Polaris GEM 2011 User manual

2011 Owner’s Manual
Global Electric Motorcars® by

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GEM Owner’s Manual - Page 1
Table of Contents
.Introduction ..................................................................................3
.Vehicle Identication and Specications......................................8
.Things to Know Before You Operate Your Vehicle.....................16
.Understanding the Standard Features of Your Vehicle ..............21
.Understanding the Optional Features of Your Vehicle ...............56
.Operation and Maintenance.......................................................73
.Limited Warranty and Customer Service .................................105
.Word Index...............................................................................115

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Introduction
CONTENTS
.About this Manual ........................................................................4
.Introduction to Safe Ownership of GEM models..........................5
.Cautions, Warnings and Notes ....................................................7
NOTE: This manual is subject to change. For the latest version please
visit www.gemcar.com, and click on About GEM, Current GEM Owners,
and Owners Manuals.
You can be badly injured working on an electric vehicle. Take your vehicle to your
dealer or call Global Electric Motorcars Customer Service at 866-764-0616 for
your service needs.
WARNING
Any modicaons or alteraons to this vehicle could seriously aect its road
worthiness and safety and may lead to an accident resulng in serious injury or
death.
WARNING

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ABOUT THIS MANUAL
Thank you for purchasing your GEM car by Polaris Industries Inc.
Your vehicle is designed to operate exclusively on battery power. It is
an emission-free vehicle. The ideal application for a battery-powered
neighborhood electric vehicle (NEV) occurs when the daily driving
pattern is predictable and the distance is relatively short.
Polaris’ objective includes customer safety and product satisfaction.
This Owner’s Manual is designed to acquaint you with the proper and
safe operation of your GEM car. Please take the time to read and
understand the manual before operating your vehicle. Maintenance
schedules and general care instructions are included in the Operation
and Maintenance section.
This manual is applicable to the following GEM line of vehicles: GEM e2
(two passenger), GEM e4 (four passenger), GEM eS (two passenger
short-back), GEM eL (two passenger long-back), GEM eL XD (two
passenger extra duty long-back), and the GEM e6® (six passenger).
Introduction

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If questions arise after reading the manual, you may contact us at 866.764.0616.
Please have your Vehicle Identication Number (VIN) and date of purchase
information available.
NOTE: All information and specications in this Owner’s Manual are current
at the time of printing. However, due to GEM policy of continuous product
improvement, we reserve the right to make changes, at any time, without
written notice or obligation.
Introduction
INTRODUCTION TO THE SAFE OWNERSHIP OF GEM LINE OF
VEHICLES
GEM battery-electric vehicles are different from vehicles you might be
accustomed to owning. Special precautions should be followed when owning
and operating a GEM car. Please read this Manual and pay particular
attention to the cautions and warnings in this Manual, as well as those placed
on the vehicle in various locations.
In general, GEM battery-electric vehicles are designed to meet U.S. Federal
Government safety requirements for a special class of vehicle known as
“Low Speed Vehicles.” By this very name, and implicit in these safety
requirements, these vehicles are intended only for use at low speed, up to
25 mph, and on public roads (governed by individual state laws) where the
speed limits are correspondingly low.

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Specic to GEM car models, the following safe habits should always be
followed:
• GEM battery-electric vehicles are open vehicles. For this reason, safety
belts should always be worn by all occupants to prevent being thrown from
the vehicle during operation. If your GEM car is equipped with doors, these
were designed and are intended only to keep wind and water out of the vehicle
and should not be relied upon to keep occupants in the vehicle or to protect
them in case of collision.
• GEM battery-electric vehicles are not designed to meet any collision or roll-
over requirements. Therefore, you should always drive your GEM car in a
safe manner while being alert to potential dangerous situations around you.
As with all motor vehicles, never drink alcohol and attempt to drive a GEM car.
Operate a GEM car only on public or private roads where the speed limits are
appropriate for low speed vehicles (individual state laws vary, so check with
your DMV) and the trafc is light. You should never operate a GEM car so that
you are an obstacle and become an annoyance for faster moving trafc.
• GEM battery-electric vehicles are designed to be recharged from a standard
120 VAC-15 amp electrical outlet that is ground-fault protected. Charging from
a circuit of lesser capacity and/or using a cord from the outlet to the GEM car
that is not sufcient in wire gauge could create a re hazard. Please consult this
Manual for the proper extension cord gauge which depends on its length.
• The voltage in a GEM car battery pack (the battery pack is what you charge
Introduction

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GEM Owner’s Manual - Page 7
and provides the “fuel” to the GEM cars electric drive system) is sufcient to
cause death by electrocution. For this reason, GEM car owners should NEVER
attempt to do any maintenance or repair work on their GEM cars electric drive
system, including the battery pack, unless they have had special training. The
one exception is inspection and relling, if necessary, of the water in ooded type
batteries that can be ordered with the GEM line of vehicles.
In this Owner’s Manual, the above safe ownership and operation habits will be
pointed out to you as the different aspects of owning and operating a GEM car
are explained. Please read, understand and abide by them for years of safe
operation and enjoyment of your GEM car.
WARNINGS, CAUTIONS, NOTICES AND NOTES
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.
The safety alert symbol indicates a potential personal injury
hazard.
WARNING indicates a hazardous situation which, if not avoided,
may result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, may
result in minor or moderate injury.
NOTICE indicates a situation that may result in property damage.
NOTE indicates information to help clarify procedures.
Introduction

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Vehicle Identication and Specications
CONTENTS
.Vehicle Information ......................................................................9
.General Specications ...............................................................10

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VEHICLE INFORMATION
Figure 1 - VIN/Certication Label Location
For all model vehicles, the Vehicle Identication Number (VIN) can be
found on the VIN/Certication Label, located on the left rear section of
the roof panel. The VIN indicates the model year, the model type and
the serial number of the vehicle.
NOTE:Be sure to record the Vehicle Identication Number in the
space provided.
0001
1
Vehicle Identication and Specications
Vehicle Identication Number (VIN):
__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
Key # ___________ (Stamped on Key)
Optional Rear Accessory # _______________ (Stamped on Key)
Date purchased: _____ /_____ /_____

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GENERAL SPECIFICATIONS
GEM e2 Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 99”
Vehicle Height: 70”
Wheelbase: 72”
Turning Circle: 24 feet*
Curb Weight: 1120 lbs.
GVWR: 1850 lbs.
Payload Capacity: 730 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
Vehicle Identication and Specications

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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM e4 Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 128”
Vehicle Height: 70”
Wheelbase: 102”
Turning Circle: 32 feet*
Curb Weight: 1280 lbs.
GVWR: 2200 lbs.
Payload Capacity: 920 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.

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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM eS Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 108”
Vehicle Height: 70”
Wheelbase: 72”
Turning Circle: 25 feet*
Curb Weight: 1160 lbs.
GVWR: 1850 lbs.
Payload Capacity: 690 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.

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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM eL Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 144”
Vehicle Height: 70”
Wheelbase: 114”
Turning Circle: 35 feet*
Curb Weight: 1230 lbs.
GVWR: 2300 lbs.
Payload Capacity: 770 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.

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GENERAL SPECIFICATIONS
GEM eL XD Specications
Motor: GE Heavy Duty 7 hp vented, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires TR13” P185/70R13 86H
Battery Pack: Nine 8-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 144”
Vehicle Height: 70”
Wheelbase: 114”
Turning Circle: 35 feet*
Curb Weight: 1570 lbs.
GVWR: 3000 lbs.
Payload Capacity: 1430 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
Vehicle Identication and Specications

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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM e6® Specications
Motor: GE Heavy Duty 7 hp vented, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires TR13” P185/70R13 86H
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number (e6 w/S option) Nine 8-volt lead acid gel
batteries of specic make and model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Onboard Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
DC output
Vehicle Width: 55”
Vehicle Length: 162”
Vehicle Height: 70”
Wheelbase: 133”
Turning Circle: 39 feet*
Curb Weight: 1560 lbs.
1860 lbs w/S option
GVWR: 3000 lbs.
Payload Capacity: 1440 lbs.** (options + passengers + cargo)
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.

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Things to Know Before You OperateYour Vehicle
CONTENTS
.Driving and Alcohol ....................................................................17
.Safety Information......................................................................18

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DRIVING AND ALCOHOL
Your ability to drive your GEM car can be seriously impaired with
blood alcohol levels far below the legal minimum. If you are drinking
alcohol, don’t drive. Ride with a designated non-drinking driver, call a
cab, or use public transportation.
Things to Know Before You OperateYour Vehicle
Driving aer drinking alcohol can lead to an accident resulng in death or serious
injury. Your percepons are less sharp, your reexes are slower, and your judgment
is impaired when you have been drinking. Never drink alcohol and drive.
WARNING

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SAFETY INFORMATION
• Read the Owner’s Manual before operating this vehicle.
• Charge vehicle in a well-ventilated area only.
• Keep children away from the vehicle during charging.
• Batteries can emit explosive hydrogen gases when charging. Keep
sparks and ames away from the battery area of the vehicle. Tools,
wires and metal objects can cause sparks when shorted across the
battery connections. Follow all instructions carefully when dealing
with batteries.
• The batteries in the GEM car are either 12 volt or 8 volt lead acid
batteries. They are connected in a pack conguration to produce
HIGH VOLTAGE DC (72 to 100 volts). These batteries are either
Flooded electrolyte type or Gel electrolyte type and are selected
specically to optimize the operation and performance of your vehicle.
Never use or substitute any battery other than the original
factory approved batteries.
Things to Know Before You OperateYour Vehicle
Your vehicle is baery powered. If handled improperly, baeries can be dangerous.
Follow the precauons provided on pages 18-19 during charging operaons to avoid
personal injury or damage to electrical components in the vehicle.
WARNING

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• Electrolyte can leak from damaged or defective ooded batteries. Avoid
contact with skin, eyes or clothing.
• Batteries contain acid, which can cause severe burns. If battery uid
comes in contact with your skin, ush the affected areas with water for at
least 15 minutes and then seek medical assistance.
• Internal ingested: Get medical assistance as soon as possible.
• Contact with eyes: Flush with water and get medical assistance as soon as
possible. While you are being driven to get medical assistance, continue
to rinse your eyes by using a sponge or soft cloth saturated with water.
Things to Know Before You OperateYour Vehicle
Baery posts, terminals, and related accessories contain lead and lead compounds.
Always wash hands aer handling the baery.
WARNING
Improper handling of high voltage wiring, baeries, or control systems could result
in serious or fatal injury by electric shock. Only qualied technicians should repair
or access high voltage wiring, baery packs, and associated systems.
WARNING
When checking the electrolyte level in ooded baeries, be careful to never touch
the baery terminals.
CAUTION