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2014 Owner`s Manual - GEM Electric Car Sales

1. 32 Operati Meese di Dua e c ca a a c il a me 86 Maintenance Loos disce ond ac ira amr dria 96 Specifications s suse eer rx Rr RE ee Rma 134 crc Meer Troc 140 Maintenance Log cassa RR E rk REEL ERA tee a mam d 150 NAEK A r 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 Low emission vehicles LEVs e RANGERQ utility vehicles RZR sport vehicles VICTORY motorcycles GEM electric vehicles WELCOME For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your 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 dea
2. 32 53 Customer Service 5 149 Defogger Heater Fan 84 Direction Switch 40 41 Dome Lights vere vere 68 nk tr Re 81 Driving in Reverse 90 Driving on Slippery Surfaces 91 Driving Procedure 88 89 E Electrical Components 33 E Meter ier areri rue 38 39 Equipment Modifications 24 F Fan Heater Defogger 84 Fluid Levels During Storage 131 Fluid Battery 119 121 Fluid Brake losses 98 99 Fuse Recommendations 103 Fuse Replacement 102 103 153 INDEX G Glove BOX eni nr stereo ea 35 Grab Handle Package 82 Gross Vehicle Weight Rating 22 23 H Hazard Signals 53 Headlight Beam Adjustment 111 112 Headlight Replacement 109 Headlight Switch 33 Heater Defogger Fan 84 eiA wA 35 K Key Switch sete tn 34 154 L LCD Display Indicators 42 51 Lights 109 112 Brake Lights 110 Dome Light eren 68 Front Turn Signal 109 Headlight Adjustment 111 112 Headlight Replacement 109 Rear Turn Signal 110 M Main Disconnect Switch 52 53 Maintenance Precautions 31 Maintenance Periodic 96 97 Manufacturer s Label 9 11 Modifications 24 Odometer 38 39 On Board Charg
3. 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 e2 eS 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 Always apply the brakes before setting or releasing the park brake The park brake is adjustable and should be checked periodically as outlined in the Periodic Maintenance Chart beginning on page 96 See your authorized GEM dealer for service 1 To set the park brake apply the brakes Pull the park brake lever upward as far as possi ble 2 To 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 Battery Pack 8 Volt Gel 12 Volt Gel Your vehicle is equipped with a battery pack con Battery Battery 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 pr
4. 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 Safety 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 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pres
5. Apply the brakes Turn the key on Turn the headlights to high beam Tip Include the weight of a rider on the seat while performing the following step 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall 5 Ifa headlight needs adjustment access the adjustment screw under the hood or through the wheel well 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted 112 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 related 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 113 MAINTENANCE Batteries AWARNING Improperly connecting or disconnecting battery cables can result in a
6. 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 126 49 FEATURES AND CONTROLS Console LCD Display 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 50 FEATURES AND CONTROLS Console LCD Display 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 ZO Either the high beam or low beam headlight indicator illuminates to indicate which E headlight beam is selected See page 33 Service Required Indicator YF When the service indicator illumina
7. 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 4411 Single speed On board charger Brakes 120 volt 15 amp 60 Hz AC input 72 100 volt 12 amp DC output Brake System 4 Wheel hydraulic brakes disc front drum rear Park Brake Console mounted lever activated mechanical park brake 135 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 Street rated 12 inch 165 70R 12 Options 12 inch aluminum turf 14 inch aluminum Tire pressure 12 inch 38 psi 262 kPa 14 inch 36 psi 248 kPa DEEST TEE Gauge LCD Display Auxiliary power 12 volt accessory outlet Seat belts Automotive style 3 point seat belts Direction switch High Low Reverse Headlights Hi Low Beam 35W 35W Taillights brake lights Halogen Horn Turn Signals Standard Hazard Signals Standard Mirrors Interior rear view mirror Exterior left and right side view mirrors 136 SPECIFICATIONS GEM eL GEM eL XD GEM e6 Curb Weight 1235 Ibs 560 kg 1550 Ibs 703 kg 1620 Ibs 735 kg Length 144 in 365 8 cm 144 in 365 8 cm 162 in 411 5 cm
8. 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 Pullthe seat belt latch downward and across your chest toward the buckle at the inner edge of the seat Slide the buckle up the webbing as far as needed for the belt to reach across your hips 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 slightly longer To release the seat belt press the square red button in the buckle s center If necessary slide the buckle down the webbing to allow it to retract fully 73 FEATURES AND CONTROLS Seat Belts Seat Belt Safety 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
9. 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 7 Remove the wheel 107 MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your authorized GEM dealer for service 1 Set the park brake 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion 3 Attach the wheel nuts and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 105 108 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp wit
10. 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 Left Turn sound 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 momentarily if equipped see page 85 Pull the lever toward the steering wheel to turn the wiper off If the wiper fails to work check for a blown fuse at the fuse block See page 102 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 meters per hour km h and miles to kilometers Toggle between odometer trip meter and e meter to display accumulated po
11. h When LOW mode is selected the rate of acceleration is also limited Reverse A reverse warning alert will automatically sound when the key is on and reverse mode is selected Vehicle speed is limited when operating in reverse See page 90 for safe reverse operation procedures 41 FEATURES AND CONTROLS Console LCD Display Indicators Left Turn Speedometer Service Code Charge Display Brake Warning a i ox Tur High Motor BRAKE i1 Temperature D Li imn Odometer Trip Meter Oe 101102102 11 km TRIP Mies Service Charger Connected Required sl State of Charge xe High Beam Battery Discharge Headlight Current Limiting Mode z3 Low Beam R DL DH 20 Headlight Seat Belt Warning Reverse Drive Low Drive High Selected Selected Selected 42 FEATURES AND CONTROLS Console LCD Display Indicators Speedometer Service Code Charge Display Indicator 7 4 When driving the speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h The display can be changed to display either standard or metric units of measurement See page 38 When the batteries are charging this area displays the percent of charge When the service indicator illuminates a service code displays in this area m 74 Charge 43 FEATURES AND CONTROLS Console LCD Display Indicators Speedometer Service Code Charge Display Indicator Common service cod
12. 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 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
13. 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 127 MAINTENANCE Cleaning and Storage Cleaning the Windshield and Sunroof We recommend using GEM Windshield Cleaner and Protectant to remove normal dust and dirt A liquid household glass cleaner can also be used Do not use abrasive cleaners on the windshield and sunroof as they will cause scratches To remove oil grease or road tar use isopropyl alcohol then wash the windows with water Dry gently with a soft cloth or cham ois NOTICE Be very careful when cleaning the acrylic windows 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 128 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 remov
14. 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 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 Pulleach 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 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 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 detailed op
15. strap Oo LI OON tA 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 Rugged Bumpers Option Front bumpers are for appearance only and will protect the body panels only from minor dents and scratches They will not provide protection to the vehicle in front collisions NOTICE Never use your GEM vehicle for pushing Damage to the vehicle may result 80 FEATURES AND CONTROLS Doors WARNING Doors do not offer structural protection in the event of an accident and do not change the open body characteristics of the vehicle The doors provide protection from the weather only Always use seat belts Failure to use the seat belts puts the driver and passengers at greater risk of serious injury or death in the event of an accident Soft Doors Accessory 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 posi tion using the straps and snaps located on the pillars or do
16. use of unauthorized parts This warranty excludes damages or failures resulting from improper lubrication corrosion surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 142 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse accident fire explosion or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs Sealed beam lamps Painted or otherwise finished surfaces Upholstery Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Electronic components 143 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDI
17. 118 Wheels fasteners Inspect ensure fastener tightness 105 87 OPERATION Driving Procedure 88 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 key 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 Drive slowly Practice maneuvering and using the accelerator and brakes on level sur faces OPERATION Driving Procedure 11 Before turning activate a turn signal to alert others of your intentions See page 36 12 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Allow a passenger to ride only in a designated passenger seat with seat belt secured 13 To stop the vehicle release the accelerator pedal completely and brake to a complete stop NOTICE Always bring the vehicle to a complete stop before changing the position of the direction Switch 14 Set the 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 1
18. 2014 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death The following are registered trademarks of POLARIS Industries Inc POLARIS VICTORY Global Electric Motorcars RANGER GEM Road America is a trademark of Brickell Financial Services Motor Club Inc Global Electric Motorcars is a division of POLARIS Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of produc tion 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 liabil ity can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2014 GEM Owner s Manual P N 9924946 2 TABLE OF CONTENTS MEC vr nk eae ee 6 Safety P C P 12 Features and
19. 5 of the cost of an approved GEM battery at a GEM dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to GEM within three days Upon receipt of this registration GEM will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH GEM 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 141 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed or for any damages which occur during trailer transit or as a result of unauthorized service or the
20. 6 Recharge the batteries daily or after each use of the vehicle 89 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 Ou PWN Never accelerate suddenly 90 OPERATION Driving On Slippery 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 Turn in direction such as wet or icy pavement or loose skid of skid gravel follow these precautions D Os PA NA 1 Do not operate on excessively slip ES S S pery surfaces Coec5 A 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 91 OPERATION Parking the Vehicle 1 2 92 Apply the brakes Stop the vehicle on a level surface When parking inside a garage or other structure be sure that the s
21. 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 injury or death Special precautions must be followed when owning and operating a battery powered vehicle This vehicle is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Readthis 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 private 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 your vehicle s identification numbers and key number in the spaces provided on pa
22. ES The battery coverage included in this warranty provides no coverage for Batteries that fail due to lack of battery maintenance over charging under charging abuse or neglect Batteries that fail due to fire wreckage explosion or freezing Broken batteries Batteries damaged 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 This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time 144 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES The exclusive remedy for breach of this warranty shall be at Polaris s sole 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 POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OTHER TORT OR OTHER WISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND
23. RES AND CONTROLS Console LCD Display Indicators High Motor Temperature Warning Indicator If the motor temperature warning illuminates or if service code 41 displays in the speedometer service code display the motor or motor controller may be 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 Display 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 display can be changed to display either standard or metric units of measurement See page 38 Charger Connected Indicator This indicator illuminates approximately 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 may not be charging If this occurs make sure the main disconnect switch is in the ON position See pages 61 65 for more information about charging the batteries 47 FEATURES AND CONTROLS C
24. SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIM ITED TO THE IMIPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE 2YEAR OR 8 000 MILE WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT INCLUDED IN THIS WARRANTY STATEMENT SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAM AGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 145 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a GEM Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any GEM Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized GEM dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any a
25. TURES AND CONTROLS Batteries Alternate Battery Charging Method 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 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 Battery Charging Method 1 Turn the main disconnect switch off 2 Set the battery charger to the medium amp setting 10 to 30 amps 3 Charge each battery for 10 20 minutes 4 Move quickly from battery to battery as this is only a residual charge and it will 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 If the on board charger does not recognize the residual charge and activate repeat the alternate charging method 66 FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING Do not work in or near the battery compartment or on a
26. URE TO FOLLOW THESE WARNINGS COULD RESULT IN SERIOUS OR FATAL INJURY 13 SAFETY Safety Labels and Locations Door Seat Belt Warning This label is located near the lower edge of the window on the driver s side door on models equipped with doors WARNING The doors on this vehicle are designed only for protection against the elements Do not rely on the doors to contain occupants within the vehicle or to protect against injury during an accident WEAR SEAT BELTS AT ALL TIMES 14 SAFETY Safety Labels and Locations High Voltage Warning High voltage warning labels are located in two places on your vehicle near the battery com partment and under the hood near the motor controller WARNING e dia HIGH VOLTAGE You could be seriously or fatally injured by electric shock if you attempt to open repair test inspect or adjust Only qualified technicians should open and service Consult service manual SAFETY Safety Labels and Locations Cargo Warning Cargo warning labels are located in the beds of the following models WARNING GEM eS Maximum cargo capacity of this bed should never exceed 330 Ibs 149 7 kg Distribute weight equally over axle No passengers permitted Abuse or noncompliance will void warranty GEM e4S Maximum cargo capacity of this bed should never exceed 250 Ibs 113 4 kg Distribute weight equally over axle No passengers permitted Abuse or noncompliance will void warranty GEM e6 S Maximum car
27. Width 55 in 139 7 cm 55 in 139 7 cm 55 in 139 7 cm Height 70 in 177 8 cm 70 in 177 8 cm 70 in 177 8 cm Wheelbase 114 in 289 6 cm 114 in 289 6 cm 133 in 337 8 cm Turning Circle Radius Payload Capacity occupants cargo options 17 feet 5 2 m 17 feet 5 2 m Load Capacity 1065 Ibs 483 kg 1450 Ibs 657 7 kg 19 feet 5 8 m 1380 Ibs 626 kg Gross Vehicle Weight Rating GVWR page 22 2300 Ibs 1043 kg 3000 165 1360 8 kg 3000 165 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 2 2 6 Seating 137 SPECIFICATIONS GEM eL GEM eL XD GEM e6 Performance Motor 5 HP 7 HP optional 7 HP vented shunt DC electric shunt DC electric Motor peak 23 HP Peak 17kw Controller Flight Systems T4 350 amp DC Controller Battery pack Six 12 volt flooded lead Nine 8 volt gel batteries Nine 8 volt gel batteries acid batteries e69 w S option 12 volt gel optional Maximum speed 25 MPH 40 km h Range 30 miles 48 3 km will vary with conditions Drive System 12 4411 Single speed On board charger 120 volt 15 amp 60 Hz AC input 72 100 volt 12 amp DC output Brake System Brakes 4 Wheel hydraulic brakes disc front drum rear Park Brake Console mounted lever activated mechanical p
28. ailure 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 Safety Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual SAFETY 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 SAFETY Operator Safety Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have your authorized GEM dealer inspect the entire machine for possible damage including but not limited to brakes accelerator steering system and electrical system Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control
29. ark brake 138 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 Street rated 12 inch 165 70R 12 Options 12 inch aluminum turf 14 inch aluminum Tire pressure 12 inch 46 psi 317 kPa 14 inch 36 psi 248 kPa Gauge LCD Display Auxiliary power 12 volt accessory outlet Seat belts Automotive style 3 point seat belts Direction switch High Low Reverse Headlights Hi Low Beam 35W 35W Taillights brake lights Halogen Horn Turn Signals Standard Hazard Signals Standard Mirrors Interior rear view mirror Exterior left and right side view mirrors 139 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR or 8 000 MILE 12 900 km whichever comes first LIMITED WARRANTY on all components except batteries of your GEM vehicle against defects in material or workmanship Mileage is unlimited for the first 6 months of the vehicle warranty Any time after month 6 the vehicle warranty expires at 8 000 miles 12 900 km or at the end of the two year period whichever comes first This warranty covers the parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another consumer during the warranty period th
30. battery compartment for any signs of worn insulation frayed cables or damaged cable ends If found see your 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 123 MAINTENANCE Batteries Battery Replacement With proper care and maintenance battery life could be extended up to four years or longer depending on the amount of use When battery replacement is necessary please see your authorized GEM dealer NOTICE Always install batteries of the exact type and make originally supplied with the vehicle to prevent damage to the vehicle s electrical system WARNING Handling batteries and electrical components improperly can result in serious injury or death 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 re
31. ble the battery pack HIGH VOLTAGE will be present at the battery terminals HIGH BATTERY VOLTAGE IS ALWAYS PRESENT DO NOT TOUCH THE BATTERY TERMINALS 118 MAINTENANCE Batteries Battery Inspections Maintenance Check Battery Fluid Flooded Batteries Gel batteries are maintenance free batteries They do not have fill wells On flooded batter les 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 119 MAINTENANCE Batteries Battery Inspections Maintenance Check Battery Fluid Flooded Batteries Maintain the fluid level between the battery plates and the bottom of the fill well Do not overfill WARNING The fluid in an overfilled battery may boil over and cause electrolyte to spill Inspect the fluid level of each battery 1 Remove one of the fill well caps Tip The battery plates should be visible when looking into the fill well Use a flashlight if necessary 2 View the fluid level 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 l
32. 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 types 12 gauge wire with 3 wire grounded 50 feet 15 25 m or shorter 14 gauge wire with 3 wire grounded 25 feet 7 6 m or shorter 62 FEATURES AND CONTROLS Batteries Battery Charging Always follow these precautions when charging Position the vehicle on a level surface Make sure the charging area is well ventilated Make sure the key is off Always use the recommended extension cord type Inspect the extension cord for cracks loose connections and frayed wiring Never use a damaged extension cord Always connect the charging cord to the vehicle s charge receptacle first then plug the cord into a wall receptacle continued on next page 1 Plug into vehicle 2 Plug into outlet 63 FEATURES AND CONTROLS Batteries Battery Charging Tip Always 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 FEA
33. e 105 Wheel Removal 106 107 Windshield Washer 85 Windshield Wiper 37 2 Zero Speed Detection Feature 35 155 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 9924946 Rev 01 Printed in USA
34. e 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 129 MAINTENANCE Cleaning and Storage Cleaning the Exterior The best way to preserve your vehicle s finish is to wash the vehicle regularly Use GEM Fiberglass Plastic and Rubber Restorer or mild liquid detergents Do not use strong soaps or chemical detergents Rinse promptly Dry the finish with a soft clean chamois or towel to avoid surface scratches and water spotting Tip To prevent spotting avoid washing the vehicle in direct sunlight Protection From the Elements Prolonged exposure to sunlight may 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 130 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 th
35. e vehicle as recommended in the Periodic Main tenance Chart beginning on page 96 Check Fluid Levels Inspect the fluid levels Add or change fluids as recommended Change brake fluid every two years and any time the fluid looks dark or contaminated 131 MAINTENANCE Cleaning and Storage Storing the Vehicle Any time the vehicle will be parked for more than 10 days follow the recommended storage procedures 1 Make any necessary repairs and clean the vehicle See page 128 2 Clean the batteries See page 122 3 Prepare the batteries for storage See page 126 NOTICE Batteries can be permanently damaged and the warranty voided if allowed to remain 30 days or more with low charge Fully charge batteries before storing 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 5 Besure the storage area is well ventilated 6 Turn the key off 132 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 Ifthe vehicle is not connected to the charger turn off the main disconnect switch Cover the vehicle with a genuine GEM vehicle cover Do not use plastic or coated materials They do not allow enough
36. egister your product under your name and address with a local GEM dealer in your country to ensure that you receive safety information and notices regarding your product 147 WARRANTY Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products 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 Bulletins Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the app
37. er 60 Operator Safety 17 31 P Park Brake Lever 56 57 Parking an Incline 93 Parking the Vehicle 92 Periodic Maintenance Chart 96 97 Pre Ride Inspection 86 87 R Rear Accessory Backs 77 79 Removing Vehicle from Storage 133 Reverse Operaton 90 Roadside Assistance 149 S Safety Labels 12 16 Safety 5 7 Seat Adjustment 70 Seat Belt Inspection 75 Seat Belt Safety Tips 74 Seat Belt Proper Use 72 73 Seat 71 75 S Seat Removal Bench 70 Signal 7 State of Charge Indicator 48 49 Steering Column Lock 83 Steering Column Adjustable Tilt 84 Steering Wheel Inspection 101 Stereo System cisco ce emnes 76 Stordge eene era msns 128 133 Storage Tips 131 Storage Removal 133 Storing the Vehicle 132 133 Switches Direction Switch 40 41 Headlight Switch 33 Key Switch oessa rsa saes 34 Main Disconnect Switch 52 53 Wheel Installation Wheel Nut Torque Wheel Removal Transporting the Vehicle Turn Signal Light Replacement INDEX Warning Symbols 7 Washing Windshield amp Sunroof 128 Weight Capacity 22 23 Wheel Installation 108 Wheel Nut Torqu
38. erating instructions 76 FEATURES AND CONTROLS Rear Accessory Backs Option Rear accessory back options are available These rear accessory backs are interchangeable Trunk Cover Lock Latch Release Handle TrunkBack LinksBack Clip In StakeBack 77 FEATURES AND CONTROLS Rear Accessory Backs Option WARNING Never carry a passenger on a rear accessory back Do not overload an accessory back Overloading the vehicle can reduce stability and handling and could cause loss of control Never exceed the GVWR or the GAWR See page 22 NOTICE Use only GEM approved rear accessories Others may cause damage to the locking system or vehicle and will void warranty 1 Remove the contents of the installed rear accessory back 2 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 Usethe ignition key to unlock the latch release handle Tip There is a separate key for the TrunkBack cover lock 78 FEATURES AND CONTROLS Rear Accessory 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
39. es are detailed below Code Condition Remedy 06 Accelerator pedal is depressed Release pedal apply 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 Display Indicators a Turn Indicators The corresponding turn signal indicator flashes when a signal is activated D 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 Item Solution Park brake Release the park brake Brake fluid level If low add brake fluid See page 98 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 worn or damaged brake hoses replaced promptly 45 FEATU
40. evel 120 MAINTENANCE Batteries Battery Inspections Maintenance Check Battery Fluid Flooded Batteries 3 Maintain the fluid level between the battery plates and the bottom of the fill well Add distilled water as needed Do not overfill Reinstall the fill well cap securely Fill Well Cap Top of Battery Battery Plates Bottom of Fill Well 121 MAINTENANCE Batteries Battery Inspections Maintenance Clean the Batteries NOTICE Do not allow cleaning solution or tap water to enter the batteries Before cleaning make sure all battery fill well caps are installed securely 1 Remove corrosion with a stiff wire brush 2 Wash the terminals and tops of the batteries with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels 3 Make sure battery terminals are tight Use an insulated wrench to tighten as needed 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 122 MAINTENANCE Batteries Battery Inspections Maintenance Check Battery Connections WARNING Improper handling of high voltage wiring batteries or control systems could result in serious injury or death by electric shock Only qualified technicians should repair or access high voltage wiring battery packs and associated systems Check Battery Cables and Wiring Check the
41. f by pressing the switch on the side of the light The dome light is powered by four AA batteries To replace the batteries remove the light cover and install the new batteries Instructions are located inside the battery compartment Dome Light Switch 68 FEATURES AND CONTROLS Accessory Outlet The optional accessory outlet is located on the lower console to the right of the fuse access panel This outlet will accept a standard automotive 12 volt accessory and is intended for moderately powered accessories such as a cellular phone It will not operate large current items such as cigarette lighters Accessory Outlet The fuse for the power outlet plug is located in the fuse block under the access panel in the center of the lower console Always use 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 69 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
42. ge 11 The Vehicle Identification Number VIN is on the manufacturer s label located on the left rear section of the roof panel The VIN indicates the model year model type and serial num ber of your vehicle The manufacturer s label also contains the Gross Vehicle Weight Rating GVWR and Gross Axle Weight Rating GAWR information for your vehicle Never exceed the GVWR or the GAWR See page 22 To order an extra or replacement key for your vehicle please contact GEM customer service See page 5 Be prepared to provide your key number and VIN INTRODUCTION Manufacturer s Label Vehicle Information Label Date of Tire Wheel Information Manufacture Manufacturer s GAWR Information Label POLARIS INDUSTRIES INC il Em TTE EU Label TENES AUTONONLES DY CANADA EN VIGUEUR NA DATE DE FABRICATION USA Label Information 10 INTRODUCTION Manufacturer s Label Vehicle Information Label Vehicle Identification Number VIN a ee i EGRE Vehicle Model Number Motor Serial Number on case of motor Key Number stamped on key Optional Rear Accessory stamped on key Date Purchased SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your veh
43. go capacity of this bed should never exceed 440 Ibs 199 6 kg Distribute weight equally over axle No passengers permitted Abuse or noncompliance will void warranty GEM 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 GEM 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 SAFETY Operator Safety 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 e 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 Never permit a guest to operate this vehi GEM 91 t occupants cle unless the guest has read this manual GEM eS 2 occupants and all product labels GEM eL 2 occupants GEM eL XD 2 occupants GEM e6 6 occupants 17 SAFETY Operator Safety Never exceed the gross vehicle we
44. h bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Replacement If a headlight fails to work properly an expired lamp may need replacement 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 109 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 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 110 MAINTENANCE Lights 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 m 111 MAINTENANCE Lights Headlight Beam Adjustment 3
45. ht rating of your vehicle can reduce stability and handling and could cause loss of control NEVER exceed the GVWR of your vehicle The maximum payload capacity of your vehicle is the maximum weight you may add to your vehicle without exceeding the GVWR This capacity is determined by calculating the difference between your vehicle s GVWR and wet weight Refer to the specification section of this manual or the Manufacturer s Label on the vehicle for model specific information 22 SAFETY Operator Safety Gross Vehicle Weight Rating GVWR When determining the weight you will be adding to your vehicle and to ensure you do not exceed the maximum payload capacity include the following operator body weight passenger body weight weight of all occupants apparel and items in or on apparel weight of any options or accessories and their contents weight of any additional cargo on the vehicle 23 SAFETY Operator Safety Equipment Modifications Never install any equipment or make vehicle modifications to increase the speed or power of the vehicle Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your vehicle is termi nated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blade
46. icle 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 y J P Net 12 SAFETY Safety Labels and Locations General Warning Although most states prohibit this vehicle from operating on streets having posted speed limits of more than 35 MPH 56 km h state and local rules may vary Check with your local law enforcement city and state officials for variations in your area Never exceed the passenger and cargo limits of this vehicle Do not start or operate vehicle until all occupants are seated with seat belts fastened Avoid sharp turns an inclines and at high speeds may cause rollover Reduce speed on wet and slippery surfaces and in turns Do not leave children unattended in vehicle Set handbrake before leaving the vehicle Remove key when leaving vehicle unattended Stop vehicle before reversing direction Be aware of small children and objects behind you before reversing direction ALWAYS DRIVE SAFELY FAIL
47. ight 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 or improper installation or use of accesso people behind your vehicle when operat PO ing in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse 18 SAFETY Operator Safety 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 SAFETY Operator Safety Do notcarry a passenger until you have at least two hours of driving experience with this vehicle Always kee
48. ituation requiring caution espe cially if your vehicle becomes disabled on or near a road Press the switch again to cancel the hazard signals Hazard Switch 53 FEATURES AND CONTROLS Brake Pedal The brake pedal is located on the floor to the left of the accelerator pedal Push the brake pedal toward the floor to slow or stop the vehicle Apply the brakes before turning the key on WARNING Constant brake use riding the brakes can cause brakes to overheat and fail which could lead to an accident resulting in serious injury or death Do not drive with your foot resting or riding on the brake pedal 54 Brake Pedal Accelerator Pedal FEATURES AND CONTROLS Accelerator Pedal The accelerator pedal is located on the floor to the right of the brake pedal To begin moving or to increase vehicle speed gradually push the accelerator pedal toward the floor Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed The accelerator pedal will function only if the key is on To slow the vehicle release the accelerator pedal Electric motor braking provides braking when the pedal is released 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
49. l fuse used for accessory 30 amp T ix Turn Signals Brake Lamps 10A 10A Windshield Wiper Accessories Radio PA Accessories 10A 10A Radio 10 amp Display Odometer Switch Tail Lamp Headlamps Horn License Plate 1A 1A Lam p Radio Display Heater 10 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 103 MAINTENANCE Tires AWARNING 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 see the manufacturer s label on your vehicle or the specifications section beginning on page 134 NOTICE After inspecting or adjusting the ti
50. lated service 124 MAINTENANCE Batteries Battery Disposal Lead acid batteries are recyclable Return whole scrap batteries to a distributor manufac turer or lead smelter for recycling 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 5 125 MAINTENANCE Batteries Battery Care During Storage WARNING Always turn off the main disconnect switch before servicing or unplugging any electrical components See page 52 The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor It does not disable the battery pack HIGH VOLTAGE will be present at the battery terminals HIGH BATTERY VOLTAGE IS ALWAYS PRESENT DO NOT TOUCH THE BATTERY TERMINALS 126 Batteries MAINTENANCE Battery 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
51. ler 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 4 four passenger GEM eS two passenger short bed GEM eL two passenger long bed GEM eL XD two passenger extra duty long bed GEM e6 six passenger INTRODUCTION Safety Signal Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A NOTICE The safety alert symbol indicates a potential sell ao asituation that may resultin personal injury hazard WARNING The Prohibition Safety 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
52. lt 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 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 Heater Defogger Fan or Fan Only Options 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 HEAT position then adjust airflow to the windshield as needed using the deflectors located on the top of the console Move the switch to the FAN position to operate air flow without heat Deflector gt 84 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 momentarily Check the washer reservoir fluid level frequently When the level is low remove the cap and add windshield antifreeze not radiator antifreeze rated for 25 F 31 C Operate the system for a few seconds to flush out any residual water WARNING Commercial windshield washer solvents are flammable Kee
53. n 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 114 MAINTENANCE Batteries Battery Configurations NOTICE Before removing the seat to access the batteries make sure any wire or metal items including seat belt latches remain clear of the battery compartment to avoid causing a Short circuit to the electrical system Two battery pack configurations exist for GEM vehicles The standard configuration consists of six 12 volt batteries An optional configuration consists of nine 8 volt batteries See pages 116 117 for battery locations and access instructions 115 MAINTENANCE Batteries Battery Locations Standard 12 Volt Battery Configurations GEM e4 short bed option 4 under bench seat 2 in rear bed GEM eL Model Quantity Locations GEM e2 6 4 under bench seat 2 in rear spat GEM e4 6 4 under bench sea
54. nd replace parts as necessary When inspection reveals the need for replacement parts always use genuine GEM parts available from your autho rized GEM dealer Record maintenance and service in the Maintenance Log beginning on page 150 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 96 MAINTENANCE Periodic Maintenance Chart Check steering wheel freeplay Monthly Maintenance See Page Check battery fluid level flooded only 119 Wash tops and terminals of batteries and allow to dry 122 Check cables and terminal connections 123 Check for worn insulation or frayed wires 123 Check battery hold down bar to ensure batteries are tightly secured 123 Check tires for correct air pressure and wear 104 Check brake fluid reservoir for proper brake fluid level 98 Check brake lines for leaks Check seat belts for proper operation 75 Check headlights horn turn signals windshield wiper and brake lights for proper s operation 101 97 MAINTENANCE Brakes Brake Fluid Inspect the brake system routinely Inspect the brake fluid level before each operation If the level drops between fluid checks add brake fluid as needed See your authorized GEM dealer for service WARNING After opening a bottle of brake fluid always discard any unused po
55. ntenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 150 MAINTENANCE 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 69 B Batteries 58 68 113 127 PROCESS ie suem rne pda 117 Battery Pack 58 Care During Storage 126 127 Chatglng 61 64 Charging Alternate Method 65 66 122 Configurations 115 Disposal ssepe n 125 119 121 Handling Precautions 67 68 Inspections 118 123 Locations oeste 116 Monthly Maintenance 118 123 On Board Charger 60 Performance Tips 59 Replacement 124 B Battery Discharge Indicator 48 49 Brake Lever Park 56 57 Brake Lights cese 110 Brake Pedal ees 54 Brakes cer yen 98 100 Brake Fluid 98 99 Brake Inspection 100 Bumpers Optional 80 C Cargo Carrier Enclosed 82 Cleaning Extenot oes rers 130 Inte fiot acd etr thee 129 nio RTL 129 Windshield and Sunroof 128 Cleaning and Storage 128 133 Console
56. ny 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 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 a 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 Battery Handling Precautions Never connect jumper cables to any of the batteries of this vehicle Always wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and gloves when working with or around batteries and electrical 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 122 Dome Light Turn the dome light on or of
57. ogrammed 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 Battery Performance Tips New batteries will not perform to their fullest capacity until they 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 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 battery 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 monit
58. onsole LCD Display Indicators State of Charge Battery Discharge Indicator BDI This indicator contains 8 green bars a yellow bar and a red bar It shows available battery capacity by illuminating one or more bars The indicator illuminates when the key is turned on It also 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 ey 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 Display Indicators FEATURES AND CONTROLS State of Charge Battery Discharge Indicator BDI State of Charge Battery Discharge Indicator Bars Color 96 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 more with low charge Fully charge batteries before storing
59. or sup ports Framed Canvas Doors Option To open the doors from outside the vehicle 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 position 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 P Enclosed Cargo Carrier Option To open the cargo carrier door insert the key and turn the lock e Pull the handle outward and rotate it to open the door Reverse the process to close and lock the door 82 FEATURES AND CONTROLS Steering Column Lock Option To lock the steering column insert the key into the steering column lock and turn it clockwise while turning the steering wheel The wheel may need to turn up to one full revolution When you feel the lock engage remove the key WARNING Do not leave the key in the column lock while driving as the lock may inadvertently activate and cause loss of steering control which could resu
60. or 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 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 Battery Charging WARNING Using a non recommended extension cord could result in fire heat damage or charger failure which could result in serious injury or death Always use the recommended type of cord to charge the batteries Tip Do not use a ground fault interrupt GFI type cord on a GFCI protected outlet 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 Battery Charging The battery
61. p 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 Safety Never operate on excessively rough slip pery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized GEM dealer if it has been involved in an accident SAFETY 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 operate this vehicle on steep hills 21 SAFETY Operator Safety Gross Vehicle Weight Rating GVWR WARNING Exceeding the gross vehicle weig
62. p sparks flames and cigarettes away Handle with caution 85 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 98 Brake fluid Ensure proper level 98 Indicator lights switches Ensure operation 42 Headlamp Check operation 109 Brake light tail lamp Check operation 110 86 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 101 Tires Check tire condition and pressure 104 105 Latches hood seat Ensure all latches are secure Batteries Ensure full charges proper water levels clean terminals 113 126 Battery cables Inspect for proper cable routing secure connections
63. 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 away the electric motor will resist vehicle motion if the accelerator pedal is released while the key is on and the vehicle is moving Horn Press the turn signal wand inward toward the instrument pod to sound the horn 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 activate a turn signal before turning to alert others of your intentions Tip The key must be in the ON position to
64. re pressure always reinstall the valve stem cap if equipped This will prevent moisture and dirt from entering the valve stem which could cause damage 104 MAINTENANCE Tires Tire Tread Depth 1 8 3 mm v Any accelerated wear of tires may be an indicator of improper alignment or poor driving habits See your authorized GEM dealer for service Always replace tires when tread depth is worn to 1 8 3 mm or less Wheel Nut Torque Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut 14 inch Aluminum 12 inch Turf 12 inch Steel 95 ft Ibs 128 Nm accessory 65 ft los 88 Nm 95 ft Ibs 128 Nm 105 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 Position the vehicle on a dry firm level surface 2 Setthe park brake 3 Turn the key off Frame viewed from bottom Jack Points 106 MAINTENANCE Tires Wheel Removal 4 Block both the front and rear of the tire that is located diagonally opposite the jacking position For example if the right front tire is being changed block the left rear wheel 5
65. ront sub frame and the rear axle of the GEM vehicle Never place tie straps across any plastic body or floor panel components continued on next page 94 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 Always 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 95 MAINTENANCE Periodic Maintenance Chart WARNING Always wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and gloves when working with or around batteries and electrical connectors Always use insulated tools when working with or near batteries Failure to follow these instructions could result in serious injury or death NOTICE Damage to electrical connections and components will occur if they are unplugged before the main disconnect switch is turned off Always turn off the main disconnect switch before servicing or unplugging any electrical components Careful periodic maintenance will help keep your vehicle in the safest most reliable condi tion Inspect clean lubricate adjust a
66. ropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect 148 WARRANTY GEM Customer Service Phone 855 RIDEGEM 855 743 3436 Web www gemcar com Roadside Assistance Emergency Roadside Assistance is available to you 24 hours a day 365 days a year throughout the United States and Canada during the term of the manufacturer s warranty This service is available through ROAD It includes towing for up to 50 miles from your vehicle s location and other benefits Some limitations and exclusions apply Please call 800 442 4690 to get more information or to request assistance When calling please refer to the last 8 digits of your VIN when ROAD AMERICA asks for your contract number AII of the emergency roadside assistance services are provided by Brickell Financial Services Motor Club Inc d b a Road America Motor Club administrative offices at 7300 Corporate Center Drive Suite 601 Miami Florida 33126 For Mississippi and Wisconsin customers services are provided by Brickell Financial Services Motor Club Inc For California customers services are provided by Road America Motor Club Inc d b a Road America Motor Club 149 MAINTENANCE LOG Use the following chart to record periodic mai
67. rough a GEM dealer but any such transfer will not extend the original term of either warranty The duration of this warranty and or the battery warranty may vary by international region based upon local laws and regulations BATTERY COVERAGE Battery coverage in this Limited Warranty begins on the date of purchase by the original retail purchaser and continues for twenty four months or 8 000 miles 12 900 km whichever comes first Mileage is unlimited for the first 6 months of the battery warranty Any time after month 6 the battery warranty expires at 8 000 miles 12 900 km or at the end of the two year period whichever comes first During this time period Polaris warrants your vehicle s batteries against defects in materials or workmanship After the first six months in service a defective battery will be replaced on a manufacturer customer shared basis provided that the warranty limit of 8 000 miles 12 900 km has not yet occurred Review the following table for guidelines 140 WARRANTY BATTERY COVERAGE TERM FOR VEHICLES WITH LESS WARRANTY COVERAGE THAN 8 000 MILES 12 900 km FOR BATTERIES 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 2
68. rtion 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 DOT4 brake fluid 98 MAINTENANCE Brakes Brake Fluid Minimum Maximum 1 Position the vehicle on a level surface 2 Open the hood The brake fluid reservoir is located on the driver s side of the vehicle above and to the rear of the front tire 3 View the brake fluid level in the reservoir The level 4 5 should be between the upper MAX and lower MIN level lines If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 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 99 MAINTENANCE Brakes Brake Inspection The front and rear brakes are hydraulic disc type brakes 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and loo
69. s 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 Safety SAFETY Failure to operate this vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions 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 29 SAFETY Operator Safety 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 read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle 26 Ventilation When Charging Batteries F
70. se ness 4 Inspect the brake disc spline and pad wear surface for excessive wear 5 Change pads when worn to 3 64 1 mm 100 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay 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 101 MAINTENANCE Fuse Replacement NOTICE Always turn off the main disconnect switch before servicing or unplugging any electrical components See page 52 If you experience electrical failures not related to the batteries a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse See your m authorized GEM dealer if you suspect a 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 102 MAINTENANCE Fuse Replacement Fuse Label Fuse Recommendations Tum Signals Hope Fuse Application Fuse Size 10A 10A Heater Coi
71. sure as described in the owner s manual and on safety labels Unauthorized Use of the Vehicle Leaving the keys in the vehicle can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the key when the vehicle is not in use 30 Hot Drive Systems The motor and controller are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot drive System components Always keep combustible materials away from the drive system Operator Safety Precautions During Maintenance WARNING The voltage in the battery pack is sufficient to cause death by electrocution With the exception of battery inspections and refilling the water in flooded type batteries never attempt to perform service on the electric drive system including the battery pack unless you are properly trained to work on electrical systems 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 sure the vehicle is properly immobilized before beginning any maintenance Always block the chassis securely before work ing under the vehicle Turn the ke
72. t 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 6 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 116 Batteries Battery Access Batteries located in the rear spat or rear bed can be accessed through the battery access covers Remove the four cover screws to remove a cover Tip Remove any rear accessory options that may obstruct the rear spat access cover Batteries located under a middle seat optional configuration can be accessed through the panel on the front of the pedestal MAINTENANCE Spat Access Cover 117 MAINTENANCE Batteries Battery Inspections Maintenance Perform the following battery inspections and maintenance procedures monthly as outlined in the Periodic Maintenance Chart beginning on page 96 Perform these operations more often for vehicles subjected to heavy use WARNING Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries Always turn off the main disconnect switch before servicing or unplugging any electrical components See page 52 The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor It does not disa
73. tes a service code displays in the speedometer service code display See page 43 for common codes and descriptions 51 FEATURES AND CONTROLS Console Main Disconnect Switch WARNING The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor It does not disable the battery pack HIGH VOLTAGE will be present at the battery terminals HIGH BATTERY VOLTAGE IS ALWAYS PRESENT DO NOT TOUCH THE BATTERY TERMINALS The main disconnect switch is located inside the y J 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 battery pack from the motor After the switch is turned off some power may remain in the system 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 Hazard Signals 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 s
74. tructure 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 f parking in an open area block the wheels on the downhill side of the vehicle after turn ing the key off f 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 93 OPERATION Transporting the Vehicle NOTICE Towing your GEM vehicle could result in severe damage to the vehicle Vehicle failures resulting from dolly towing will void warranty When transporting the GEM vehicle on a trailer always use a trailer with an approved load rating greater than the GEM vehicle s curb weight plus any installed accessories or cargo Refer to the specifications section beginning on page 134 Always tie the frame of the GEM vehicle to the transporting unit securely with suitable straps Always secure the straps to the f
75. uthorized GEM dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized GEM dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair 146 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local GEM dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a GEM vehicle from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless r
76. ventilation to prevent condensation and may promote corro sion 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 86 4 Inspect and verify the tightness of the bolts nuts and other fasteners 133 SPECIFICATIONS Curb Weight GEM e2 1120 Ibs 508 kg GEM e4 1270 Ibs 576 kg GEM eS 1150 1 5 521 6 kg Length 99 in 251 5 cm 128 in 825 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 11 5 feet 3 5 m 15 feet 4 6 m Load Capacity 730 lbs 331 kg 930 Ibs 421 8 kg 11 5 feet 3 5 m 700 Ibs 317 5 kg Gross Vehicle Weight Rating GVWR page 22 1850 165 839 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 2 134 SPECIFICATIONS GEM e2 GEM e4 GEM eS Performance Motor 5 HP 7 HP optional shunt DC electric
77. wer 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 display Press and hold for less than 2 seconds Reset the trip meter to zero Press and hold for 3 9 seconds while display is in trip mode TRIP is illuminated see page 42 Change the display from standard to metric MPH to km h and miles to kilometers Press and hold for 10 12 seconds while display is in odometer mode Display consumed power Press and release twice 39 FEATURES AND CONTROLS Console Direction Switch NOTICE Always bring the vehicle to a complete stop before changing the position of the direction switch 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 vehicle at speeds of 0 25 MPH 0 40 km h Drive Low The LOW mode allows operation of the vehicle at speeds of 0 15 MPH 0 24 km
78. y 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 Cup Holders LCD Display Instrument Pod Storage Tray i Glove Box Loc Key Switch Windshish Wiper Headlight Trip Odometer Direction Switch Horn Lever Switch Switch 32 FEATURES AND CONTROLS Console Headlight Switch Press the top of the switch to turn the headlights to high beam Press the bottom of the switch to turn the headlights to low beam Move the switch to the center position to turn the headlights off Electrical Components Electrical wiring circuit boards and components are located under and behind the upper and lower console 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 Key Switch When the key is turned to the ON position clockwise the display will Key light up and all electrical accessories can be used OFF ON Leaving the key in the ON position will discharge the batteries Always turn the key to the OFF

2014 Owner`s Manual - GEM Electric Car Sales

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