Instruction/ maintenance manual of the product 419C GEM
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P antone 419C 2013 Owner's Manual for Maintenance and Safety Read this manual carefully . It contains important safety information..
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2 The following are registered trademarks of POLARIS Industries Inc.: Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Features and Controls .
4 WELCOME Thank you for purchasing a GEM by POLARIS, and welcome to our world-wide POLARIS family of recreational and utility vehicle owners. W e believe POLARIS sets a standard of excellence for all recreational and utility vehicles manufactured in the world today .
5 WELCOME For safe and enjoyable operation of your vehicle, be sure to follow the instructions and rec- ommendations in this owner ’ s manual. Y our manual contains instructions for minor mainte- nance, but information about major repairs is outlined in the GEM Service Manual and should be performed only by an authorized GEM dealer technician.
6 INTRODUCTION This vehicle complies with the U.S. Department of T ransportation National Highway T raffic Safety Administration (NHTSA) low-speed vehicle regulations and can be operated on many streets posted with low speed limits. Please familiarize yourself with all laws and regulations concerning the operation of th e vehicle in your area.
7 INTRODUCTION Safety Signal Words and Symbols The following signal words and symbols appear th roughout this manual an d on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
8 INTRODUCTION Failure to follow the warning s contained in this manual can result in severe injury or death. S p ecial precautions must be followed whe n owning and operating a battery-po wered vehicle. This vehicle is not a toy and can be hazardous to operate.
9 INTRODUCTION Manufacturer ’ s Label (V ehicle Information Label) Record your vehicle's ide ntification numbers and key number in the spaces provided on page 11 . The V ehicle Identification Number (VIN) is on the manufacturer ’ s label, located on the left rear section of the roof panel.
10 INTRODUCTION Manufacturer ’ s Label (V ehicle Information Label) Manufacturer ’s Label VIN GVWR Informati on T ire / Wheel Information GA WR Informatio n Date of Manufacture USA Label EU Label.
11 INTRODUCTION Manufacturer ’ s Label (V ehicle Information Label) V eh icle Identification Number (VIN): |___|___|___|___|___|___|___|___|___|___|___|___|__ _|___|___|___|___| V eh icle Model Numb.
12 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle .
13 SAFETY Safety Labels and Locations General W arning • Although most states prohibit this vehicle from operati ng on streets having posted speed limits of more than 35 MPH (56 km/h), state and local rules may vary . Check with your local law enforcement (city and state officials) for variations in your area.
14 SAFETY Safety Labels and Locations Door/Seat Belt W arning This label is located near the lower edge of the window on t he driver ’ s side door on models equipped with doors. W ARNING The doors on this vehicle are designed only for protection agai nst the elements.
15 SAFETY Safety Labels and Locations High V oltage W arning High voltage warning labels are located in two places on your vehicle: near the battery com- partment and under the hood near the motor controller .
16 SAFETY Safety Labels and Locations Cargo W arnings Cargo warning labels are lo cated in the beds of GEM eL and GEM eL XD models. CARGO W ARNING (e L) • Maximum cargo capacity of this bed should never exceed 700 lbs. (317.5 kg). • Distribute weight equally over axle.
17 SAFETY Operator Safety Serious injury or death can result if you do not follow these instructio ns 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.
18 SAFETY Operator Safety • Never exceed the gross vehicle weight rating (GVWR) of your vehicle. • The cab frame is not designed or intended to provide rollover protection. A void situ- ations that could result in a rollover . • Always be sure there are no obstacles or people behind your vehicle when operat- ing in reverse.
19 SAFETY Operator Safety • Never carry loads on the roof of the vehi- cle. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions on cargo warning labels for hauling car go.
20 SAFETY Operator Safety • Do not carry a passenger until you have at least two hours of driving experience with this vehicle. • Always keep arms and legs inside the cab frame while the vehicle is in motion. • Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation.
21 SAFETY Operator Safety • Never operate on excessively rough, slip- pery 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.
22 SAFETY Operator Safety Gross V ehicle Weight Rating (GVWR) W ARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling and could cause loss of control.
23 SAFETY Operator Safety Gross V ehicle 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.
24 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 .
25 SAFETY Operator Safety Failure to operate this vehicle properly can result in a collision, loss of contro l, accident or overturn, which may result in serious injury or death. Hee d all safety warnings outlined in this sectio n of the owner ’s manual.
26 SAFETY Operator Safety Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident. The opera tor must understand how to operate the vehicle properly in different situations and on different types of terrain.
27 SAFETY Operator Safety Failure to Inspect Before Operating Failure to inspect and verify that the ve hicle is in safe operating condition before op erating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
28 SAFETY Operator Safety Operating a Damaged V ehicle Operating a dama ged vehicle can result in an accident. After any overturn or accident, have your authorized GEM dealer inspect th e entire machine for possible damage, inclu ding (but not limited to) brakes, accelerator , steering system and electrical system.
29 SAFETY Operator Safety T urning Improperly T urning improperly could cau se loss of traction, loss of control, accident or overturn. Always follow proper proced ures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster spee ds.
30 SAFETY Operator Safety Improper Tire Maintena nce Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or a ccident. Always u se the size and type of tire s specified for your ve hicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
31 SAFETY Operator Safety Precautions During Maintenance W ARNING! The vo ltage in the battery pack is sufficient to cause death by electrocution. With the exception of battery inspections and refilli.
32 FEA TURES AND CONTROLS Console T rip/Odometer Switch Headlight Switch T urn Signal Windshield Wiper Horn Lever Direction Switch Key Switch LCD Display Glove Box Lock Cup Holders Instrument Pod S to.
33 FEA TURES AND CONTROLS Console Headlight Switch Press the top of the switch to turn the headlights to high beam. Press the bottom of the switch to turn the headlights to low beam.
34 FEA TURES AND CONTROLS Console Key Switch When the key is turned to the ON position (clockwise), the display will light up and all electrica l accessories can be used. Leaving the key in the ON position will di scharge the batteries. Always turn the key to the OFF position when not operating.
35 FEA TURES AND CONTROLS Console Zero S peed Detection Feature T o 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 sound the horn.
36 FEA TURES AND CONTROLS Console T urn 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.
37 FEA TURES AND CONTROLS Console Windshield W iper Push the turn signal lever toward the cons ole and release it to turn the windshield wipers on. Push the lever toward the con- sole again to activate the washer momentarily (if equipped, see page 85).
38 FEA TURES AND CONTROLS Console T rip Meter/Odometer/E-Meter The trip switch has four functions: • T oggle between the odometer and trip meter . • Reset the trip meter . • Change the function of the speedometer and odometer from miles per hour (MPH) to kilo- meters per hour (km/h) and miles to kilometers.
39 FEA TURES AND CONTROLS Console T rip Meter/Odometer/E-Meter T rip Switch Operation Desired Result Press T rip Switch T oggle between the odo meter and trip meter modes on the display Press and hold.
40 FEA TURES AND CONTROLS Console Direction Switch NOTICE: Always bring the vehicle to a comp lete stop before changing the position of the direction switch. 1. W ith the key in the ON position, apply the brakes. 2. Move the direction switch to the desired mode.
41 FEA TURES AND CONTROLS Console Direction Switch Drive High The HIGH mode allow s 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.
42 FEA TURES AND CONTROLS Console LCD Display Indicators km MILES TRIP BRAKE km/h MPH Left T urn Brake W arning High Motor T emperature W arning Odometer/T rip Meter Charger Connected S tate of Charge.
43 FEA TURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/C harge Display Indicator When driving, the speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). The display can be changed to display either standard or metric uni ts of measurement.
44 FEA TURES AND CONTROLS Console LCD Display Indicators Speedometer/Service Code/C harge Display Indicator Common service codes are detailed below . Tip : If any other codes display , contact your authorized GEM dealer or call GEM customer service. Code Condition Remedy 06 Accelerator pedal is depressed, no direction is selected.
45 FEA TURES AND CONTROLS Console LCD Display Indicators T urn Indicators The corresponding turn signal indicator flashes when a signal is activated. Brake W a rning Indicator The brake warning illuminates when the park brake is engaged or when a brake sys- tem failure has occurred.
46 FEA TURES AND CONTROLS Console LCD Display Indicators High Motor T emperature W arning Indicat or If the motor temperature warning illuminates, or if service code “41” displays in the speedometer/service code display , the motor or motor controller may be overheat- ing.
47 FEA TURES AND CONTROLS Console LCD Display Indicators Odometer/T rip Meter Indicator The odometer indicator logs the total distance the vehicle has been driven since it was manu- factured. The trip meter is useful for logging distanc es traveled on separate trips.
48 FEA TURES AND CONTROLS Console LCD Display Indicators St ate 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.
49 FEA TURES AND CONTROLS Console LCD Display Indicators St ate of Charge/Battery Discharge Indicator (BDI) NOTICE: Batteries can be permanently damaged (and the warranty voide d) if allowed to remain 30 days or more with low charge. Fully ch arge batteries before storing.
50 FEA TURES 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-char ge/battery-dischar ge indicator will also indicate low voltage.
51 FEA TURES AND CONTROLS Console LCD Display Indicators Direction Indicators When the key is on, one of the three direction indi cators illuminate to indicate the selected position of the direction switch (REVERSE, DRIVE LOW or DRIVE HIGH). See page 40.
52 FEA TURES AND CONTROLS Console Main Disconnect Switch W ARNING! The ma in disconnect switch will disable the vehicle by disconnecting the battery pack from the motor . It does no t disable the battery pack. HIGH VOL T AGE will be present at the battery terminals.
53 FEA TURES AND CONTROLS Console Main Disconnect Switch Move the switch to the left (OFF) to disconnect the battery pack from the motor . After the switch is turned off, some power may remain in the system until all capacitors have dis- charged.
54 FEA TURES 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.
55 FEA TURES AND CONTROLS Accelerator Pedal The accelerator pedal is located on the floor to the right of the brake pedal. T o begin moving or to increase vehicle speed, gradually push th e accelerator pedal toward the floor . Holding the accelerator pedal down co ntinuously will accelerate the vehicle to the maximum speed.
56 FEA TURES AND CONTROLS Park Brake Lever W ARNING! A rollin g vehicle can ca use serious injury . Always set the park brake when leavin g the vehicle unattended. Remove the key from the igni tion to prevent unauthorized use . NOTICE: Be sure the park brake is ful ly disengaged before driving.
57 FEA TURES AND CONTROLS Park Brake Lever The park brake lever is located to the lower right of the driver seat. T o help prevent the vehi- cle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, the vehicle will not move.
58 FEA TURES AND CONTROLS Batteries Battery Pack Y our vehicle is equipped with a battery pack con- taining either six 12-volt gel batteries, six 12-volt flooded batteries or nine 8-volt gel batteries that supply the power needed to operate the vehicle.
59 FEA TURES AND CONTROLS Batteries Battery Performance Tip s • New batteries will not perform to their fullest capacity until they have been dis- charged and rechar ged 20 to 30 times. • Batteries should be fully charged before the first use. • Recharge the batteries daily , or after each use of the vehicle.
60 FEA TURES AND CONTROLS Batteries On-Board Charger The on-board battery char ger is lo cated under the hood and can be viewed through the left front wheel well.
61 FEA TURES AND CONTROLS Batteries Battery Charging W ARNING! Using a non-recommended extensi on cord could result in fire, heat da mage or charger failure, which could resul t in serious injury or death. Always use the recommended type of cord to charge the batteries.
62 FEA TURES AND CONTROLS Batteries Battery Charging The battery char ge rece ptacle 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 groun ded, 50 feet (15.
63 FEA TURES AND CONTROLS Batteries Battery Charging Always follow these pr ecau tions when char ging: • Position the vehicle on a level surface. Make sure the charging area is well ventilated. • Make sure the key is of f. • Always use the recommended extension cord type.
64 FEA TURES AND CONTROLS Batteries Battery Charging Tip : Always use a 1 10-volt AC, 15 amp breake r outlet. A GFI (Ground Fault Interrupt) receptacle is rec- ommended. See your authorized GEM dealer if you do not ha ve a GFI receptacle at your regu lar recharge site.
65 FEA TURES AND CONTROLS Batteries Alternate Battery Charging Method If the combined voltage of all batteries reaches 68 volts or less, a safe ty feature in the on- board charger will not allow the charger to activ ate. Use the alternate ch ar ging method to add a small charge to each battery separately .
66 FEA TURES AND CONTROLS Batteries Alternate Battery Charging Method 1. T urn the main disconnect switch off. 2. Set the battery char ger to the medium amp setting (10 to 30 amps).
67 FEA TURES AND CONTROLS Batteries Battery Handling Precautions W ARNING! Do not work in or near the battery compartment or on any other electrical component of the vehicle while chargin g the batteries. Alwa ys turn off the main disconne ct switch before servicing or unplugging any electrical components.
68 FEA TURES AND CONTROLS Batteries Battery Handling Precautions • Never connect jumper cables to any of the batteries of this vehicle. • Always wear safety glasses or approved eye protection when servicing the vehicle. W ear a full-face shield and gloves when working with or around batteries and electrical connec- tors.
69 FEA TURES AND CONTROLS Accessory Outlet The optional accessory outlet is located on the lower console, to the right of the fuse access panel. This outlet will accept a standard automotive 12-volt accessory and is intended for moderately powered accessories, such as a cellular phone.
70 FEA TURES AND CONTROLS Bench Seat Removal Pull up on the front of the seat to disengage the front latches. Slide the seat forward and lift it away from the seat base. T o reinstall the seat, a lign the rear plunger to the socket at the rear of the seat base.
71 FEA TURES AND CONTROLS Seat Belt s Failure to properly use seat belts and child restra ints can result in serious in jury or death. Always follow all legal requiremen ts for seat belt and child restraint use in on-road vehicles. • Always make sure the seat belts are secured for operator and a ll passengers before operating.
72 FEA TURES AND CONTROLS Seat Belt s Proper Seat Belt Use This vehicle is equipped with three-point lap and diago- nal seat belts for all occupants. Always make sure the seat belts are secured for operator and all passengers before operating. T o wear the seat belt properly , follow this procedure: 1.
73 FEA TURES AND CONTROLS Seat Belt s Proper Seat Belt Use 2. Push the latch plate into the buckle until it clicks. 3. Release the strap, it will self tighten. 4. T o remove slack in the lap belt portion of the belt, pull upward on the shoulder belt. T o loosen the lap belt if it is too tight, tilt the buckle and pull the lap belt slightly longer .
74 FEA TURES AND CONTROLS Seat Belt s Seat Belt Safety T ip s • 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.
75 FEA TURES AND CONTROLS Seat Belt s Seat Belt Inspection Inspect all seat belts for prope r 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.
76 FEA TURES AND CONTROLS Stereo System (Option) The optional stereo sy stem is moun ted in an overhead console and fea- tures speakers, FM radio, CD player and MP3 capabilities. Refer to your stereo system’ s user manual for detailed operating instructions.
77 FEA TURES AND CONTROLS Rear Accessory Backs (Option) Rear accessory back options are available. These rear accessory backs are interchangeable. Latch Rele ase Handle T runk Cover Lock T runkBack .
78 FEA TURES AND CONTROLS Rear Accessory Backs (Option) W ARNING! Never carry a passenger on a rear accessory back. Do not overl oad an accessory back. Overloading the vehicle can reduc e stability and handling and could cause loss of control. Never exceed the GVWR or the GAWR .
79 FEA TURES AND CONTROLS Rear Accessory Backs (Option) 5. Rotate the release handle to release the dual latches. 6. Remove the safety strap and carefully remove th e existing accessory back. 7. Install the desired a ccessory back onto the mounting brackets.
80 FEA TURES AND CONTROLS Chrome Bumpers/Rugged Bumpers (Option) Front bumpers are for appearance only and will protect the body panels only from minor dents and scratches. They will not provide protection to the vehicle in front collisions. NOTICE: Never use your GEM vehicle for pushing.
81 FEA TURES AND CONTROLS Doors (Option) W ARNING! Doors do not offer structural protection in the event of an accident an d do not change the open body characteristics of the vehicle. The doors provide protecti on from the weather only . Always use seat belts.
82 FEA TURES AND CONTROLS Grab Handle Package (Option) Grab handles can be added at each seat position to assist riders in entering and exiting the vehicle. Interior grab handles are not intended to retain passengers in the vehicle. Always make sure the seat belts are secured for operator and all passengers before operating.
83 FEA TURES 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.
84 FEA TURES AND CONTROLS Adjust able T ilt Steering Column (Option) T o adjust the tilt steering column, pull the lever at the left of the column rearward toward the driver ’ s seat to release the latch. Adjust the steering column to the desired position, then push the lever toward the console to lock the steering column.
85 FEA TURES AND CONTROLS Windshield W asher (Option) Push the turn signal lever toward the console to turn the wind- shield wipers on. Push the lever toward the console again to activate the washer momentarily . Check the washer reservoir fluid level frequen tly .
86 OPERA TION Failure to operate the vehicle properly can result in a collision, loss of contro l, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual.
87 OPERA TION Pre-Ride Inspection Item Remarks Page T urn signals Ensure operation of all sign al lamps 36 Mirrors Adjust mirrors for proper side and rear view - Horn Ensure operation 35 Seat belts Ch.
88 OPERA TION 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 sea t belt. Make sure passenge rs are seated with seat belts secured. 3. Adjust mirrors as needed.
89 OPERA TION Driving Procedure 1 1. 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 desi gnated passenger seat with seat belt secured.
90 OPERA TION 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. A void backing down hill. 3. Back slowly .
91 OPERA TION Driving On Slippery Surfaces Skidding or sliding can cause loss of control or overturn (if tires regain traction unexp ectedly). When operating on slippery surfa ces, reduce speed and use ex tra caution to reduce the chan ce of skidding or sliding out of co ntrol.
92 OPERA TION Parking the V ehicle 1. Apply the brakes. S top the vehicle on a level surface. 2. When parking inside a garage or ot her structure, be sure that the structure is well venti- lated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
93 OPERA TION Parking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: • If parking in an open area, block the wheels on the downhill side of the vehicle after turn- ing the key of f. • If parking parallel to a curb, stop the vehicle close to the curb.
94 OPERA TION T ransporting the V ehicle NOTICE: T owing your GEM vehicle could result in severe damage to the vehicle. V ehicle failures resulting from dolly towing will void warranty .
95 OPERA TION T ransporting the V ehicle T ransport the vehicle in a closed trailer if possible. Use the following guidelines when trans- porting the vehicle on an open trailer . 1. Always transport the GEM vehicle facing forward on the trailer . 2. Set the park brake.
96 MAINTENANCE Periodic Maintenance Chart W ARNING! Always wear safety glasses or app roved eye protection when servicing the vehicle . Wear a full-face shield and gloves when working with or arou nd batteries and electrical connectors. Always use insulated tools when working with or near batteries.
97 MAINTENANCE Periodic Maintenance Chart Monthly Maintenance See Page Check battery fluid level (floode d only) 1 19 W ash tops and terminals of batteries and allow to dry 122 Check cables and termin.
98 MAINTENANCE Brakes Brake Fluid Inspect the brake system routinely . Inspect the brake fluid level before each operation. If the level drops between fluid checks, add brake fluid as needed. See your authorized GEM dealer for service. W ARNING! After opening a b ottle of brake fluid, al ways discard an y unused portion.
99 MAINTENANCE Brakes Brake Fluid 1. Position the vehicle on a level surface. 2. Open the hood. The brake fluid reservoir is located on the driver ’ s side of the vehicle, above and to the rear of the front tire. 3. V iew the brake fluid level in the reservoir .
100 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 t ravel or a spongy feel. 3. Check the friction pads fo r wear , damage and loose- ness.
101 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.
102 MAINTENANCE Fuse Replacement NOTICE: Always turn off the main disconnect switch before servicing or unplugging any el ectrical components. See page 52. If you experience electrical failures not related to the batteries, a fuse may need replacement.
103 MAINTENANCE Fuse Replacement NOTICE: Always install fuses with the recommended amperage to avoid damage to the electrical system. Tip : See the label attached to the inside of the fuse access panel for the function and amp rating of each fuse. The spare and he ater coil fuses are u sed for accesso ries.
104 MAINTENANCE Ti r e s Operating your vehicle with worn tires, imprope rly in flated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serio us injury or death. Always follow all tire maintenance proced ures as outlined in this manua l and on the labels on the vehicle.
105 MAINTENANCE Ti r e s Tire T read Depth Any accelerated wear of tires may be an indica- tor of improper alignment or poor driving hab- its. See your authorized GEM dealer for service. Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
106 MAINTENANCE Ti r e s Wheel Removal W ARNING! A falling vehicle can cause serious inj ury or death. Never place any part of your body under an elevated vehicle. If you need access to the bottom of the vehicle, use automotive jack stands to support the vehicle on a firm, level surface, or see your au thorized GEM dealer for service.
107 MAINTENANCE Ti r e s Wheel Removal 4. Block both the front and rear of the tire that is located diagonally opposite the jacking position. For example, if the right front tire is being changed, block the left rear wheel. 5. Use a small floor style jack or low profile scissors jack only .
108 MAINTENANCE Ti r e s Wheel Inst allation W ARNING! Impro perly installed wheels can adversely affect tire wear and vehicle handling, whi ch can result in serious injury or death. Always ensure tha t all nuts are torqued to specification. Do no t service axle nuts that have a cotter pin installed.
109 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Clean lights frequently and replace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility . When servicing a halogen lamp, don't touch the lamp with bare fingers.
110 MAINTENANCE Light s Rear T urn Signal Light Replacement 1. Remove the rear turn signal lens. 2. Remove the expired lamp. 3. Apply dielectric grease to the soc ket before installing the new lamp. 4. T est the light for proper operation. Brake Light s 1.
111 MAINTENANCE Light s 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.
112 MAINTENANCE Light s Headlight Beam Adjustment 3. Apply the brakes. T urn the key on. T urn the headlights to high beam. Tip : Include the weight of a rider on the se at while performing the fo llowing step.
113 MAINTENANCE Batteries The voltage in the battery pack is sufficient to cause death by electrocution. With the exception of battery inspections and refil ling the water in flooded type b atteries, .
114 MAINTENANCE Batteries Improperly connecting or disconnecting battery cables can result in an explosion and cause serio us injury or death. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
115 MAINTENANCE Batteries Battery Configurations NOTICE: Before removing the seat to access the batteries, make sure any wire or metal items (including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system.
116 MAINTENANCE Batteries Battery Locations St andard 12-V olt Battery Configurations Model Quantity Locations GEM e2 6 4 under bench seat, 2 in rear spat GEM e4 6 4 under bench seat, 2 in rear spat G.
117 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 th at may obstruct the rear sp at access cover .
118 MAINTENANCE Batteries Battery Inspections/Maintenance Perform the following battery inspections and maintenance procedures monthly as outlined in the Periodic Maintenance Chart beginning on page 96. Perform these operations more often for vehicles subjec ted to heavy use.
119 MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Fluid (Flooded Batteries) Gel batteries are maintenance-free batteries. They do not have fill wells. On flooded batter - ies, check the fluid level often. Add only distilled water .
120 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. W ARNING! The flu id in an overfilled battery may boil over and cause el ectrolyte to spill.
121 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 .
122 MAINTENANCE Batteries Battery Inspections/Maintenance Clean the Batteries NOTICE: Do not allow cleaning solution or tap water to enter the batteries. Before clean ing, make sure all battery fill well caps are installed securely . 1. Remove corrosion with a stiff wire brush.
123 MAINTENANCE Batteries Battery Inspections/Maintenance Check Battery Connections W ARNING! Improper handling of high voltage wiring, batteries or control systems could result in serious injury or death by electric shock. Only qua lified technicians sh ould repair or access high voltage wiring, battery packs and associated systems.
124 MAINTENANCE Batteries Battery Replacement W ith proper care and maintenance, battery life could be extended up to four years or longer , depending on the amount of use. When battery replac ement is necessary , please see your authorized GEM dealer .
125 MAINTENANCE Batteries Battery Disposal Lead-acid batteries are recyclable . Return whole scrap batteries to a distributor , manufac- turer or lead smelter for recycling.
126 MAINTENANCE Batteries Battery Care During Storage W ARNING! Always turn off the main disconnect switch before servicing or u nplugging any electrical components. See page 52. The main disconnect switch will disable the vehicle by disconne cting the battery pack from the motor .
127 MAINTENANCE Batteries Battery Care During St orage When the vehicle will not be used for a period of 10 days or longer , check battery water lev- els (flooded type batteries) and perform one of the battery storage procedures listed in the chart below .
128 MAINTENANCE Cleaning and S torage Cleaning the Windshield a nd Sunroof W e recommend using GEM W indshield Clea ner 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.
129 MAINTENANCE Cleaning and S torage Cleaning Seat s Use GEM Foaming All Surface Cleaner to clean the seats. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Su bstances such as tar, asphalt and other soils will stain if not removed quickly .
130 MAINTENANCE Cleaning and S torage Cleaning the Exterior The best way to preserve your vehicle’ s finish is to wash the vehicle regularly . Use GEM Fiber glass Plastic an d Rubber Restor e r or mild liquid detergents. Do not use strong soaps or chemical detergents.
131 MAINTENANCE Cleaning and S torage Storage T ip s Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 96.
132 MAINTENANCE Cleaning and S torage Storing the V ehicle Any time the vehicle will be parked for more than 10 days, fo llow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 128. 2. Clean the batteries.
133 MAINTENANCE Cleaning and S torage Storing the V ehicle 7. V erify that tire pressure is at specification. 8. Block the wheels to prevent rolling. W ARNING! Do not cover the ve hicle while the charger is connected. Dang erous levels of hydrogen gas could accumulate.
134 SPECIFICA TIONS GEM e2 GEM e4 GEM eS Dimensions Curb Weight 1 120 lbs. ( 508 kg) 1270 lbs. (576 kg) 1 150 lbs. (521.6 kg) Length 99 in. (251.5 cm) 128 in. (325 cm) 108 in. (274.3 cm) Width 55 in. (139.7 cm) 55 in. (139.7 cm) 55 in. (139.7 cm) Height 70 in.
135 SPECIFICA TIONS GEM e2 GEM e4 GEM eS Performance Motor 5 HP (7 HP optional), shunt DC electric Motor peak 23 HP Peak (17kw) Controller Flight Systems, T4, 350 amp DC Controller Battery pack Six 12-volt flooded lead acid batteries (12-volt ge l optional) Maximum speed 25 MPH (40 km/h) Range 30 miles (48.
136 SPECIFICA TIONS GEM e2 GEM e4 GEM eS Suspension Front suspension Independent wishbone w/coil over shock Rear suspension Solid rear axle w/coil over shock T ires Street rated 12-inch 165/70R-1 2 (O.
137 SPECIFICA TIONS GEM eL GEM eL XD GEM e6 ® Dimensions Curb Weight 1235 lbs. (560 kg) 1550 lbs. (703 kg) 1620 lbs. (735 kg) Length 144 in. (365.8 cm) 144 in. (365.8 cm) 162 in. (41 1.5 cm) Width 55 in. (139.7 cm) 55 in. (139.7 cm) 55 in. (139.7 cm) Height 70 in.
138 SPECIFICA TIONS GEM eL GEM eL XD GEM e6 ® Performance Motor 5 HP (7 HP optional), shunt DC electric 7 HP vented, shunt DC electric Motor peak 23 HP Peak (17kw) Controller Flight Systems, T4, 350 .
139 SPECIFICA TIONS GEM eL GEM eL XD GEM e6 ® Suspension Front suspension Independent wishbone w/coil over shock Rear suspension Solid rear axle w/coil over shock T ires Street rated 12-inch 165/70R-.
140 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR or 8,000 MILE (12,900 km), whichever comes first, LI MITED W ARRANTY on all components of your GEM vehicle ag ainst defects in mate- rial or workmanship.
141 W ARRANTY BA TTER Y W ARRANTY EXCLUSIONS • Batteries that fail due to lack of battery maintenance, over -charg ing, under-char ging, abuse or neglect is excluded from coverage • Batteries that.
142 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES The GEM limited warranty excludes any failures that are not caused by a defe ct in material or workmanship. This warranty does not cover accidental damage, normal wear and tear , abuse or improper handling.
143 W ARRANTY REGISTRA TION At the time of sale, the W arranty Registration Form must be completed by your dealer and submitted to GEM within three days.
144 W ARRANTY HOW TO OBT AIN W ARRANTY 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 W arranty Registration form to the dealer . THE COST OF TRANS- POR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY .
145 W ARRANTY How to Get Service In the Country wher e your vehicle was pur chased: W arranty or Service Bulletin repairs must be done by an authorized GEM dealer . If you move or are traveling within the country where your vehicle was purchased, W arranty or Service Bulletin repairs may be requested from any authorized GEM dealer .
146 W ARRANTY How to Get Service If Pur chased Fr om A Private Party: If you purchase a GEM product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
147 MAINTENANCE LOG Use the following chart to record periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS.
148 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS.
149 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS.
150 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS.
151 INDEX A Accelerator Pedal . . . . . . . . . . . . . 55 Accessory Backs . . . . . . . . . . . . 77-79 Accessory Outlet, 12-Volt . . . . . . 69 B Batteries . . . . . . . . . . 58-68, 113-127 Access . . . . . . . . . . . . . . . . . . 117 Battery Pack.
152 INDEX G Glove Box . . . . . . . . . . . . . . . . . . . 35 Grab Handle Pack age . . . . . . . . . . . 82 Gross Vehicle Weight Rating . . 22-23 H Hazard Signals . . . . . . . . . . . . . . . . 53 Headlight Beam Adjustment 111-112 Headlight Replacement .
153 INDEX S Seat Removal, Ben ch . . . . . . . . . . 70 Signal Words . . . . . . . . . . . . . . . . . . 7 State of Charge Indicator . . . . . 48-49 Steering Column L ock . . . . . . . . . 83 Steering Column, Adjustable Tilt . 84 Steering Wheel Inspection .
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. 9924250 Rev 02 Printed in USA.
An important point after buying a device GEM 419C (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought GEM 419C yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data GEM 419C - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, GEM 419C you will learn all the available features of the product, as well as information on its operation. The information that you get GEM 419C will certainly help you make a decision on the purchase.
If you already are a holder of GEM 419C, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime GEM 419C.
However, one of the most important roles played by the user manual is to help in solving problems with GEM 419C. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device GEM 419C along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
