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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. WARNING Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
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2018 Owner’s Manual for Maintenance and Safety...
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POLARIS®, GEM®, Global Electric Motorcars®, and e6® are trademarks of POLARIS Industries Inc. Copyright 2017 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.
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SAFETY SYMBOLS AND SIGNAL WORDS 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
OVERVIEW Please familiarize yourself with all laws and regulations concerning the operation of the vehicle in your area. This manual applies to the following GEM vehicles: • GEM e2 (two-passenger) • GEM e4 (four-passenger) • GEM eL XD (two-passenger extra duty long-bed) •...
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Never exceed the GVWR or the GAWR. See page 15. Vehicle Model Number: Vehicle Identification Number: REPLACEMENT KEYS To order an extra or replacement key for the ignition or for accessory locks, please contact GEM customer service. Be prepared to provide your key number and VIN.
If any label becomes illegible or comes off, contact your authorized GEM dealer to purchase a replacement. Replacement safety labels are provided at no charge.
SAFETY LOW SPEED VEHICLE DISCLOSURE This Vehicle: • Has a maximum speed of greater than 20 miles per hour, but not greater than 25 miles per hour; • May be a hazard on the roadways if it impedes traffic; • May subject the driver to citations for impeding traffic; •...
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SAFETY GENERAL WARNING WARNING • Read your owner’s manual before operating this vehicle. • Do not operate this vehicle under the influence of alcohol, drugs or medication. • This vehicle is not intended to be driven at speeds exceeding 25 MPH (40 km/ •...
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SAFETY SOLAR PANEL DO NOT STACK WARNING This label is located at the rear center of the solar panel (if equipped). WARNING DO NOT STACK. PASSENGER/REAR CARGO WARNING This label is centrally located under the center high mount stop lamp (if equipped) .
. See page 55 for towing procedures. WARNING CAPACITIES GEM EL XD A: Occupant Capacity 300 lbs. (136 kg) B: Cargo Capacity (includes cargo, 1150 lbs. (522 kg)** bed load and optional equipment) C: Maximum Trailer Tongue Weight 150 lbs.
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Your authorized GEM dealer can provide battery-related service. • Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
SAFETY • Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation. • Never consume alcohol or drugs before or while operating this vehicle. • Never operate at excessive speeds. Always travel at a speed proper for the traffic, visibility and operating conditions, and your experience.
Never install any accessory that grounds to the vehicle chassis. The chassis is a floating ground to protect against electrical short circuits and hazards. Do not install any non-GEM-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non- GEM-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.
SAFETY SEAT BELTS Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop. Occupants must wear seat belts at all times. Always make sure the seat belts are secured for operator and all passengers before operating.
SAFETY OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the traffic, the visibility and operating conditions, your skills and your passengers’ skills. EXHIBITION DRIVING Exhibition driving increases the risk of an accident or overturn.
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Your authorized GEM dealer can provide battery- related service. WARNING Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries.
FEATURES AND CONTROLS FEATURES AND CONTROLS CONSOLE Left Control Lever Glove Box Lock Cup Holder Gauge Key Switch Trip Switch/MODE Switch Right Control Lever Storage Tray...
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FEATURES AND CONTROLS 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 The key must be in the ON position to activate the turn signals. Check turn signal lamps before each ride.
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FEATURES AND CONTROLS RIGHT CONTROL LEVER The right control lever contains the hazard signal switch, and the windshield wiper and washer switches (if equipped). HAZARD SIGNAL SWITCH Press the tip of the lever inward cause all turn signal lamps to flash simultaneously.
FEATURES AND CONTROLS STEERING WHEEL ADJUSTER If equipped, the steering wheel can be tilted upward or downward for rider preference. Pull and hold the adjustment lever upward while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
FEATURES AND CONTROLS Always come to a complete stop before reversing direction. To choose the forward option, push the top of the switch . Push the bottom of the switch to choose reverse operation . When the direction selector is in the center position , the vehicle is in neutral.
FEATURES AND CONTROLS DIGITAL/ANALOG GAUGE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.
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Check hoses for cracks, scuffs and worn spots. If you discover signs of wear or damage, do not operate the Brake system vehicle. Your authorized GEM dealer can provide service. WARNING Worn or damaged brake hoses can cause brake failure. Always have worn or...
FEATURES AND CONTROLS RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer.
Cold weather can have a drastic effect on all electric vehicles. The colder the ambient storage temperature, the slower the rate of charge and discharge of batteries. In the application of an electric vehicle like GEM, cold weather will drastically decrease the achieved range on a charge.
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GEM is used in colder temperatures, as long as it is used periodically, and does not sit idle for an extended period.
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If you are working on a MY16-18 core GEM vehicle, and suspect that the cab heater’s usage is not being accounted for in the state of charge, reference Team Tip L-18-04-02.
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FEATURES AND CONTROLS 1. Turn the key to the ON position. Use the MODE button to toggle to the clock display. 2. Press and hold the MODE button until the hour segment flashes. Release the button. 3. With the segment flashing, tap the MODE button to advance to the desired setting.
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FEATURES AND CONTROLS DISCONNECTING POWER 1. Position the vehicle on a dry, firm, level surface. 2. Set the park brake. 3. Turn the key off. 4. Remove the hood. See page 48. 5. Locate the main power connector at the lower left front of the vehicle, below the horn assembly.
FEATURES AND CONTROLS 4. Reconnect the main power connector. 5. Reinstall the hood, rear access panel, and dash. BRAKE AND ACCELERATOR PEDALS 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.
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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.
Each vehicle is programmed at the factory for a particular battery type. Switching battery types should be done only by an authorized service technician. Your authorized GEM dealer can provide battery-related service. To access the battery pack, remove any rear accessory back installed on the vehicle.
FEATURES AND CONTROLS IMPORTANT Avoid temperature extremes when choosing a storage area. 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.
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A GFI (Ground Fault Interrupt) receptacle is recommended. See your authorized GEM dealer if you do not have a GFI receptacle at your regular recharge site. • Make sure the charger uses a dedicated circuit to prevent overloading. If charging multiple vehicles, each vehicle should use a dedicated circuit.
FEATURES AND CONTROLS FAST CHARGE RECEPTACLE The following information applies to use of the fast charge receptacle. See page 38 for information that applies to the use of the standard charge receptacle. NOTE Enhanced standard charge cord will not insert into the fast charge receptacle and damage may occur if forced.
FEATURES AND CONTROLS It is not necessary to remove or disconnect battery post connections during the alternate charging method. 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. 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...
FEATURES AND CONTROLS BRAMMO® LITHIUM-ION COLD BATTERY PERFORMANCE • The Brammo li-ion batteries in your vehicle will not accept a charge unless internal battery temperatures are at or above 41° F (5° C). • When ambient temperature is at or above -16° F (-27° C), the battery heaters will use battery pack energy to warm the batteries to an internal temperature of 41°...
FEATURES AND CONTROLS USB PORT The fuse for the USB port is located under the hood in the fuse block. Always use fuses with the same type and rating. NOTICE Do not plug in devices requiring power exceeding 25 watts. Damage to the vehicle electrical system may occur or an accessory fuse may blow.
FEATURES AND CONTROLS DOORS Accessory doors are available for most models. 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.
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FEATURES AND CONTROLS 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 illuminate if the driver’s seat belt is not fastened.
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FEATURES AND CONTROLS 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.
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FEATURES AND CONTROLS SOLAR PANEL (OPTION) The optional solar panel is mounted on top of the vehicle. Refer to your solar panel user manual for details. WARNING Do not stack items on the solar panel. Never exceed the GVWR or GAWR. REAR ACCESSORY BACKS (OPTION) Rear accessory back options are available.
Never exceed the GVWR or the GAWR of the vehicle. See page 15. NOTICE Use only GEM-approved rear accessories. Others may cause damage to the locking system or vehicle, and will void warranty. GRAB HANDLE PACKAGE (STANDARD) Grab handles can be added at each seat position to assist riders in entering and exiting the vehicle.
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-end collisions. NOTICE Never use your GEM vehicle for pushing. Damage to the vehicle may result.
FEATURES AND CONTROLS HEATER/FAN (OPTION) The heater unit can be used to provide heat inside the vehicle. The switch is located on the console. Move the switch to the HEAT position. Move the switch to the FAN position to operate air flow without heat. HEATED WINDSHIELD (OPTION) The heated windshield has heating elements within the glass to assist in defogging the windshield.
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FEATURES AND CONTROLS WINDSHIELD WASHER (OPTION) Rotate the knurled barrel forward to turn the windshield wipers on. Pull the control lever toward the driver’s seat to activate the 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).
OPERATION OPERATION OPERATION WARNING 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.
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OPERATION ITEM REMARKS PAGE Seat belts Check length of belt for damage, check latches page 43 for proper operation Steering Ensure free operation page 24 Tires Check tire condition page 62 and pressure Latches (doors/seats/ Ensure all latches are accessory back) secure Batteries Ensure full charges,...
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.
OPERATION DRIVING IN REVERSE Your vehicle comes with a reverse camera located on the rear-view mirror. Operation of the camera is automatic and is activated when the vehicle’s drive mode switch is in the reverse position. Follow these precautions when operating in reverse: 1.
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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.
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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 frame of the GEM vehicle. Never place tie straps across any plastic body or floor panel components.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine GEM parts are available from your authorized GEM dealer. Record maintenance and service in the Maintenance Log at the back of the book.
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MAINTENANCE MONTHLY MAINTENANCE Check for worn insulation or frayed page 72 wires Check battery hold-down bar to page 72 ensure batteries are tightly secured page 62 Check tires for correct air pressure and wear Check wheels for proper torque after page 66 first 100 miles driven, and after first 100 miles after any wheel if removed...
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.
MAINTENANCE WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.
MAINTENANCE blown fuse, then replace the fuse. If you suspect a relay or diode needs replacement, your authorized GEM dealer can assist. Open the hood to access the fuse box . See the label attached to the fuse box cover for the function and amp rating of each fuse.
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MAINTENANCE STANDARD 48V FUSES APPLICATION SIZE LOCATION Motor Controller/ BMC 5 amp 48V Fuse Center DC-DC; Charger 30 amp 48V Fuse Center OPTIONAL 48V FUSES APPLICATION SIZE LOCATION Lithium-ion 5 amp Lithium-ion Harness Heater Heating Element 30 amp Heater Harness Defrost 30 amp Defrost Harness...
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TIRE TREAD DEPTH Any accelerated wear of tires may be an indicator of improper alignment or poor driving habits. Your authorized GEM dealer can assist. Rotate wheels every 5,000 miles, or more frequently if needed. Always replace tires when tread depth...
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MAINTENANCE WHEEL NUT TORQUE Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud, the lug nut, or the washers (washers equipped on vehicles with factory steel wheels). Check wheels for proper torque after first 100 miles driven and the first 100 miles after nay wheel is removed.
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If you need access to the bottom of the vehicle, use automotive jack stands to support the vehicle on a firm, level surface. Your authorized GEM dealer can assist. 1. Position the vehicle on a dry, firm, level surface.
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MAINTENANCE 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.
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MAINTENANCE JOINT INSPECTION CHART IMPORTANT A secondary dealer representative must verify that all sixteen flange nuts are raised off of the rim and do not make contact with the rim. Then mark each lug nut with a paint pen. FRONT WHEELS...
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MAINTENANCE REAR WHEELS LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced.
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MAINTENANCE 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. 3.
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Your authorized GEM dealer can provide battery-related service. WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.
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Before accessing the batteries, make sure any wire or metal items remain clear of the battery compartment to avoid causing a short circuit to the electrical system. Several battery pack configurations exist for GEM vehicles. • Four 12-volt lead acid batteries • Eight 6-volt lead acid batteries •...
Using an insulated wrench, torque bolts to 8 lb-ft (10.8 Nm). 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.
With proper care and maintenance as outlined in this owner’s manual battery life can be maximized depending on the amount of use. 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.
Accessory watering systems are available for 12-volt and 6-volt flooded batteries. See your authorized GEM dealer for more information. NOTICE Never charge batteries if plates are exposed above the water level.
For neutralized spills, place residue in acid- resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information. You can also contact GEM Customer Service for information.
These products scratch or destroy acrylic surfaces. 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.
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12-volt battery (if equipped), then disconnect the negative terminal from the main battery pack. See page 32. Cover the vehicle with a genuine GEM vehicle cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent...
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) 55.5 in. (141 cm) 55.5 in. (141 cm) Width Height 73.1 in. (186 cm) 73.1 in.
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14-inch Aluminum 4.5-inch ET11 165/70R14 Tires This tire should only be replaced by a 165/70R14 81T tire Tire pressure 35 psi (241 kPa) GEM EL XD GEM E6® DIMENSIONS Dry Weight 1585 lbs. (720 kg) 1696 lbs. (769 kg) Length 145.5 in.
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SPECIFICATIONS 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 Standard 1 kW, 120/240V input (optional 3 kW or 6 On-board charger kW, SAE J1772) BRAKE SYSTEM...
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.
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POLARIS Industries Inc. gives a FIVE-YEAR/30,000-MILE (48,300 km) LIMITED parts and labor warranty on the battery pack against defects in material or workmanship on your GEM vehicle. The FIVE-YEAR/30,000- MILE (48,300 km) term begins on the purchase date, is fully transferable and has no deductible.
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WARRANTY adjustment or altitude compensation; snow, water, dirt or other foreign substance contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center. 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...
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CONTROLLING STATE LAW. HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a GEM Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER MAY BE YOUR RESPONSIBILITY).
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.
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100 miles (160 km) each. A trip includes towing from your vehicle’s location to the nearest GEM dealer, a second trip can be used to return the vehicle from the GEM dealer to your location. Your VIN is your vehicle’s contract number.
MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. SERVICE MILES (KM) OR DATE TECHNICIAN PERFORMED / HOURS COMMENTS...
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MAINTENANCE LOG SERVICE MILES (KM) OR DATE TECHNICIAN PERFORMED / HOURS COMMENTS...
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MAINTENANCE LOG....89 Miles/Kilometers Indicator ... 28 Headlight Beam Adjustment..69 Mode Button......26 Headlight, Turn Signal, and Brake Light Replacement... 68 Heated Windshield..... 49 Heater/Fan....... 49 Hitches........48 Noise and Vibration....16 Hood ........48 Notice ........87 Hot Drive Systems ..... 19 HOW TO OBTAIN WARRANTY SERVICE .......
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Seat Belt Safety Tips ....45 Wheel Installation ...... 66 Seat Belt Warning...... 11 Wheel Nut Torque...... 64 Seat Belts ......17, 43 Wheel Removal......65 Signal Words ......4 Windshield Washer ....50 Solar Panel ......46 Solar Panel Do Not Stack Warning .........
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For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9928180 Rev 04 Printed in USA...
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