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Polaris GEM Owner's Manual For Maintenance And Safety

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2015 Owner's Manual for Maintenance and Safety
Read this manual carefully.
It contains important safety information.

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  • Page 1 2015 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 2014 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 produc- tion 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...
  • Page 7 Vehicle Identification Number (VIN) and date of purchase. Your authorized GEM dealer knows your vehicle best and is interested in your total satisfac- tion. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

  • Page 8: Introduction

    Safety Administration (NHTSA) low-speed vehicle regulations and can be operated on many streets posted with low speed limits. Please familiarize yourself with all laws and regulations concerning the operation of the vehicle in your area. This manual applies to the following GEM vehicles: • GEM e2 (two-passenger) • GEM e4 (four-passenger) •...
  • 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 (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.
  • Page 12 INTRODUCTION Manufacturer’s Label (Vehicle Information Label) Date of Manufacture Tire / Wheel Information Manufacturer’s GAWR Information Label 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): __________________________________________________________ Key Number (stamped on key): _________________________________________________________________ Optional Rear Accessory # (stamped on key): ______________________________________________________ Date Purchased: _____________________________________________________________________________...

  • Page 14: Safety

    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.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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 HIGH VOLTAGE You could be seriously or fatally injured by electric shock if you attempt to open, repair, test, inspect or adjust.
  • Page 18 No passengers permitted. Abuse or noncompliance will void warranty. GEM eL XD: Maximum cargo capacity of this bed should never exceed 1100 lbs. (499 kg). Distribute weight equally over axle. No passengers permitted. Abuse or noncompliance will void warranty.

  • Page 19: Operator Safety

    4 occupants • Never permit a guest to operate this vehi- GEM eS 2 occupants cle unless the guest has read this manual and all product labels. GEM eL 2 occupants GEM eL XD 2 occupants ® 6 occupants GEM e6...
  • 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 • Never carry loads on the roof of the vehi- • The voltage in the battery pack is suffi- cle. Never exceed the stated load capacity cient to cause death by electrocution. for this vehicle. Cargo should be properly With the exception of battery inspections distributed and securely attached.
  • 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 • Always have this vehicle checked by an trol. authorized GEM dealer if it has been involved in an accident. • Never operate this vehicle on steep hills.
  • 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 The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only GEM-approved accessories, and familiarize yourself with their function and effect on the vehicle.

  • Page 27: Seat Belts

    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: Operating Without Instruction

    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: Using Alcohol Or Drugs

    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 Exhibition driving increases the risk of an accident. After any overturn or accident, have accident or overturn. Never attempt wheelies, your authorized GEM dealer inspect the entire jumps, doughnuts or other stunts. Avoid machine for possible damage, including (but not exhibition driving.

  • Page 31: Turning Improperly

    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: Improper Tire Maintenance

    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 Always turn off the main disconnect Remove the batteries, or cover the exposed ter- switch before servicing or unplugging any minals with an insulating material. electrical components. See page 52. FOR MORE INFORMATION ABOUT SAFETY PLEASE CONTACT GEM CUSTOMER SERVICE. See page 5.

  • Page 34: Features And Controls

    FEATURES AND CONTROLS Console LCD Display Storage Tray Instrument Pod Cup Holders Glove Box Lock Switch Turn Signal Direction Switch Trip/Odometer Headlight Windshield Wiper Switch Switch Horn Lever...
  • Page 35 FEATURES AND CONTROLS Console Headlight Switch HIGH 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.
  • Page 36 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 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 Horn Press the turn signal wand inward toward the instrument pod to sound the horn.
  • Page 38 FEATURES AND CONTROLS Console Turn Signal The turn signal lever contains the controls for the turn signals, horn, windshield wiper and windshield washer (if equipped). Check turn signal lamps before each ride. When driving, activate a turn signal before turning to alert others of your intentions. Tip: The key must be in the ON position to activate the turn signals.
  • Page 39 FEATURES AND CONTROLS Console Windshield Wiper Push the turn signal lever toward the console and release it to Wiper ON turn the windshield wipers on. Push the lever toward the con- sole again to activate the washer momentarily (if equipped, see page 85).
  • Page 40 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.
  • Page 41 FEATURES AND CONTROLS Console Trip Meter/Odometer/E-Meter Trip Switch Operation Desired Result Press Trip Switch Toggle between the odometer and trip meter Press and hold for less than 2 seconds modes on the display Reset the trip meter to zero Press and hold for 3-9 seconds while display is in trip mode (“TRIP”...
  • Page 42 FEATURES AND CONTROLS Console Direction Switch Drive High NOTICE: Always bring the vehicle to a complete stop before changing the position of the direction switch. 1. With the key in the ON position, apply the brakes. Drive Low 2. Move the direction switch to the desired mode. Reverse 3.
  • Page 43 FEATURES AND CONTROLS Console Direction Switch Drive High The HIGH mode allows operation of the vehicle at speeds of 0-25 MPH (0-40 km/h). Drive Low The LOW mode allows operation of the vehicle at speeds of 0-15 MPH (0-24 km/h). When LOW mode is selected, the rate of acceleration is also limited.
  • Page 44 FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Left Turn Right Turn Brake Warning High Motor BRAKE km/h Temperature Warning Odometer/Trip Meter Service TRIP MILES Required Charger Connected State of Charge/ High Beam Battery Discharge Headlight Current Limiting Mode Low Beam Headlight Seat Belt Warning...
  • Page 45 FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Indicator When driving, the speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). The display can be changed to display either standard or metric units of measurement. See page 38. 74% Charge When the batteries are charging, this area displays the percent of charge.
  • Page 46 Charge batteries before operating. 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.
  • Page 47 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...
  • Page 48 FEATURES AND CONTROLS Console LCD Display Indicators High Motor Temperature Warning Indicator If the motor temperature warning illuminates, or if service code “41” displays in the speedometer/service code display, the motor or motor controller may be 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.
  • Page 49 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.
  • Page 50 FEATURES AND CONTROLS Console LCD Display Indicators State of Charge/Battery Discharge Indicator (BDI) This indicator contains 8 green bars, a yellow bar and a red bar. It shows available battery capacity by illuminating one or more bars. The indicator illuminates when the key is turned on. It also illumi- nates 8-10 seconds after the charging cord is connected, turning off when the batteries are 100% charged.
  • Page 51 FEATURES AND CONTROLS Console LCD Display Indicators State of Charge/Battery Discharge Indicator (BDI) NOTICE: Batteries can be permanently damaged (and the warranty voided) if State of Charge/Battery Discharge allowed to remain 30 days or more Indicator with low charge. Fully charge batteries before storing.
  • Page 52 FEATURES AND CONTROLS Console LCD Display Indicators Current Limiting Mode Indicator This indicator illuminates if the system limits the amount of current available due to extremely low battery voltage. The state-of-charge/battery-discharge indicator will also indicate low voltage. If you continue to drive, acceleration and power will begin to decrease.
  • Page 53 FEATURES AND CONTROLS Console LCD Display Indicators Direction Indicators When the key is on, one of the three direction indicators illuminate to indicate the selected position of the direction switch (REVERSE, DRIVE LOW or DRIVE HIGH). See page 40. Headlight Beam Indicators Either the high beam or low beam headlight indicator illuminates to indicate which headlight beam is selected.
  • Page 54 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.
  • Page 55 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.

  • Page 56: 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 57: 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 58: Park Brake Lever

    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 e4, e6® GEM e2, eS, eL, eL XD...
  • Page 59 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.
  • Page 60 Recharge the batteries daily, or after each use of the vehicle. NOTICE: Each vehicle is programmed at the factory for a particular battery type. Switching battery types should be done only by an authorized GEM service technician. 12-Volt Flooded Battery...
  • Page 61 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 dis- when recharging. Do not charge batteries charged and recharged 20 to 30 times. at temperatures of 110°F (43°C) or higher.
  • Page 62 FEATURES AND CONTROLS Batteries On-Board Charger The on-board battery charger is located under the hood and can be Green Indicates 100% Charge viewed through the left front wheel well. When batteries are 100% charged, a green light on the charger will illuminate. When the vehicle will not be used for 10 or more days, leave the main disconnect switch on and connect the charger.

  • Page 63: 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 64 FEATURES AND CONTROLS Batteries Battery Charging The battery 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.
  • Page 65 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 66 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.
  • Page 67 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 68 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.
  • Page 69 FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components.
  • Page 70 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.
  • Page 71 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.

  • Page 72: Seat Adjustment

    Slide the seat fully rearward, then push down firmly along the front edge of the seat to secure the latches. Seat Adjustment The front seats on the GEM e4 and GEM e6® models are equipped with manual seat adjustments. The seat adjustment lever is directly under the front of the seat.
  • Page 73 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 74 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use This vehicle is equipped with three-point lap and diago- nal seat belts for all occupants. Always make sure the Latch seat belts are secured for operator and all passengers Plate before operating. To wear the seat belt properly, follow this procedure: 1.
  • Page 75 FEATURES AND CONTROLS Seat Belts Proper Seat Belt Use 2. Push the latch plate into the buckle until it clicks. 3. Release the strap, it will self tighten. 4. To remove slack in the lap belt portion of the belt, pull upward on the shoulder belt. To loosen the lap belt if it is too tight, tilt the buckle and pull the lap belt slightly longer.
  • Page 76 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. Dis- connect the latch plate from the buckle and twist the short buckle-end belt several times to shorten it.
  • Page 77 3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not oper- ate properly, have the seat belt system checked and/or replaced by your authorized GEM dealer.
  • Page 78 FEATURES AND CONTROLS Stereo System (Option) The optional stereo system is mounted in an overhead console and features speakers, FM radio, CD player and MP3 capabilities. Refer to your stereo system’s user manual for detailed operating instructions. Solar Panel (Option) Solar Panel The optional solar panel is mounted on top of the vehicle.
  • Page 79 FEATURES AND CONTROLS Rear Accessory Backs (Option) Rear accessory back options are available. These rear accessory backs are interchangeable. Latch Release Trunk Cover Lock Handle ™ ™ ™ TrunkBack LinksBack Clip-In StakeBack...
  • Page 80 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.
  • Page 81 FEATURES AND CONTROLS Rear Accessory Backs (Option) 5. Rotate the release handle to release the dual latches. 6. Remove the safety strap and carefully remove the existing accessory back. 7. Install the desired accessory back onto the mounting brackets. 8. Secure the safety strap. 9.
  • Page 82 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.
  • Page 83 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.
  • Page 84 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.
  • Page 85 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.
  • Page 86 FEATURES AND CONTROLS Adjustable Tilt Steering Column (Option) Tilt To adjust the tilt steering column, pull the lever at the left of Lever 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.
  • Page 87 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).

  • Page 88: 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 89 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 90: Driving Procedure

    OPERATION Driving Procedure 1. Disconnect the charging cable. Make sure the main disconnect switch is on. 2. Sit in the driver's seat and fasten the seat belt. Make sure passengers are seated with seat belts secured. 3. Adjust mirrors as needed. 4.
  • Page 91 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 92 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 93: Driving On Slippery Surfaces

    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 94: Parking The Vehicle

    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 venti- lated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 95: Parking On An Incline

    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 turn- ing the key off. •...

  • Page 96: Transporting The Vehicle

    Always tie the frame of the GEM vehicle to the transporting unit securely with suitable straps. Always secure the straps to the front sub-frame and the rear axle of the GEM vehicle. Never place tie straps across any plastic body or floor panel components.
  • Page 97 Transport the vehicle in a closed trailer if possible. Use the following guidelines when trans- porting the vehicle on an open trailer. 1. Always transport the GEM vehicle facing forward on the trailer. 2. Set the park brake. 3. Remove the key to prevent loss.

  • Page 98: Maintenance

    Inspect, clean, lubricate, adjust and 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.

  • Page 99: Periodic Maintenance Chart

    MAINTENANCE Periodic Maintenance Chart Monthly Maintenance See Page Check battery fluid level (flooded only) Wash tops and terminals of batteries and allow to dry Check cables and terminal connections Check for worn insulation or frayed wires Check battery hold-down bar to ensure batteries are tightly secured Check tires for correct air pressure and wear Check brake fluid reservoir for proper brake fluid level.
  • Page 100 Brake Fluid Inspect the brake system routinely. Inspect the brake fluid level before each operation. If the level drops between fluid checks, add brake fluid as needed. See your authorized GEM dealer for service. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
  • Page 101 MAINTENANCE Brakes Brake Fluid Maximum Minimum 1. Position the vehicle on a level surface. 2. Open the hood. The brake fluid reservoir is located on the driver’s side of the vehicle, above and to the rear of the front tire. 3.
  • Page 102 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 loose- ness.

  • Page 103: Steering Wheel Inspection

    2. Lightly turn the steering wheel left and right. There should be 0.8-1.0 inch (20-25 mm) of freeplay at the outer rim of the steering wheel. 3. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by your authorized GEM dealer.

  • Page 104: Fuse Replacement

    Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. See your authorized GEM dealer if you suspect a relay or Access Panel Fuse Block diode needs replacement.
  • Page 105 MAINTENANCE Fuse Replacement Fuse Label Fuse Recommendations Tail/Headlamps Turn Signals Horn Brake Lamps License P. Lamp Fuse Application Fuse Size Spare Heater Coil (fuse used for accessory) 30 amp Wiper Heater Turn Signals / Brake Lamps Windshield Wiper Accessories Radio / PA Accessories Heater Coil Radio...
  • Page 106 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 107 Tire Tread Depth 1/8” (3 mm) 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.

  • Page 108: Wheel Removal

    Frame viewed automotive jack stands to support the vehicle on a firm, level from bottom surface, or see your authorized GEM dealer for service. 1. Position the vehicle on a dry, firm, level surface. 2. Set the park brake. 3. Turn the key off.
  • Page 109 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 110 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.
  • Page 111 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...
  • Page 112 MAINTENANCE Lights Rear Turn Signal Light Replacement 1. Remove the rear turn signal lens. 2. Remove the expired lamp. 3. Apply dielectric grease to the socket before installing the new lamp. 4. Test the light for proper operation. Brake Lights 1.
  • Page 113 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 114 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 115 Always see your authorized GEM dealer for battery-related service. WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.
  • Page 116 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 117 (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...
  • Page 118 3 under bench seat, 3 in rear spat GEM eS 4 under bench seat, 2 in rear bed GEM e4 (short-bed option) 4 under bench seat, 2 in rear bed GEM eL 3 under bench seat, 3 in rear bed...
  • Page 119 MAINTENANCE Batteries Battery Access Spat Batteries located in the rear spat or rear bed can be Access Cover 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.
  • Page 120 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.
  • Page 121 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- ies, check the fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a battery. NOTICE: Never charge batteries if plates are exposed above the water level.
  • Page 122 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.
  • Page 123 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...
  • Page 124 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.
  • Page 125 Check the 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.
  • Page 126 (+) and the negative cable is attached to the negative post (-). Battery posts are identified on the battery case as positive (+) and negative (-). Always see your authorized GEM dealer for battery-related service.
  • Page 127 Contact local and/or state environmen- tal officials regarding disposal information. You can also contact GEM Customer Service for information. See page 5.
  • Page 128 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.
  • Page 129 MAINTENANCE Batteries 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.

  • Page 130: Cleaning And Storage

    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.
  • Page 131 Cleaning and Storage Cleaning Seats Use GEM Foaming All Surface Cleaner to clean the seats. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt and other soils will stain if not removed quickly. Use a clean cloth and solvent type vinyl cleaner, then wash the area thoroughly with a damp cloth and mild liquid detergent.
  • Page 132 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 Main- tenance Chart beginning on page 96. 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 page 122. 3.
  • Page 135 9. If the vehicle is not connected to the charger, turn off the main disconnect switch. Cover the vehicle with a genuine GEM vehicle cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corro- sion and oxidation.

  • Page 136: Specifications

    SPECIFICATIONS GEM e2 GEM e4 GEM eS Dimensions Curb Weight 1120 lbs. (508 kg) 1270 lbs. (576 kg) 1150 lbs. (521.6 kg) Length 99 in. (251.5 cm) 128 in. (325 cm) 108 in. (274.3 cm) Width 55 in. (139.7 cm) 55 in.
  • Page 137 SPECIFICATIONS GEM e2 GEM e4 GEM eS Performance Motor 5 HP (7 HP optional), shunt DC electric 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)
  • Page 138 SPECIFICATIONS GEM e2 GEM e4 GEM eS Suspension 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)
  • Page 139 SPECIFICATIONS ® GEM eL GEM eL XD GEM e6 Dimensions Curb Weight 1235 lbs. (560 kg) 1550 lbs. (703 kg) 1620 lbs. (735 kg) Length 144 in. (365.8 cm) 144 in. (365.8 cm) 162 in. (411.5 cm) Width 55 in. (139.7 cm) 55 in.
  • Page 140 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...
  • Page 141 SPECIFICATIONS ® GEM eL GEM eL XD GEM e6 Suspension Front suspension Independent wishbone w/coil over shock Rear suspension Solid rear axle w/coil over shock Tires 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)

  • Page 142: Warranty

    This warranty is transferable to another consumer during the warranty period through 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.
  • Page 143 25% 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.
  • Page 144 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...
  • 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, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 148 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 authorized GEM dealer that sells the same line as your product.
  • Page 149 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 register 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.
  • 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 Accelerator Pedal ... . . 55 Battery Discharge Indicator . . . 48-49 Defogger/Heater/Fan... 84 Accessory Backs ... . 77-79 Brake Lever, Park .
  • Page 156 INDEX Glove Box ....35 LCD Display Indicators..42-51 Park Brake Lever ... 56-57 Grab Handle Package .
  • Page 157 INDEX Solar Panel ....76 Tires....104-108 Warning Symbols .
  • Page 158 For your nearest GEM dealer, call 855-RIDEGEM (855-743-3436) or visit www.gemcar.com Polaris Industries Inc. 2100 Hwy. 55 Medina, MN 55340 Part No. 9925609 Rev 01 Printed in USA...

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