2012 Polaris Universal GEM Owners Manual

2012 Polaris Universal GEM Manual

2012 Polaris Universal GEM manual content summary:

  • 2012 Polaris Universal GEM | Owners Manual - Page 1
    Global Electric Motorcars by 2012 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information.
  • 2012 Polaris Universal GEM | Owners Manual - 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.
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    The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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    R For your nearest GEM dealer, call 855-RIDEGEM (855-743-3436) or visit www.gemcar.com Polaris Sales Inc. 2100 Hwy. 55 Medina, MN 55340 Part No. 9923940 Rev 01 Printed in USA Global Electric Motorcars by
  • 2012 Polaris Universal GEM | Owners Manual - Page 5
    R Global Electric Motorcars by 1
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    . Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2012 GEM Owner's Manual P/N 9923940 2
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    TABLE OF CONTENTS Introduction...6 Safety ...12 Features and Controls ...32 Operation...88 Maintenance ...98 Specifications ...136 Warranty ...142 Maintenance Log ...149 Index ...153 3
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    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 9
    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
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    streets posted with low speed limits. Please familiarize yourself with all laws and regulations concerning the operation of the vehicle in your area. This manual applies to the following GEM vehicles: • GEM e2 (two-passenger) • GEM e4 (four-passenger) • GEM eS (two-passenger short-bed) • GEM eL (two
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    on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
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    under age 16 and NEVER operate without a valid driver's license. • Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels. • Operate this vehicle only on public or private roads where speed limits are appropriate for low speed vehicles. Be familiar
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    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. 9
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    INTRODUCTION Manufacturer's Label (Vehicle Information Label) Manufacturer's Label Tire / Wheel Information GAWR Information Date of Manufacture USA Label EU Label VIN GVWR Information 10
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    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: _____ 11
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    of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If any label becomes illegible or comes off, contact your authorized GEM dealer to purchase a replacement
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    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
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    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
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    could be seriously or fatally injured by electric shock if you attempt to open, repair, test, inspect or adjust. Only qualified technicians should open and service. Consult service manual. 15
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    SAFETY Safety Labels and Locations Cargo Warnings Cargo warning labels are located in the beds of GEM eL and GEM eL XD models. CARGO WARNING (eL) • Maximum cargo capacity of this bed should never exceed 700 lbs. (317.5 kg). • Distribute weight equally over axle. • No passengers permitted. • Abuse or
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    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. Follow the operating procedures described. • Never allow anyone under age
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    turning at sharp angles in reverse. • Always use the proper size and type of tires and always maintain proper tire pressure as specified in this manual and on safety labels. • Never modify this vehicle through improper installation or use of accessories. 18
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    be properly distributed and securely attached. Reduce speed and follow the instructions on cargo warning labels for hauling cargo. Allow a greater distance for the water in flooded type batteries, never attempt to perform service on the electric drive system, including the battery pack, unless
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    each time you use it to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. 20
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    SAFETY Operator Safety • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized GEM
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    exceeding the GVWR. This capacity is determined by calculating the difference between your vehicle's GVWR and wet weight. Refer to the specification section of this manual or the Manufacturer's Label on the vehicle for model-specific information. 22
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    SAFETY Operator Safety Gross Vehicle Weight Rating (GVWR) When determining the weight you will be adding to your vehicle, and to ensure you do not exceed the maximum payload capacity, include the following: • operator body weight • passenger body weight • weight of all occupants' apparel and items
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    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
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    , which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner's manual. See the OPERATION section of the owner's manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are
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    properly in different situations and on different types of terrain. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle. Ventilation When Charging Batteries Failure to provide adequate ventilation while charging batteries can
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    to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and
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    SAFETY Operator Safety Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident. After any overturn or accident, have your authorized GEM dealer inspect the entire machine for possible damage, including (but not limited to) brakes, accelerator, steering system and electrical
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    SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn
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    control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Hot Drive Systems The motor and controller are very hot during and after use of the vehicle. Hot components can cause
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    while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. Always follow all safety instructions in the maintenance portion of this owner's manual, as well as the following: • Make sure the vehicle is properly
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    FEATURES AND CONTROLS Console Cup Holders LCD Display Instrument Pod Storage Tray Glove Box Lock Key Switch Turn Signal Windshield Wiper Horn Lever Headlight Switch Trip/Odometer Switch Direction Switch 32
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    FEATURES AND CONTROLS Console Headlight Switch Press the top of the headlight switch to turn the headlights and taillights on. Press the bottom of the switch to turn the lights off. Electrical Components Electrical wiring, circuit boards and components are located under and behind the upper and
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    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. Remove
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    FEATURES AND CONTROLS Console Zero Speed Detection Feature To prevent the vehicle from rolling away, the electric motor will resist vehicle motion if the accelerator pedal is released while the key is on and the vehicle is moving. Horn Press the turn signal wand inward toward the instrument pod to
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    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.
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    FEATURES AND CONTROLS Console Windshield Wiper Push the turn signal lever toward the console and release it to turn the windshield wipers on. Push the lever toward the console again to activate the washer momentarily (if equipped, see page 86). Pull the lever toward the steering wheel to turn the
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    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 kilometers per hour (km/h) and miles to kilometers. •
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    FEATURES AND CONTROLS Console Trip Meter/Odometer/E-Meter Trip Switch Operation Desired Result Toggle between the odometer and trip meter modes on the display Reset the trip meter to zero Press Trip Switch Press and hold for less than 2 seconds Press and hold for 3-9 seconds while display is in
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    FEATURES AND CONTROLS Console Direction Switch NOTICE: Always bring the vehicle to a complete stop before changing the position of the direction switch. Drive High Drive Low Reverse 1. With the key in the ON position, apply the brakes. 2. Move the direction switch to the desired mode. 3. Release
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    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.
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    /Trip Meter Charger Connected State of Charge/ Battery Discharge Current Limiting Mode Seat Belt Warning Reverse Selected Drive Low Selected Drive High Selected BRAKE Speedometer/Service Code/Charge Display Right Turn km/h MPH km MILES TRIP
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    FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Indicator When driving, the speedometer displays vehicle charging, this area displays the percent of charge. When the service indicator illuminates, a service code displays in this area. 74% Charge 43
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    FEATURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/Charge Display Indicator Common service codes are detailed below. Code 06 11 15 16 Condition Accelerator pedal is depressed, If any other codes display, contact your authorized GEM dealer or call GEM customer service. 44
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    for cracks, scuffs and worn spots. If you discover signs of wear or damage, do not operate the vehicle. See your authorized GEM dealer for service. WARNING! Worn or damaged brake hoses can cause brake failure. Always have worn or damaged brake hoses replaced promptly. 45
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    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 overheating. Continued operation could result in motor damage
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    been driven since it was manufactured. The trip meter is useful for logging distances traveled on separate trips. See page 38 for trip meter instructions. The display can be changed to display either standard or metric units of measurement. See page 38. Charger Connected Indicator This indicator
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    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
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    FEATURES AND CONTROLS Console LCD Display Indicators State of Charge/Battery Discharge Indicator (BDI) State of Charge/Battery Discharge Indicator Bars 1 2 3 4 5 6 7 8 9 10 Color Red (Far Left) Yellow Green Green Green Green Green Green Green Green (Far Right) % Of Charge Less Than 10 10-20 20-30 30
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    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
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    high beam or low beam headlight indicator illuminates to indicate which headlight beam is selected. See page 83. Service Required Indicator When the service indicator illuminates, a service code displays in the speedometer/ service code display. See page 43 for common codes and descriptions. 51
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    FEATURES AND CONTROLS Console Main Disconnect Switch WARNING! The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals. HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO
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    connections and components will occur if they are unplugged before the main disconnect switch is turned off. Always turn off the main disconnect switch before servicing or unplugging any electrical components. 53
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    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
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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
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    FEATURES AND CONTROLS Park Brake Lever WARNING! A rolling vehicle can cause serious injury. Always set the park brake when leaving the vehicle unattended. Remove the key from the ignition to prevent unauthorized use. NOTICE: Be sure the park brake is fully disengaged before driving. Failure to do so
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    brake is adjustable and should be checked periodically as outlined in the Periodic Maintenance Chart beginning on page 98. 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 possible. 2. To release the park brake, apply
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    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. 8-Volt Gel Battery 12-Volt Gel Battery 12-Volt Flooded Battery 58
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    FEATURES AND CONTROLS Batteries Battery Performance Tips • New batteries will not perform to their fullest capacity until they have been discharged and recharged 20 to 30 times. • Batteries should be fully charged before the first use. • Recharge the batteries daily, or after each use of the vehicle
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    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
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    FEATURES AND CONTROLS Batteries Battery Charging WARNING! Using a non-recommended extension cord could result in fire, heat damage or charger failure, which could result in serious injury or death. Always use the recommended type of cord to charge the batteries. Tip: Do not use a ground fault
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    FEATURES AND CONTROLS Batteries Battery Charging The battery charge receptacle is located on the hood. When charging the vehicle, always use a standard 3-wire grounded extension cord of one of the following types: • 12-gauge wire with 3-wire grounded, 50 feet (15.25 m) or shorter. • 14-gauge wire
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    FEATURES AND CONTROLS Batteries Battery Charging Always follow these precautions when charging: • Position the vehicle on a level surface. Make sure the charging area is well ventilated. • Make sure the key is off. • Always use the recommended extension cord type. • Inspect the extension cord for
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    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. • Make sure the charger uses a dedicated
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    FEATURES AND CONTROLS Batteries Alternate Battery Charging Method If the combined voltage of all batteries reaches 68 volts or less, a safety feature in the onboard charger will not allow the charger to activate. Use the alternate charging method to add a small charge to each battery separately. The
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    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
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    compartment or on any other electrical component of the vehicle while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. The main disconnect switch will disable the vehicle by disconnecting the battery pack from
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    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 connectors. • Use only insulated tools when
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    FEATURES AND CONTROLS Seat Heaters (Option) For 2-passenger vehicles, the front driver and passenger seats are heated. For 4-passenger and 6-passenger vehicles both front and second row seats are heated. WARNING! Use care when using the seat heater. It may cause burns even at low temperatures,
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    front edge of the seat to secure the latches. Seat Adjustment The front seats on the GEM e4 and GEM e6® models are equipped with manual seat adjustments. The seat adjustment lever is directly under the front of the seat. Move the adjustment lever to the left and slide the seat
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    in a rear seat. Use the type of restraint that is correct for your child. When using child safety seats, always follow the manufacturer's instructions for proper installation and use in a vehicle containing only a shoulder/lap belt restraint system. Visit www.seatcheck.org or call 1-866-SEATCHECK
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    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. To wear the seat belt properly, follow this procedure: 1. Pull
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    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
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    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
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    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. Push the
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    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. Public Address System (Option) The optional public address (PA) system features a heavy-duty microphone, speaker and four-tone siren
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    FEATURES AND CONTROLS Rear Accessory Backs (Option) Rear accessory back options are available. These rear accessory backs are interchangeable. Trunk Cover Lock Latch Release Handle TrunkBack™ LinksBack™ Clip-In StakeBack™ 77
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    FEATURES AND CONTROLS Rear Accessory Backs (Option) WARNING! Never carry a passenger on a rear accessory back. Do not overload an accessory back. Overloading the vehicle can reduce stability and handling and could cause loss of control. Never exceed the GVWR or the GAWR. See page 22. NOTICE: Use
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    FEATURES AND CONTROLS Rear Accessory Backs (Option) 5. 6. 7. 8. 9. Rotate the release handle to release the dual latches. Remove the safety strap and carefully remove the existing accessory back. Install the desired accessory back onto the mounting brackets. Secure the safety strap. Push the
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    FEATURES AND CONTROLS Chrome Bumpers (Option) Chrome bumpers are for appearance only and will protect the body panels only from minor dents and scratches. They will not provide protection to the vehicle in front or rear collisions. Rugged Bumpers (Option) The rugged bumpers will protect the body
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    the door to open it. The door can be held in the open position using the straps and snaps located on the pillars or door supports. Framed Canvas Doors: To open the doors from outside the vehicle, locate the door knob and slide it in the direction of the arrows. To
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    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
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    FEATURES AND CONTROLS Steering Column Lock (Option) To lock the steering column, insert the key into the steering column lock and turn it clockwise while turning the steering wheel. The wheel may need to turn up to one full revolution. When you feel the lock engage, remove the key. WARNING! Do not
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    of the light. The dome light is powered by four AA batteries. To replace the batteries, remove the light cover and install the new batteries. Instructions are located inside the battery compartment. Switch 84
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    FEATURES AND CONTROLS Heater/Defogger (Option) The heater/defogger unit can be used to provide heat inside the vehicle and to assist in defogging the windshield. The switch is located on the console. Move the switch to the ON position, then adjust airflow to the windshield as needed using the
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    FEATURES AND CONTROLS Windshield Washer (Option) Push the turn signal lever toward the console to turn the windshield 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
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    FEATURES AND CONTROLS Accessory Outlet (Option) 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
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    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
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    OPERATION Pre-Ride Inspection Item Turn signals Mirrors Horn Seat belts Steering Tires Latches (hood/seat) Batteries Battery cables Wheels/fasteners Remarks Ensure operation of all signal lamps Adjust mirrors for proper side and rear view Ensure operation Check length of belt for damage, check
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    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. Turn the key clockwise to the ON position. 5. Apply
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    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
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    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. Avoid
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    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
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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. 3.
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    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. • If parking parallel to a curb, stop the vehicle close to the curb.
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    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
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    OPERATION Transporting the Vehicle Transport the vehicle in a closed trailer if possible. Use the following guidelines when transporting 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. 4.
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    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
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    MAINTENANCE Periodic Maintenance Chart Monthly Maintenance 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
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    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. Brake fluid is hygroscopic
  • 2012 Polaris Universal GEM | Owners Manual - Page 105
    MAINTENANCE Brakes Brake Fluid Minimum Maximum 1. Position the vehicle on a level surface. 2. Open the hood. The brake fluid reservoir is located above and to the rear of the left front tire. 3. View the brake fluid level in the reservoir. The level should be between the upper (MAX) and lower (MIN)
  • 2012 Polaris Universal GEM | Owners Manual - Page 106
    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 looseness. 4. Inspect the brake disc spline and pad
  • 2012 Polaris Universal GEM | Owners Manual - Page 107
    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. If
  • 2012 Polaris Universal GEM | Owners Manual - Page 108
    MAINTENANCE Fuse Replacement NOTICE: Always disconnect the main disconnect switch before servicing or unplugging any electrical components. See page 52. If you experience electrical failures not related to the batteries, a fuse may need replacement. Locate and correct
  • 2012 Polaris Universal GEM | Owners Manual - Page 109
    MAINTENANCE Fuse Replacement Fuse Recommendations Fuse Application Heater Coil (fuse used for accessory) Turn Signals / Brake Lamps Windshield Wiper Accessories Radio Tail Lamp/Headlamps / Horn / License Plate Lamp Heater Radio / Public Address System Odometer Switch Fuse Size 30 amp Spare Wiper
  • 2012 Polaris Universal GEM | Owners Manual - Page 110
    affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Tire Pressure WARNING! Improper tire
  • 2012 Polaris Universal GEM | Owners Manual - Page 111
    or poor driving habits. See your authorized GEM dealer for service. Always replace tires when tread depth is worn to 1/8" Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Aluminum Wheel (12-inch /
  • 2012 Polaris Universal GEM | Owners Manual - Page 112
    an elevated vehicle. If you need access to the bottom of the vehicle, use automotive jack stands to support the vehicle on a firm, level surface, or see your authorized GEM dealer for service. Frame viewed from bottom 1. Position the vehicle on a dry, firm, level surface. 2. Set the park brake
  • 2012 Polaris Universal GEM | Owners Manual - Page 113
    only. Jack the vehicle only from the side of the vehicle, on the main frame rail, at the point where the tub or floor panel support and the main frame rail are welded. Alternative locations include the rear frame rail and the center of the front crossmember. NOTICE: Jacking at any
  • 2012 Polaris Universal GEM | Owners Manual - Page 114
    can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your authorized GEM dealer for service. 1. Set the park brake. 2. Place the wheel in the correct position on the wheel hub. Be sure the
  • 2012 Polaris Universal GEM | Owners Manual - Page 115
    life of the lamp. Headlight Replacement If a headlight 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 lamp can be replaced. Apply dielectric grease to the socket
  • 2012 Polaris Universal GEM | Owners Manual - Page 116
    MAINTENANCE Lights Rear Turn Signal Light Replacement 1. Remove the rear turn signal lens. 2. Remove the expired lamp. 3. Apply dielectric grease to the socket before installing the new lamp. 4. Test the light for proper operation. Brake Lights 1. Remove the brake light lens. 2. Remove the expired
  • 2012 Polaris Universal GEM | Owners Manual - Page 117
    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. Mark 8" (20 cm) X 25 ft. (7.6 m)
  • 2012 Polaris Universal GEM | Owners Manual - Page 118
    MAINTENANCE Lights Headlight Beam Adjustment 3. Apply the brakes. Turn the key on. Turn the headlights on. Tip: Include the weight of a rider on the seat while performing the following step. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below
  • 2012 Polaris Universal GEM | Owners Manual - Page 119
    to cause death by electrocution. With the exception of battery inspections and refilling the water in flooded type batteries, never attempt to perform service on the electric drive system, including the battery pack, unless you are properly trained to work on electrical systems. Always see your
  • 2012 Polaris Universal GEM | Owners Manual - Page 120
    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:
  • 2012 Polaris Universal GEM | Owners Manual - Page 121
    standard configuration consists of six 12-volt batteries. An optional configuration consists of nine 8-volt batteries. See pages 118-119 for battery locations and access instructions. 117
  • 2012 Polaris Universal GEM | Owners Manual - Page 122
    MAINTENANCE Batteries Battery Locations Standard 12-Volt Battery Configurations Model GEM e2 GEM e4 GEM e6® GEM eS GEM e4 (short-bed option) GEM e6® (short-bed option) GEM eL GEM eL XD Quantity 6 6 6 6 6 6 6 6 Locations 4 under bench seat, 2 in rear spat 4 under bench seat, 2 in rear spat 3 under
  • 2012 Polaris Universal GEM | Owners Manual - Page 123
    MAINTENANCE Batteries Battery Access Batteries located in the rear spat or rear bed can be accessed through the battery access covers. Remove the four cover screws to remove a cover. Tip: Remove any rear accessory options that may obstruct the rear spat access cover. Spat Access Cover Batteries
  • 2012 Polaris Universal GEM | Owners Manual - Page 124
    compartment or on any other electrical component of the vehicle while charging the batteries. Always turn off the main disconnect switch before servicing or unplugging any electrical components. See page 52. The main disconnect switch will disable the vehicle by disconnecting the battery pack from
  • 2012 Polaris Universal GEM | Owners Manual - Page 125
    MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Fluid (Flooded Batteries) Gel batteries are maintenance-free batteries. They do not have fill wells. On flooded batteries, check the fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a
  • 2012 Polaris Universal GEM | Owners Manual - Page 126
    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 127
    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 128
    MAINTENANCE Batteries Battery Inspections/Maintenance Clean the Batteries NOTICE: Do not allow cleaning solution or tap water to enter the batteries. Before cleaning, make sure all battery fill well caps are installed securely. 1. Remove corrosion with a stiff wire brush. 2. Wash the terminals and
  • 2012 Polaris Universal GEM | Owners Manual - Page 129
    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. Failure to do so may
  • 2012 Polaris Universal GEM | Owners Manual - Page 130
    to the negative post (-). Battery posts are identified on the battery case as positive (+) and negative (-). Always see your authorized GEM dealer for battery-related service. 126
  • 2012 Polaris Universal GEM | Owners Manual - Page 131
    , 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. See page 5. 127
  • 2012 Polaris Universal GEM | Owners Manual - Page 132
    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 133
    MAINTENANCE Batteries 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. Battery Storage Options Storage Period Less than 10
  • 2012 Polaris Universal GEM | Owners Manual - Page 134
    MAINTENANCE Cleaning and Storage Cleaning the Windshield and Sunroof We recommend using GEM Windshield Cleaner and Protectant to remove normal dust and dirt. A liquid household glass cleaner can also be used. Do not use abrasive cleaners on the windshield and sunroof, as they will cause scratches.
  • 2012 Polaris Universal GEM | Owners Manual - Page 135
    MAINTENANCE Cleaning and Storage Cleaning Seats Use GEM Foaming All Surface Cleaner to clean the seats. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt and other soils will stain if not removed quickly. Use a clean cloth and solvent type
  • 2012 Polaris Universal GEM | Owners Manual - Page 136
    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 137
    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
  • 2012 Polaris Universal GEM | Owners Manual - Page 138
    MAINTENANCE Cleaning and Storage Storing the Vehicle Any time the vehicle will be parked for more than 10 days, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 130. 2. Clean the batteries. See page 124. 3. Prepare the batteries for storage.
  • 2012 Polaris Universal GEM | Owners Manual - Page 139
    MAINTENANCE Cleaning and Storage Storing the Vehicle 7. Verify that tire pressure is at specification. 8. Block the wheels to prevent rolling. WARNING! Do not cover the vehicle while the charger is connected. Dangerous levels of hydrogen gas could accumulate. 9. Cover the vehicle with a genuine GEM
  • 2012 Polaris Universal GEM | Owners Manual - Page 140
    SPECIFICATIONS GEM e2 Dimensions Curb Weight Length Width Height Wheelbase Turning Circle/Radius Payload Capacity (occupants, cargo, options) Gross Vehicle Weight Rating (GVWR) (page 22) Gross Axle Weight Rating (GAWR) Seating 1120 lbs. (508 kg) 99 in. (251.5 cm) 55 in. (139.7 cm) 70 in. (177.8 cm)
  • 2012 Polaris Universal GEM | Owners Manual - Page 141
    SPECIFICATIONS GEM e2 Performance Motor Motor peak Controller Battery pack Maximum speed Range Drive System On-board charger Accessory power supply Brakes Park Brake GE Heavy Duty 5 HP, shunt DC electric motor 23 HP Peak (17kw) Flight Systems, T4, 350 amp DC Controller Six 12-volt flooded lead acid
  • 2012 Polaris Universal GEM | Owners Manual - Page 142
    SPECIFICATIONS GEM e2 Suspension Front suspension Rear suspension Tires Tire pressure Independent wishbone w/coil over shock Solid rear axle w/coil over shock 2-ply street rated tires 12-inch 165/70R-12 (12-inch aluminum turf available) 10-inch: 30 psi (207 kPa) / 12-inch: 32 psi (221 kPa) 13-inch:
  • 2012 Polaris Universal GEM | Owners Manual - Page 143
    SPECIFICATIONS GEM eL Curb Weight 1230 lbs. (558 kg) GEM eL XD Dimensions 1570 lbs. (712 kg) GEM e6® 1560 lbs. (707.6 kg) (e6®) 1860 lbs. (843.7 kg) (e6® w/S option) 162 in. (411.5 cm) 55 in. (139.7 cm) 71 in. (180.3 cm) 133 in. (337.8 cm) 39 feet (11.9 m) 1440 lbs. (653.2 kg) 3000 lbs. (1360.8 kg
  • 2012 Polaris Universal GEM | Owners Manual - Page 144
    SPECIFICATIONS GEM eL Motor Motor peak Controller Battery pack Six 12-volt flooded lead acid batteries (12-volt gel optional) GE Heavy Duty 5 HP, shunt DC electric motor GEM eL XD Performance GEM e6® GE Heavy Duty 7 HP vented, shunt DC electric motor 23 HP Peak (17kw) Flight Systems, T4, 350 amp
  • 2012 Polaris Universal GEM | Owners Manual - Page 145
    SPECIFICATIONS GEM eL Front suspension Rear suspension Tires Tire pressure GEM eL XD Suspension Independent wishbone w/coil over shock Solid rear axle w/coil over shock GEM e6® 2-ply street rated tires 2-ply street rated tires 2-ply street rated tires 12-inch 165/70R-12 TR13" P185/70R13 86H TR13"
  • 2012 Polaris Universal GEM | Owners Manual - Page 146
    for guidelines: TERM FOR VEHICLES WITH LESS THAN 8,000 MILES (12,900 km) Purchase Date - 6th Month of Service 7th - 12th Month of Service 13th - 18th Month of Service 19th - 24th Month of Service WARRANTY COVERAGE FOR BATTERIES DEEMED DEFECTIVE BY GEM 100% of the cost of an approved GEM battery at
  • 2012 Polaris Universal GEM | Owners Manual - Page 147
    WARRANTY BATTERY WARRANTY EXCLUSIONS • Batteries that fail due to lack of battery maintenance, over-charging, under-charging, abuse or neglect is excluded from coverage • Batteries that fail due to fire, wreckage, explosion, or freezing • Broken batteries • Batteries ruined by defective chargers •
  • 2012 Polaris Universal GEM | Owners Manual - Page 148
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2012 Polaris Universal GEM | Owners Manual - Page 149
    COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH GEM. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 145
  • 2012 Polaris Universal GEM | Owners Manual - Page 150
    or federal law, all other warranty terms will remain in effect. Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to
  • 2012 Polaris Universal GEM | Owners Manual - Page 151
    . You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair. If You Move: If you move to another country, be sure to contact GEM
  • 2012 Polaris Universal GEM | Owners Manual - Page 152
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2012 Polaris Universal GEM | Owners Manual - Page 153
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 149
  • 2012 Polaris Universal GEM | Owners Manual - Page 154
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 150
  • 2012 Polaris Universal GEM | Owners Manual - Page 155
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 151
  • 2012 Polaris Universal GEM | Owners Manual - Page 156
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 152
  • 2012 Polaris Universal GEM | Owners Manual - Page 157
    ...82 Cleaning Exterior ...132 Interior ...131 Seats ...131 Windshield and Sunroof ...130 Cleaning and Storage ...130-135 Console ...32-53 Customer Service ...5, 148 Direction Switch ...40-41 Dome Light ...84 Doors ...81 Driving in Reverse ...92 Driving on Slippery Surfaces ...93 Driving Procedure
  • 2012 Polaris Universal GEM | Owners Manual - Page 158
    INDEX Electrical Components ...33 E-Meter...38-39 Equipment Modifications...24 Fluid Levels During Storage ...133 Fluid, Battery ...121-123 Fluid, Brake ...100-101 Fuse Recommendations ...105 Fuse Replacement ...104-105 Glove Box ...35 Grab Handle Package ...82 Gross Vehicle Weight Rating. . 22-23
  • 2012 Polaris Universal GEM | Owners Manual - Page 159
    INDEX Rear Accessory Backs...77-79 Removing Vehicle from Storage 135 Reverse Operaton ...92 Safety Labels...12-16 Safety Symbols ...7 Seat Adjustment ...70 Seat Belt Inspection ...75 Seat Belt Safety Tips...74 Seat Belt, Proper Use ...72-73 Seat Belts ...71-75 Seat Heaters ...69 Seat Removal, Bench
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2012 Owner's Manual for Maintenance and Safety
Read this manual carefully.
It contains important safety information.
Global Electric Motorcars
by