Polaris 2016 GEM e2 Owner's Manual
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Polaris 2016 GEM e2 Owner's Manual

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2016 Owner's Manual for Maintenance and Safety
Read this manual carefully.
It contains important safety information.

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Summary of Contents for Polaris 2016 GEM e2

  • Page 1 2016 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information.
  • Page 2 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.
  • Page 4 Global Electric Motorcars® is a division of POLARIS. Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction..........6 Safety .
  • Page 6 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.
  • Page 7 WELCOME For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the GEM Service Manual and should be performed only by an authorized GEM dealer technician.

  • Page 8: Introduction

    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: •...
  • Page 9 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. NOTICE A NOTICE indicates a situation that may result in The safety alert symbol indicates a potential...
  • Page 10 INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. Special precautions must be followed when owning and operating a battery-powered vehicle. This vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles.
  • Page 11 INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Record your vehicle’s identification numbers and key numbers in the VIN Tag spaces provided on page 11. The Vehicle Identification Number (VIN) is stamped on a tag affixed to the left dash at the base of the windshield. The VIN is also printed on the manufacturer’s label, which is located on the left rear section of the interior roof panel.
  • Page 12 INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Date of Manufacturer’s Manufacture Tire / Wheel Information Label GAWR Information USA Label EU Label GVWR Information...
  • Page 13 INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Vehicle Identification Number (VIN): |___|___|___|___|___|___|___|___|___|___|___|___|___|___|___|___|___| Vehicle Model Number: _______________________________________________________________________ Motor Serial Number (on case of motor): __________________________________________________________ Ignition Key Number (stamped on key): ___________________________________________________________ Accessory Lock Key # (stamped on key): _________________________________________________________ Accessory TrunkBack Lock Key # (if equipped): ____________________________________________________ Date Purchased: _____________________________________________________________________________...

  • Page 14: Safety

    SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
  • Page 15 SAFETY Safety Labels and Locations General Warning (7178180) 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). •...
  • Page 16 SAFETY Safety Labels and Locations Seat Belt Warning (7180898) One seat belt warning is located on the headliner above the front passenger seat. Second and third row seat belt warning labels are located on the seat belt drop-down bars for the row ahead.
  • Page 17 SAFETY Safety Labels and Locations Passenger/Rear Cargo Warning (7183756) This label is centrally located under the center high mount stop lamp (if equipped). This label is also located on the S-Bed and TrunkBack. WARNING Never carry passengers on rear platform. Passengers can be thrown off. This can cause serious injury or death.
  • Page 18 SAFETY Safety Labels and Locations Cargo Limit Warning Cargo Limit Warning (7184570) The eL XD cargo limit warning label is located at the rear of the cab. See page 96 for towing procedures. WARNING Capacities GEM eL XD A: Occupant Capacity 300 lbs.

  • Page 19: Operator Safety

    SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. • Always make sure the seat belts are Follow the operating procedures secured for operator and all passengers described.
  • Page 20 SAFETY Operator Safety • Never exceed the gross vehicle weight • Always use the proper size and type of rating (GVWR) of your vehicle. tires and always maintain proper tire pressure as specified in this manual and • The cab frame is not designed or intended on safety labels.
  • Page 21 SAFETY Operator Safety • Always set the park brake and remove the key when leaving the vehicle unattended. • The voltage in the battery pack is sufficient to cause death by electrocution. 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...
  • Page 22 SAFETY Operator Safety • Do not carry a passenger until you have at • Never operate at excessive speeds. least two hours of driving experience Always travel at a speed proper for the with this vehicle. traffic, visibility and operating conditions, and your experience.
  • Page 23 SAFETY Operator Safety • Never operate on excessively rough, • Always be alert for obstacles when slippery or loose terrain. operating this vehicle. Never attempt to operate over obstacles. • Always follow proper procedures for turning. Practice turning at slow speeds •...
  • Page 24 SAFETY Operator Safety Gross Vehicle Weight Rating (GVWR) WARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling and could cause loss of control. NEVER exceed the GVWR of your vehicle. The maximum payload capacity of your vehicle is the maximum weight you may add to your vehicle without exceeding the GVWR.
  • Page 25 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 •...
  • Page 26 SAFETY Operator Safety Equipment Modifications Never install any equipment or make vehicle modifications to increase the speed or power of the vehicle. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury. The warranty on your vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
  • Page 27 SAFETY Operator Safety WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions Seat Belts This vehicle is an ADULT...
  • Page 28 SAFETY Operator Safety Operating Without Instruction Ventilation When Charging Batteries Operating this vehicle Failure to provide adequate ventilation while without proper instruction charging batteries can result in an explosion. increases the risk of an Volatile hydrogen gas is emitted during charging accident.
  • Page 29 SAFETY Operator Safety Failure to Inspect Before Operating Using Alcohol or Drugs Operating the vehicle after Failure to inspect and verify that the vehicle is in consuming alcohol or drugs safe operating condition before operating could adversely affect increases the risk of an accident. Always inspect operator judgment, reaction the vehicle before each use to make sure it's in time, balance and...
  • Page 30 SAFETY Operator Safety Operating a Damaged Vehicle Exhibition Driving Operating a damaged vehicle can result in an Exhibition driving increases the risk of an accident. After any overturn or accident, have accident or overturn. Never attempt wheelies, qualified service dealer inspect the entire jumps, doughnuts or other stunts.
  • Page 31 SAFETY Operator Safety Turning Improperly Carrying Cargo Turning improperly could cause loss of traction, Carrying loads on the roof could damage the roof loss of control, accident or overturn. Always and affect vehicle handling, which could result in follow proper procedures for turning. Never turn an accident or overturn.
  • Page 32 SAFETY Operator Safety Improper Tire Maintenance Hot Drive Systems Operating this vehicle with improper tires or with The motor and controller are very hot during and improper or uneven tire pressure could cause after use of the vehicle. Hot components can loss of control or accident.
  • Page 33 SAFETY Operator Safety Precautions During Maintenance negative terminal from the main battery pack. See page 53. WARNING! The voltage in the battery pack is Always follow all safety instructions in the sufficient to cause death by electrocution. With maintenance portion of this owner’s manual, as the exception of battery inspections and refilling well as the following: the water in flooded type batteries, never attempt...

  • Page 34: Features And Controls

    FEATURES AND CONTROLS Console Right Control Lever Left Control Storage Lever Tray Glove Box Lock Holders Gauge Trip Switch/MODE Switch Switch...
  • Page 35 FEATURES AND CONTROLS Console Electrical Components Fuse Box 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.

  • Page 36: Key Switch

    FEATURES AND CONTROLS Console Key Switch When the key is turned to the ON position (clockwise), the display will light up and all electrical accessories can be used. Leaving the key in the ON position will discharge the batteries. Always turn the key to the OFF position when not operating.

  • Page 37: Glove Box

    FEATURES AND CONTROLS Console Zero Speed Detection Feature To prevent the vehicle from rolling away while stopped, the electric motor will resist vehicle motion if the accelerator pedal is released while the key is on, and the vehicle starts moving. Glove Box The glove box is equipped with a lock to protect items from theft or damage.
  • Page 38 FEATURES AND CONTROLS Console Left Control Lever The left control lever contains the turn signal switch, the horn switch, the headlight on/off switch and the high/low headlight beam switch. Turn Signal Switch Check turn signal lamps before each ride. When driving, activate a turn signal before turning to alert others of your intentions.
  • Page 39 FEATURES AND CONTROLS Console Left Control Lever Horn Switch Horn Switch Press the tip of the left control lever inward to sound the horn. Headlight On/Off Switch Headlight On Rotate the knurled barrel forward to turn the headlights on. Headlight High Beam/Low Beam Switch High Beam/Low Beam Toggle Pull the control lever toward the driver’s seat to toggle the...
  • Page 40 FEATURES AND CONTROLS Console Right Control Lever The right control lever contains the hazard signal switch, the direction switch and the windshield wiper and washer switches (if equipped). Hazard Signal Switch Hazard Signal Switch Press the tip of the lever inward to cause all turn signal lamps to flash simultaneously.
  • Page 41 FEATURES AND CONTROLS Console Right Control Lever Direction Selection Switch NOTICE: Always bring the vehicle to a complete stop before changing the position of the direction switch. MODE PROCEDURE Forward Move the lever fully upward to operate in forward mode. The forward mode allows operation of the vehicle at speeds of 0-25 MPH (0-40 km/h).
  • Page 42 FEATURES AND CONTROLS Console Right Control Lever Windshield Wiper Rotate the knurled barrel forward to turn the windshield Wipers wipers on. Pull the control lever toward the driver’s seat to activate the washer (if equipped). If the wiper fails to work, check for a blown fuse at the fuse block.
  • Page 43 FEATURES AND CONTROLS Digital/Analog Gauge High water pressure may damage components. Wash Speedometer Indicator the vehicle by hand or with a garden hose using mild Lamps soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
  • Page 44 FEATURES AND CONTROLS Digital/Analog Gauge Indicator Lamps Lamp Indicates Condition Vehicle Speed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Brake This lamp illuminates when the park brake is engaged or when a brake Indicator system failure has occurred.
  • Page 45 FEATURES AND CONTROLS Digital/Analog Gauge Indicator Lamps Brake Indicator The brake indicator illuminates when the park brake is engaged or when a brake system failure has occurred. If the brake warning illuminates, check the following items before operating the vehicle. Brake System Item Solution Park brake...
  • Page 46 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display The rider information center is located in the instrument cluster. The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 47.
  • Page 47 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Fault Indicator When both the chassis fault lamp and the fault indicator (wrench symbol) illuminate, use the mode button to toggle through fault codes or warning messages in the display. Your autho- rized dealer can provide code details and diagnosis.
  • Page 48 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center State of Charge State of Charge This indicator illuminates when the key is turned on. It also Indicator illuminates 8-10 seconds after the charging cord is connected, turning off when the batteries are 100% Bars % Of Charge charged.
  • Page 49 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode This area will display clock, odometer, trip meter, state of charge (SOC), range meter, efficiency rate (EFF) or any existing fault codes or warning messages. The display can be changed to show either standard or metric units of measurement for each of the following settings.
  • Page 50 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode 1. Turn the key to the OFF position. 2. Press and hold the MODE button while turning the key to the ON position. 3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.
  • Page 51 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode Clock Resetting Tip: The clock must be reset any time the batteries have been disconnected or fully discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the clock display.
  • Page 52 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode Odometer The odometer displays the distance traveled by the vehicle since manufacture. Trip Meter The trip meter displays distance traveled since the last reset of the trip meter. To reset, toggle to the trip meter display.
  • Page 53 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode Battery State of Charge This mode displays the remaining system voltage level in percentage format. Range Meter The range meter displays the approximate distance the vehicle could travel on the remaining battery voltage level.
  • Page 54 FEATURES AND CONTROLS Digital/Analog Gauge Rider Information Center Information Display Mode Efficiency Rate (EFF) This mode displays the rate at which electrical power (Wh) is consumed per mile or per kilometer. A higher number indicates less desirable efficiency. A lower number indicates better efficiency.
  • Page 55 FEATURES AND CONTROLS Main Power Connector When the main power connector is unplugged, the battery pack is disconnected from all electrical components, with the exception of the contactor. After servicing the vehicle, the main power connector should be the last connection to be made. Disconnecting Power 1.
  • Page 56 FEATURES AND CONTROLS Main Power Connector 5. Locate the main power connector at the lower left front of the vehicle, below the horn assembly. Unplug the main power connector. 6. Locate and disconnect electrical accessory connectors (such as a heater or a heated windshield).
  • Page 57 FEATURES AND CONTROLS Main Power Connector 7. If equipped, disconnect the negative cable from the auxiliary 12-volt battery. WARNING! 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 terminals with an insulating material.
  • Page 58 FEATURES AND CONTROLS Main Power Connector 8. Disconnect the main NEGATIVE cable from the traction batteries. Isolate the cable end to ensure the circuit cannot be completed during service. Reconnecting Power 1. Reconnect the negative cable to the traction batteries. Torque the nut to 8 lb-ft (10.8 Nm). 2.

  • Page 59: Brake Pedal

    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.

  • Page 60: 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.
  • Page 61 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. If the key is turned off without setting the park brake, an alert will sound.
  • Page 62 FEATURES AND CONTROLS Batteries Battery Pack Your vehicle is equipped with a battery pack. This battery pack supplies the power needed to operate the vehicle. These batteries perform best when recharged fully and often. Recharge the batteries daily, or after each use of the vehicle. NOTICE: Each vehicle is programmed at the factory for a particular battery type.
  • Page 63 FEATURES AND CONTROLS Batteries Battery Performance Tips • New batteries will not perform to their • Batteries should be at room temperature fullest capacity until they have been when recharging. Do not charge batteries discharged and recharged 20 to 30 times. at temperatures of 110°F (43°C) or higher.
  • Page 64 FEATURES AND CONTROLS Batteries On-Board Charger The on-board battery charger is located under the hood. The state of charge of the batteries displays in the rider information center and a “C” displays when the vehicle is charging. When the vehicle will not be used for 10 or more days, connect the charger. The state of charge of the batteries will be monitored, and charging will automatically be initialized when the state of charge drops below 97% or when 28 days have passed since the last charge completed.

  • Page 65: Battery Charging

    FEATURES AND CONTROLS Batteries On-Board Charger If the combined voltage of all batteries reaches 36 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.
  • Page 66 FEATURES AND CONTROLS Batteries Battery Charging Your vehicle is equipped with either a standard charge receptacle or a fast charge receptacle. The battery charge receptacle is located at the rear of the hood, just below the windshield. Standard Charge Receptacle The following information applies to use of the standard charge receptacle.
  • Page 67 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. •...
  • Page 68 FEATURES AND CONTROLS Batteries Battery Charging Tip: Always use a 110-volt AC, 15 amp breaker outlet. A GFI (Ground Fault Interrupt) receptacle is recommended. See your authorized GEM dealer if you do not have a GFI receptacle at your regular recharge site. •...
  • Page 69 FEATURES AND CONTROLS Batteries Battery Charging Fast Charge Receptacle The following information applies to use of the fast charge receptacle. See page 64 for information that applies to the use of the standard charge receptacle. 1. Always use SAE J1772 approved charge stations and connectors.
  • Page 70 FEATURES AND CONTROLS Batteries Alternate Battery Charging Method If the combined voltage of all batteries reaches 36 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.
  • Page 71 FEATURES AND CONTROLS Batteries Alternate Battery Charging Method 1. Set the battery charger to the medium amp setting (10 to 30 amps). 2. Charge each battery for 10-20 minutes. 3. Move quickly from battery to battery, as this is only a residual charge and it will dissipate in a short period of time.
  • Page 72 FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. WARNING! Before servicing the vehicle’s electrical system, always disconnect the main power connector first, then disconnect any electrical accessory connections, then disconnect the negative cable from the 12-volt battery (if equipped), then disconnect the negative terminal from the main battery pack.
  • Page 73 FEATURES AND CONTROLS Batteries Battery Handling Precautions • Never connect a 12-volt accessory directly to the batteries. Always connect any powered accessory to the 12-volt terminal board. See page 72. • Never connect jumper cables to any of the batteries of this vehicle. •...
  • Page 74 FEATURES AND CONTROLS Batteries 12-Volt Terminal Board Connections Negative (Ground) Remove the upper dash to access the 12-volt Accessory (ACC) Positive (+) terminal board. See page 104. Always make sure that all 12-volt electrical accessories are grounded directly to the negative (-) post on the terminal board.
  • Page 75 FEATURES AND CONTROLS USB Port 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. The fuse for the USB port is located under the hood in the fuse block.
  • Page 76 FEATURES AND CONTROLS Doors Accessory doors are available for most models. Options include soft doors, hard doors with crank windows and locks, half doors and quarter 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.
  • Page 77 FEATURES AND CONTROLS Seat Adjustment Seats can be adjusted forward or rearward. The seat adjustment lever is directly under the front of the seat. 1. Move the adjustment lever to the left and slide the seat to the desired position. 2.
  • Page 78 FEATURES AND CONTROLS Seat Belts WARNING Failure to properly use seat belts and child restraints can result in serious injury or death. Always follow all legal requirements for seat belt and child restraint use in on-road vehicles. • Always make sure the seat belts are secured for operator and all passengers before operating. •...
  • Page 79 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use This vehicle is equipped with three-point lap and diagonal seat belts for all occupants. Always make sure the seat belts are secured for operator and all passengers before operating. When the key is turned on, the seat belt indicator lamp will Latch Plate illuminate if the driver’s seat belt is not fastened.
  • Page 80 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use 3. Push the latch plate into the buckle until it clicks. 4. Release the strap, it will self tighten. 5. 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.
  • Page 81 FEATURES AND CONTROLS Seat Belts Seat Belt Safety Tips • In a rear seat, you may have trouble tightening the lap/shoulder belt on the child restraint because the buckle or latch plate is too close to the belt path opening on the restraint. Disconnect the latch plate from the buckle and twist the short buckle-end belt several times to shorten it.
  • Page 82 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2.
  • Page 83 FEATURES AND CONTROLS Stereo System (Option) The optional stereo system is mounted in the dash and features speakers, FM radio, MP3 capabilities and Blue- tooth functionality. Refer to your stereo system’s user manual for detailed operating instructions. Stereo Solar Panel (Option) Solar Panel The optional solar panel is mounted on top of the vehicle.
  • Page 84 FEATURES AND CONTROLS Rear Accessory Backs (Option) Rear accessory back options are available. These accessory backs are interchangeable. Short Bed with Cargo Carrier TrunkBack™ LinksBack™ Short Bed Short Bed with Solid Sides Short Bed with StakeBack™...
  • Page 85 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 of the vehicle. See page 22. NOTICE: Use only GEM-approved rear accessories.
  • Page 86 FEATURES AND CONTROLS Hood Remove the hood to access the fuse box, windshield washer fluid tank (if equipped), main power connector and electrical accessory connectors. 1. Remove the two hood screws located under the charge port door. 2. Keeping the hood parallel with the ground, pull the hood forward to release it from the grommets.
  • Page 87 FEATURES AND CONTROLS Hitches A rear hitch (if installed) is for light-duty off-road use. Hitch use is not approved for on-road operation. WARNING! Never exceed the GVWR or the GAWR of the vehicle. See page 22. Chrome Bumpers/Rugged Bumpers (Option) Front bumpers are for appearance only and will protect the body panels only from minor dents and scratches.
  • Page 88 FEATURES AND CONTROLS Heated Windshield (Option) The heated windshield has heating elements within the glass to assist in defogging the windshield. Press the heated windshield switch on the console to turn on the heating elements. A light on the switch illuminates when the elements are heating. Press the switch again to turn off the heating elements.
  • Page 89 FEATURES AND CONTROLS Windshield Washer (Option) Wipers Rotate the knurled barrel forward to turn the windshield wipers on. Pull the control lever toward the driver’s seat to activate the washer. Washer 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).

  • Page 90: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
  • Page 91 OPERATION Pre-Ride Inspection Item Remarks Page Turn signals Ensure operation of all signal lamps Mirrors Adjust mirrors for proper side and rear view Horn Ensure operation Seat belts Check length of belt for damage, check latches for proper operation Steering Ensure free operation Tires Check tire condition and pressure...
  • Page 92 OPERATION Driving Procedure 1. Disconnect the charging cable. 2. Sit in the driver's seat and fasten the seat belt. Make sure passengers are seated with seat belts secured. 3. Adjust mirrors as needed. 4. Turn the key clockwise to the ON position. 5.
  • Page 93 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.
  • Page 94 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.
  • Page 95 OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever driving on slippery surfaces Sideways Turn in direction...
  • Page 96 OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
  • Page 97 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: • If parking in an open area, block the wheels on the downhill side of the vehicle after turning the key off. •...
  • Page 98 OPERATION Towing Loads (eL XD) Your vehicle has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. See page 16. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

  • Page 99: Transporting The Vehicle

    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.

  • Page 100: Maintenance

    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.
  • Page 101 MAINTENANCE Periodic Maintenance Chart Monthly Maintenance See Page Check battery fluid level (on flooded batteries) Wash tops and terminals of batteries and allow to dry (flooded) Check cables and terminal connections 120, 121 Check for worn insulation or frayed wires Check battery hold-down bar to ensure batteries are tightly secured Check tires for correct air pressure and wear Check brake fluid reservoir for proper brake fluid level.

  • Page 102: Brake Fluid

    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. Your authorized dealer can provide service. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
  • Page 103 MAINTENANCE Brakes Brake Fluid 1. Position the vehicle on a level surface. Maximum Minimum 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.
  • Page 104 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear.
  • Page 105 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. There should be 0.8-1.0 inch (20-25 mm) of freeplay at the outer rim of the steering wheel. 3.
  • Page 106 MAINTENANCE Upper Dash Removal/Installation Some maintenance procedures require removal of the upper dash to access components. 1. Remove the eight (8) plastic push rivets securing the dash to the frame. Two of the rivets are located inside the glove box. Rivets Switch Connections (if equipped)
  • Page 107 MAINTENANCE Upper Dash Removal/Installation 2. Slight raise the dash and unplug any switch connections located between the cup holders. 3. Carefully remove the dash from the vehicle. 4. Reverse this procedure to reinstall the dash.
  • Page 108 MAINTENANCE Fuses and Relays WARNING! Before servicing the vehicle’s electrical system, always disconnect the main power connector first, then disconnect any electrical accessory connections, then disconnect the negative cable from the 12-volt battery (if equipped), then disconnect the negative terminal from the main battery pack.
  • Page 109 MAINTENANCE Fuse and Relay Recommendations Standard 12V Fuses Standard 48V Fuses Application Size Location Application Size Location Drive; Constant; 5 amp 12V Fuse Center Motor Controller/ 5 amp 48V Fuse Center Internal Lighting Horn; Display 10 amp 12V Fuse Center DC-DC;...
  • Page 110 MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle.
  • Page 111 MAINTENANCE Tires Tire Tread Depth 1/8” (3 mm) Any accelerated wear of tires may be an indicator of improper alignment or poor driving habits. Your authorized GEM dealer can assist. 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...

  • Page 112: Wheel Removal

    MAINTENANCE Tires Wheel Removal WARNING! A falling vehicle can cause serious Frame viewed injury or death. Never place any part of your body from bottom 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.
  • Page 113 MAINTENANCE Tires Wheel Removal 4. Block both the front and rear of the tire that is located diagonally opposite the jacking position. For example, if the right front tire is being changed, block the left rear wheel. 5. Use a small floor style jack or low profile scissors jack only. Jack the vehicle only from the side of the vehicle, on the main frame rail, at the point where the tub or floor panel support and the main frame rail are welded.

  • Page 114: Wheel Installation

    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. Your authorized dealer can provide service. 1.
  • Page 115 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
  • Page 116 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 117 MAINTENANCE Lights Headlight Beam Adjustment 3. Apply the brakes. Turn the key on. Turn the headlights to high beam. Tip: Include the weight of a rider on the seat while performing the following step. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8"...
  • Page 118 MAINTENANCE Batteries WARNING The voltage in the battery pack is sufficient to cause death by electrocution. With the exception of battery inspections and refilling the water in flooded type batteries, never attempt to perform service on the electric drive system, including the battery pack, unless you are properly trained to work on electrical systems.
  • Page 119 MAINTENANCE Batteries WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
  • Page 120 MAINTENANCE Batteries Traction Battery Configurations NOTICE: Before accessing 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. Several battery pack configurations exist for GEM vehicles. •...
  • Page 121 MAINTENANCE Batteries Traction Battery Locations To access the battery pack, remove any rear accessory back installed on the vehicle. See page 82. Release the battery pack access cover fasteners and remove the cover. All Battery Configurations Model Location GEM e2 Under rear compartment GEM e4 Under rear compartment...
  • Page 122 MAINTENANCE Batteries Battery Inspections/Maintenance WARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. Before servicing the vehicle’s electrical system, always disconnect the main power connector first, then disconnect any electrical accessory connections, then disconnect the negative cable from the 12-volt battery (if equipped), then disconnect the negative terminal from the main battery pack.
  • Page 123 MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Cables and Wiring Check the battery compartment for any signs of worn insulation, frayed cables or damaged cable ends. If found, see your authorized GEM dealer or other qualified service person for service before operating. WARNING! If battery cable ends are damaged or corroded, they should be replaced or cleaned as necessary.

  • Page 124: Battery Replacement

    MAINTENANCE Batteries Battery Inspections/Maintenance Battery Replacement Battery and electrical system service must be performed only by an authorized service facility. When battery replacement is necessary, your authorized GEM dealer can provide this service. NOTICE: Always install batteries of the exact type and make originally supplied with the vehicle to prevent damage to the vehicle’s electrical system.
  • Page 125 MAINTENANCE Batteries Battery Inspections/Maintenance Battery Care During Storage When the vehicle will not be used for a period of 10 days or longer, check battery water levels (flooded type batteries) and perform one of the battery storage procedures listed in the chart below.
  • Page 126 MAINTENANCE Batteries Battery Inspections/Maintenance Flooded Battery Fluid Check On flooded batteries, check the fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a battery. Accessory watering systems are available for 12-volt and 6-volt flooded batteries. See your authorized GEM dealer for more information.
  • Page 127 MAINTENANCE Batteries Battery Inspections/Maintenance Flooded Battery Fluid Check Inspect the fluid level of each battery. Fill Caps 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.
  • Page 128 MAINTENANCE Batteries Battery Inspections/Maintenance Flooded Battery Cleaning 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.
  • Page 129 MAINTENANCE Batteries Battery Inspections/Maintenance Flooded Battery Disposal Lead-acid batteries can be recycled. Return whole scrap batteries to a distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid- resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds.
  • Page 130 MAINTENANCE Cleaning and Storage Cleaning Windshields, Windows and Solar Panels We recommend using GEM Windshield Cleaner and Protectant to remove normal dust and dirt. A liquid household glass cleaner can also be used. To remove oil, grease or road tar, use isopropyl alcohol, then wash these surfaces with water.
  • Page 131 MAINTENANCE Cleaning and Storage Cleaning Seats GEM Foaming All Surface Cleaner can be used to clean the seats. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt and other soils will stain if not removed quickly. Use a clean cloth and solvent type vinyl cleaner, then wash the area thoroughly with a damp cloth and mild liquid detergent.
  • Page 132 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.
  • Page 133 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 98. Check Fluid Levels Inspect the fluid levels.
  • Page 134 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 pages 120 and 126. 3.
  • Page 135 MAINTENANCE Cleaning and Storage Storing the Vehicle WARNING! Do not cover the vehicle while the charger is connected. Dangerous levels of hydrogen gas could accumulate. 9. If the vehicle is not connected to the charger, disconnect the main power connector first, then disconnect any electrical accessory connections, then disconnect the negative cable from the 12-volt battery (if equipped), then disconnect the negative terminal from the main battery pack.

  • Page 136: Specifications

    SPECIFICATIONS GEM e2 GEM e4 Dimensions Dry Weight 1200 lbs. (544 kg) 1350 lbs. (612 kg) Length 103 in. (262 cm) 135 in. (343 cm) Width 55.5 in. (141 cm) 55.5 in. (141 cm) Height 73.1 in. (186 cm) 73.1 in. (186 cm) Wheelbase 69 in.
  • Page 137 SPECIFICATIONS GEM e2 GEM e4 Performance Motor 5 kW (optional 6.5 kW) AC electric Motor peak 13.3 kW (optional 18.5 kW) Controller Sevcon 450A AC Controller Maximum speed 25 MPH (40 km/h) Range Varies with conditions Drive System 17.05:1 Single speed On-board charger Standard 1 kW, 120/240V input (optional 3 kW or 6 kW, SAE J1772) Brake System...
  • Page 138 SPECIFICATIONS ® GEM eL XD GEM e6 Dimensions Dry Weight 1585 lbs. (720 kg) 1696 lbs. (769 kg) Length 145.5 in. (370 cm) 167 in. (424 cm) Width 55.5 in. (141 cm) 55.5 in. (141 cm) Height 73.1 in. (186 cm) 73.1 in.
  • Page 139 SPECIFICATIONS ® GEM eL XD GEM e6 Performance Motor 6.5 kW AC electric Motor peak 18.5 kW Controller Sevcon 450A AC Controller Maximum speed 25 MPH (40 km/h) Range Varies with conditions Drive System 17.05:1 Single speed On-board charger Standard 1 kW, 120/240V input (optional 3 kW or 6 kW, SAE J1772) Brake System Brakes 4-Wheel hydraulic brakes, disc front, drum rear...

  • Page 140: Warranty

    WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO-YEAR/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.
  • Page 141 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.
  • Page 142 Any capacity/range reduction-based claim must be confirmed by an authorized dealer and approved by Polaris to be eligible for coverage. In addition to the WARRANTY COVERAGE EXCLUSIONS listed below, the battery warranty also excludes failure, damage or capacity loss to the batteries caused by neglect, lack of charging or not following the recommended maintenance schedule outlined in the Owner’s Manual.
  • Page 143 WARRANTY REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within three days. Upon receipt of this registration, Polaris 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.
  • Page 144 BATTERY PACK 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.
  • Page 145 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: •...
  • Page 146 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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 •...
  • Page 147 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, components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS...
  • Page 148 Warranty Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER MAY BE YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any GEM Servicing Dealer to perform warranty service.
  • Page 149 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If you move: If you move to another country, be sure to contact GEM 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 GEM in order to continue your warranty coverage.
  • Page 150 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.
  • Page 151 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 AMERICA*.

  • Page 152: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 153 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 154 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 155: Index

    INDEX 12-Volt Accessory Installation . . . 72 Brake Lever, Park ... . . 59 Dash Removal/Installation . . 104-105 12-Volt Terminal Board ..72 Brake Pedal .
  • Page 156 INDEX Gauge, Digital/Analog ..41-52 Lights....113-115 Park Brake Lever ....59 Glove Box .
  • Page 157 INDEX Signal Words....7 Tires....108-112 Warning Symbols .
  • Page 158 For your nearest GEM dealer, call 855-RIDEGEM (855-743-3436) or visit www.gemcar.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9925677 Rev 01 Printed in USA...

This manual is also suitable for:

2016 gem e42016 gem el xd2016 gem e6

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