated components contain lead and lead compounds chemicals known to cause cancer and reproductive harm Always wash your hands after touching or handling the batteries AWARNING Charging a damaged battery can result in serious injury Never attempt to charge a frozen or bulging battery Discard the battery appropriately and install a new battery 115 MAINTENANCE Batteries A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death AWARNING 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 Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 116 MAINTENANCE Batteries Batterv Configurations NOTICE Before removing the seat to access the batteries make sure anv wire or metal items including seat belt latches remain clear of the batterv compartment to avoid causing a short circuit to the electrical svstem Two batterv pack configurations exist for GEM vehicles The standa
53. meters 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 38 Console Trip Meter Odometer E Meter FEATURES AND CONTROLS Trip Switch Operation Desired Result Press Trip Switch Toggle between the odometer and trip meter modes on the displav Press and hold for less than 2 seconds Reset the trip meter to zero Press hold for 3 9 seconds while display is trip mode TRIP is illuminated see page 42 Change the displav from standard to metric MPH to km h and miles to kilometers Press and hold for 10 12 seconds while displav is in odometer mode Displav consumed power Press and release twice 39 FEATURES AND CONTROLS Console Direction Switch NOTICE Alwavs bring the vehicle to a complete stop before changing the position of the direction switch 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 accel erator pedal to increase speed CAUTION Changing the direction switch position while driving could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure Drive High Drive Low Reverse 40 FEATURES AND CONTROLS Console Direction Switch Drive High The HIGH mode allows operation of the vehicl
54. n reduced visibilitv when driving Clean lights frequentiv 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 the entire assembly must be replaced See your autho rized GEM dealer for service If your vehicle is equipped with optional high low beam head lights an expired lamp can be replaced Apply dielectric grease to the socket before installing the new lamp Front Turn Signal Light Replacement If a front turn signal fails to work properly the entire assembly must be replaced See your authorized GEM dealer for service If your vehicle is equipped with optional high low beam headlights an expired front turn signal lamp can be replaced Apply dielectric grease to the socket before installing the new lamp 111 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 112 MAINTENANCE Li
55. nsure full charges proper water levels clean terminals 115 128 Battery cables Inspect for proper cable routing secure connections 120 Wheels fasteners Inspect ensure fastener tightness 107 89 OPERATION Driving Procedure 1 2 2 RY Disconnect the charging cable Make sure the main disconnect switch is on Sit in the driver s seat and fasten the seat belt Make sure passengers are seated with seat belts secured Adjust mirrors as needed Turn the kev clockwise to the ON position Apply the brakes Release the park brake Move the direction switch to the desired position See page 40 Check your surroundings and determine your path of travel Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 10 Drive slowly Practice maneuvering and using the accelerator and brakes on level sur 90 faces OPERATION Driving Procedure 11 Before turning activate a turn signal to alert others of vour 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 14 Set the
56. nward 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 The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted Buckle 72 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use 2 3 4 Push the latch plate into the buckle until it clicks Release the strap it will self tighten 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 slightiv longer To release the seat belt press the square red button in the buckle s center If necessarv slide the buckle down the webbing to allow it to retract fullv 73 FEATURES AND CONTROLS Seat Belts Seat Belt Safetv Tips 74 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 Dis connect 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 If the belt still cannot be tightened when using a child safety seat or if pulling and pushing on the restraint loosens the belt disconnect the latch plate from the buckle turn the buckle around and insert the latch
57. ons have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only GEM approved accessories and familiarize yourself with their function and effect on the vehicle 24 Operator Safetv SAFETV Failure to operate this vehicle properlv 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 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 Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Occupants must wear seat belts at all times Always make sure the seat belts are secured for operator and all passengers before operating See page 71 25 SAFETV Operator Safetv Operating Without Instruction 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 r
58. operate this vehicle on steep hills 21 SAFETV Operator Safetv Gross Vehicle Weight Rating GVWR WARNINGI Exceeding the gross vehicle weight rating of vour vehicle can reduce stabilitv and handling and could cause loss of control NEVER exceed the GVWR of vour 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 Refer to the specification section of this manual or the Manufacturer s Label on the vehicle for model specific information 22 SAFETV Operator Safetv Gross Vehicle Weight Rating GVWR When determining the weight vou will be adding to vour vehicle and to ensure vou do not exceed the maximum pavload capacitv include the following operator bodv weight passenger bodv weight weight of all occupants apparel and items in or on apparel weight of anv options or accessories and their contents weight of anv additional cargo on the vehicle 23 SAFETV Operator Safetv 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 termi nated if any equipment has been added to the vehicle or if any modificati
59. orn or damaged brake hoses replaced promptly 45 FEATURES AND CONTROLS Console LCD Displav 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 overheat ing 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 Tip Climbing steep grades while hauling heavy loads may overheat the motor or controller and shorten component life 2 46 FEATURES AND CONTROLS Console LCD Displav Indicators Odometer Trip Meter Indicator The odometer indicator logs the total distance the vehicle has been driven since it was manu factured The trip meter is useful for logging distances traveled on separate trips See page 38 for trip meter instructions The displav can be changed to displav either standard or metric units of measurement See page 38 Charger Connected Indicator This indicator illuminates approximatelv 8 10 seconds after the charger is connected and remains on until the charger is disconnected If the indicator fails to illuminate when the charger is connected the charger mav not be charging If this occurs make sure the main disconnect switch is in the ON position See pages 61 65 for more information ab
60. out charging the batteries 47 FEATURES AND CONTROLS Console LCD Displav Indicators State of Charge Batterv Discharge Indicator BDI This indicator contains 8 green bars a vellow bar and a red bar It shows available batterv capacitv bv illuminating one or more bars The indicator illuminates when the key is turned on It also illumi nates 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 As charge is depleted bars begin to turn off from right to left Remaining bars indicate remaining battery charge See page 49 Red Green Yellow Tip If only red and yellow bars are illuminated charge is very low Recharge as soon as possible A full recharge cycle from one red bar to fully charged may take 8 hours or more for a standard battery pack and up to 14 hours for a heavy duty battery pack 48 Console LCD Displav Indicators FEATURES AND CONTROLS State of Charge Batterv Discharge Indicator BDI State of Charge Batterv Discharge Indicator Bars Color Of Charge 1 Red Far Left Less Than 10 2 Yellow 10 20 3 Green 20 30 4 Green 30 40 5 Green 40 50 6 Green 50 60 7 Green 60 70 8 Green 70 80 9 Green 80 90 10 Green Far Right 90 100 NOTICE Batteries can be permanently damaged and the warranty voided if allowed to remain 30 days or mo
61. plate into the buckle again If you still cannot make the child restraint secure try a different seating position 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 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 If any damage is found or if the seat belt does not oper ate properly have the seat belt system checked and or replaced by your authorized GEM dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents 75 FEATURES AND CONTROLS Hazard Signals Option Press the hazard signal switch to cause all turn signal lamps to flash simultaneously Use this feature to alert others of an emergency or other situation requiring caution especially if your vehicle becomes disabled on or near a road Press the switch again to cancel the hazard signals Stereo System Option The optional stereo system is mounted in an overhead console and fea tures speakers FM radio CD player and MP3 capabilities Refer to your stereo system s user manual for det
62. r fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and loose ness 4 Inspect the brake disc spline and pad wear surface for excessive Wear 5 Change pads when worn to 3 64 1 mm 102 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplav and smooth operation 1 2 3 Position the vehicle on a level surface 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 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 103 MAINTENANCE Fuse Replacement NOTICE Alwavs disconnect the main disconnect switch before servicing or unplugging anv electrical components See page 52 If vou experience electrical failures not related to the batteries a fuse mav need replacement Locate and correct anv short circuits that mav have caused the blown fuse then replace the fuse See vour authorized GEM dealer if you suspect relay or Access Panel Fuse Block diode needs replacement The fuse block is located inside the fuse access panel on the lower console To open the access panel insert the ignition key in the lock and turn it counter clockwise 1 4 turn 104 MAINTENANCE
63. r uneven tire pressure could cause loss of control or accident Alwavs use the size and tvpe of tires specified for vour vehicle Alwavs maintain proper tire pressure as described in the owner s manual and on safetv labels Unauthorized Use of the Vehicle Leaving the kevs in the vehicle can lead to unauthorized use of the vehicle which could result in an accident or overturn Alwavs remove the kev when the vehicle is not in use 30 Hot Drive Svstems The motor and controller are verv hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot drive svstem components Alwavs keep combustible materials away from the drive system Operator Safetv Precautions During Maintenance WARNINGI The voltage in the batterv pack is sufficient to cause death bv electrocution With the exception of batterv inspections and refilling the water in flooded tvpe batteries never attempt to perform service on the electric drive svstem including the batterv pack unless vou are properly trained to work on electrical systems 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 SAFETY Always follow all safety instructions in the maintenance portion of this owner s manual as well as the following Make s
64. rantv No verification of registration will be sent to the purchaser as the copv of the Warrantv Registration Form will be the warrantv entitlement If vou have not signed the original registration and received the customer copv please contact vour dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 145 WARRANTV HOW TO OBTAIN WARRANTV 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 TRANS PORTATION 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 Should your dealer require any additional assistance they will contact the appropriate person at GEM This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS
65. rd configuration consists of six 12 volt batteries An optional configuration consists of nine 8 volt batteries See pages 118 119 for battery locations and access instructions 117 MAINTENANCE Batteries Batterv Locations Standard 12 Volt Batterv Configurations Model Quantitv Locations GEM e2 6 4 under bench seat 2 in rear spat GEM e4 6 4 under bench seat 2 in rear spat GEM e6 6 3 under bench seat 3 in rear spat GEM eS 6 4 under bench seat 2 in rear bed GEM e4 short bed option 6 4 under bench seat 2 in rear bed GEM 66 short bed option 6 3 under rear bench seat 3 in rear bed GEM eL 6 3 under bench seat 3 in rear bed GEM eL XD 6 3 under bench seat 3 in rear bed Optional 8 Volt Battery Configurations Model Quantity Locations GEM e6 9 3 under rear bench seat 3 under middle seat 3 in rear spat or bed GEM eL XD 9 6 under bench seat 3 in rear bed 118 MAINTENANCE Batteries Batterv Access Batteries located in the rear spat or rear bed can be accessed through the batterv access covers Remove the four cover screws to remove a cover Tip Remove anv rear accessorv options that mav 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 119 MAINTENANCE Batteries Batterv Inspections Maintenance Perform the following batterv inspections
66. re with low charge Fully charge batteries before storing In hot climates battery self discharge will increase In cold climates batteries could freeze if not properly charged If the vehicle will not be used for 10 or more days follow the battery storage procedures on page 128 49 FEATURES AND CONTROLS Console LCD Displav Indicators 4 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 batter ies and motor from damage If the state of charge is low and the current limiting indicator is illuminated stop the vehicle and recharge the batteries Seat Belt Warning When the key is turned on the seat belt warning illuminates for 45 seconds as a reminder for occupants to fasten seat belts 4 50 FEATURES AND CONTROLS Console LCD Displav Indicators R 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 Option ZO If the vehicle is equipped with this option either the high beam or low beam head light indicator illuminates to indica
67. rmance Tips New batteries will not perform to their fullest capacitv until thev have been dis charged 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 e Always maintain a full charge on the bat teries For best battery life avoid dis charging the batteries more than 80 See page 48 FEATURES AND CONTROLS Batteries should be at room temperature when recharging Do not charge batteries at temperatures of 110 F 43 C or higher In the first few years of life the batteries should provide a range of up to 30 miles 48 km at 72 F 22 C At 32 F 0 C range may be reduced to 12 15 miles 19 24 km Actual range my be affected by road conditions terrain weather and driving habits 59 FEATURES AND CONTROLS Batteries On Board Charger The on board batterv charger is located under the hood and can be Green Indicates viewed through the left front wheel well When batteries are 100 100 Charge 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 The on board battery charger will monitor the state of charge of the batteries and automatically initiate a charge cycle whenever battery voltage falls below a predetermined level The on board charger will maintain a full battery charge for up to
68. se fuses with the same type and rating NOTICE Do not plug in devices requiring power exceeding 25 watts Damage to the vehicle electrical system may occur or an accessory fuse may blow 87 OPERATION 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 Item Remarks Page Accelerator Ensure proper operation 55 Brake system pedal travel Ensure proper operation 100 Brake fluid Ensure proper level 100 Indicator lights switches Ensure operation 42 Headlamp Check operation 111 Brake light tail lamp Check operation 112 88 Pre Ride Inspection OPERATION Item Remarks Page Turn signals Ensure operation of all signal lamps 36 Mirrors Adjust mirrors for proper side and rear view Horn Ensure operation 35 Seat belts Check length of belt for damage check latches for proper 75 operation Steering Ensure free operation 103 Tires Check tire condition and pressure 106 107 Latches hood seat Ensure all latches are secure Batteries E
69. tain the fluid level between the batterv 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 Tip If the level is below the plates add just enough distilled water to cover the plates Fully charge the batteries then recheck the fluid level 122 MAINTENANCE Batteries Batterv Inspections Maintenance Check Batterv 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 Fill Well Cap Top of Battery Battery Plates Bottom of Fill Well 123 MAINTENANCE Batteries Batterv Inspections Maintenance Clean the Batteries NOTICE Do not allow cleaning solution or tap water to enter the batteries Before cleaning make sure all batterv fill well caps are installed securelv 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 Use an insulated wrench to tighten as needed
70. te which headlight beam is selected See page 83 f Service Required Indicator When the service indicator illuminates a service code displavs in the speedometer service code display See page 43 for common codes and descriptions 51 FEATURES AND CONTROLS Console Main Disconnect Switch WARNINGI The main disconnect switch will disable the vehicle bv disconnecting the batterv pack from the motor It does not disable the batterv pack HIGH VOLTAGE will be present at the batterv terminals HIGH BATTERV VOLTAGE IS ALWAVS PRESENT DO NOT TOUCH THE BATTERY TERMINALS The main disconnect switch is located inside the fuse access panel on the lower console The Access Panel FUSES Main Disconnect main disconnect switch must be turned on for Switch operation and for charging 52 FEATURES AND CONTROLS Console Main Disconnect Switch Move the switch to the left OFF to disconnect the batterv pack from the motor After the switch is turned off some power mav remain in the svstem until all capacitors have dis charged 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 Always turn off the main disconnect switch before servicing or unplugging any electrical components 53 FEATURES AND CONTROLS Brake Pedal
71. terminals HIGH BATTERY VOLTAGE IS ALWAYS PRESENT DO NOT TOUCH THE BATTERY TERMINALS 128 Batteries MAINTENANCE Batterv Care During Storage When the vehicle will not be used for a period of 10 days or longer check battery water lev els flooded type batteries and perform one of the battery storage procedures listed in the chart below Battery Storage Options Storage Period Charging Procedure Less than 10 days Fully charge the batteries park the vehicle and turn the ignition key off The battery will lose some of its charge during this period 10 days to 24 weeks Option 1 Leave the charger connected and the main disconnect switch ON only up to 24 weeks See page 60 Option 2 Disconnect the charger turn the main disconnect switch off and arrange for monthly charging Indefinitely or Unknown Disconnect the charger turn the main disconnect switch off and arrange for monthly charging 129 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 thev 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 cham 015 NOTICE very careful when cleaning the acrylic win
72. 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 Use a 24 volt charger to charge 8 volt batteries Charge in 3 groups each consisting of 3 sequentially wired batteries Tip It is not necessary to remove or disconnect battery post connections during the alternate charging method 65 FEATURES AND CONTROLS Batteries Alternate Batterv 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 dissi pate in a short period of time 5 After charging the last battery remove the off board charger leads turn the main discon nect switch on and plug the vehicle in 6 Ifthe on board charger does not recognize the residual charge and activate repeat the alternate charging method 66 FEATURES AND CONTROLS Batteries Batterv 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 disconne
73. unded 50 feet 15 25 m or shorter 14 gauge wire with 3 wire grounded 25 feet 7 6 m or shorter 62 FEATURES AND CONTROLS Batteries Batterv 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 continued on next page 1 Plug into vehicle 2 Plug into outlet FEATURES AND CONTROLS Batteries Batterv Charging Tip Alwavs use a 110 volt AC 15 amp breaker outlet A GFI Ground Fault Interrupt receptacle is rec ommended 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 When disconnecting the charger always disconnect the extension cord from the wall receptacle first then disconnect the cord from the vehicle 64 FEATURES AND CONTROLS Batteries Alternate Batterv Charging Method If the combined voltage of all batteries reaches 68 volts or less a safetv feature in the on board charger will not allow the charger
74. ure the vehicle is properly immobilized before beginning any maintenance Always block the chassis securely before work ing under the vehicle Turn the key off and remove it from the vehicle Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring Remove the batteries or cover the exposed ter minals with an insulating material FOR MORE INFORMATION ABOUT SAFETY PLEASE CONTACT GEM CUSTOMER SERVICE See page 5 31 FEATURES AND CONTROLS Console LCD Displav Instrument Pod Storage Trav Cup Holders Kev Switch Turn Signal Windshield Wiper Headight 1 Horn Lever Switch Direction Switch 32 FEATURES AND CONTROLS Console Headlight Switch Press the top of the headlight switch to turn the headlights and taillights on Press the bottom of the switch to turn the lights off Electrical Components Electrical wiring circuit boards and components are located under and behind the upper and lower console NOTICE Liquids can damage electrical components and the circuit board Handle liquids with care Do not spray water directly into the upper or lower console Electrical Access Panel Fuses Main Disconnect Switch 33 FEATURES AND CONTROLS Console Kev Switch When the key is turned to the ON position clockwise the display will Key Key light up and all electrical accessories c
75. urn 36 Turn Signal Light Front 111 Turn Signal Light Rear 112 V Vehicle Information Label 9 11 Warning Symbols 7 Washing Windshield Sunroof 130 Weight Capacity 22 23 Wheel Installation 110 Wheel Nut Torque 107 Wheel Removal 108 109 Windshield Washer 86 Windshield Wiper 37 2 Zero Speed Detection Feature 35 155
76. v varv Check with vour local law enforcement citv and state officials for variations in vour 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 Avoid sharp turns an inclines and at high speeds mav cause rollover Reduce speed on wet and slipperv surfaces and in turns Do not leave children unattended in vehicle Set handbrake before leaving the vehicle Remove kev when leaving vehicle unattended Stop vehicle before reversing direction Be aware of small children and objects behind vou before reversing direction ALWAYS DRIVE SAFELY FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN SERIOUS OR FATAL INJURY 13 SAFETV Safetv 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 oniv for protection against the elements Do not relv on the doors to contain occupants within the vehicle or to protect against injurv during an accident WEAR SEAT BELTS AT ALL TIMES 14 SAFETV Safetv Labels and Locations High Voltage Warning High voltage warning labels are located in two places on vour vehicle near the batterv com partment and under the hood near the motor controller WARNING e dia HIGH VOLTAGE Vou could be seriousiv or fatallv injured bv electric shock if vou att
77. when using the seat heater It may cause burns even at low temperatures especially if used for long periods of time Do not place anything on the seat that insulates against heat such as a blanket or cushion This may cause the seat heater to overheat The front seat heater switches are located on the lower console The rear switches are located directly below the rear of the front seat backrests For safety seat heaters automatically turn off after one hour 1 Turn the ignition key on 2 Press the heater switch once to select high heat 3 Each successive switch press selects the next lower heat level medium low and off respectively 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 The seat adjustment lever is directly under the front of the seat Move the adjustment lever to the left and slide the seat to the desired position Release the lever Make sure the seat latches securely in position Test the latch by attempting to slide the seat forward and rearward while seated Adjustment Lever 70

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