GEM 419C User Manual
2013 Owner's Manual for Maintenance and Safety
Read this manual carefully.
It contains important safety information.
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The following are registered trademarks of POLARIS Industries Inc.:
POLARIS® VICTORY® Global Electric Motorcars®
RANGER® INDIAN® GEM® e6®
Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest
product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented
in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures
contained within, whether whole or in part, is expressly prohibited.
Global Electric Motorcars® is a division of POLARIS®.
Printed in U.S.A.
2013 GEM Owner’s Manual
P/N 9924250
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TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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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 design and manufacturing, we proudly bring you only the finest
of vehicles:
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER® utility vehicles
• Low emission vehicles (LEVs)
• VICTORY® motorcycles
• INDIAN® motorcycles
• GEM® vehicles
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WELCOME
For safe and enjoyable 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 technician.
If questions arise after reading the manual, please contact GEM customer service. Be prepared to provide your Vehicle Identification Number (VIN) and date of purchase.
Your authorized GEM dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the
warranty period.
GEM Customer Service
Phone: 855-RIDEGEM (855-743-3436)
Web: www.gemcar.com
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INTRODUCTION
This vehicle complies with the U.S. Department of Transportation National Highway Traffic
Safety Administration (NHTSA) low-speed vehicle regulations and can be operated on many
streets posted with low speed limits. Please familiarize yourself with all laws and regulations
concerning the operation of the vehicle in your area.
This manual applies to the following GEM vehicles:
• GEM e2 (two-passenger)
• GEM e4 (four-passenger)
• GEM eS (two-passenger short-bed)
• GEM eL (two-passenger long-bed)
• GEM eL XD (two-passenger extra duty long-bed)
• GEM e6® (six-passenger)
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INTRODUCTION
Safety Signal Words and Symbols
The following signal words and symbols appear throughout this manual and on your vehicle.
Your safety is involved when these words and symbols are used. Become familiar with their
meanings before reading the manual.
NOTICE
The safety alert symbol indicates a potential
personal injury hazard.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, may result in death or
serious injury.
CAUTION
A CAUTION indicates a hazardous situation
which, if not avoided, may result in minor or
moderate injury.
A NOTICE indicates a situation that may result in
property damage.
The Prohibition Safety Sign indicates
an action NOT to take in order to avoid
a hazard.
The Mandatory Action Sign indicates
an action that NEEDS to be taken to
avoid a hazard.
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INTRODUCTION
WARNING
Failure to follow the warnings contained in this manual can result in severe injury or death.
Special precautions must be followed when owning and operating a battery-powered vehicle. This
vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other
vehicles. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before operating the vehicle. Keep this manual with the vehicle.
• This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are 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 with motor vehicle laws in your area of operation. Do not operate this vehicle in
situations where it could become an obstacle or an annoyance for faster-moving traffic.
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INTRODUCTION
Manufacturer’s Label (Vehicle Information Label)
Record your vehicle's identification numbers and key number in the spaces provided on page
11.
The Vehicle Identification Number (VIN) is on the manufacturer’s label, located on the left
rear section of the roof panel. The VIN indicates the model year, model type and serial number of your vehicle. The manufacturer’s label also contains the Gross Vehicle Weight Rating
(GVWR) and Gross Axle Weight Rating (GAWR) information for your vehicle. Never
exceed the GVWR or the GAWR. See page 22.
To order an extra or replacement key for your vehicle, please contact GEM customer service.
See page 5. Be prepared to provide your key number and VIN.
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INTRODUCTION
Manufacturer’s
Label
VIN
GVWR
Information
Tire / Wheel Information
GAWR Information
Date of
Manufacture
USA Label EU Label
Manufacturer’s Label (Vehicle Information Label)
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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: _____________________________________________________________________________
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SAFETY
General Warning
Safety Labels and Locations
Warning 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.
If any label becomes illegible or comes off, contact your authorized GEM dealer to purchase
a replacement. Replacement safety labels are provided at no charge. The part number is
printed on the label.
General Warning
WARNING
• Read your owner’s manual before operating this vehicle.
• Do not operate this vehicle under the influence of alcohol,
• This vehicle is not intended to be driven at speeds exceeding
(continued on next page)
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drugs or medication.
25 MPH (40 km/h).
SAFETY
Safety Labels and Locations
General Warning
• Although most states prohibit this vehicle from operating on streets having posted speed limits of
more than 35 MPH (56 km/h), state and local rules may vary. Check with your local law enforcement
(city and state officials) for variations in your area.
• Never exceed the passenger and cargo limits of this vehicle.
• Do not start or operate vehicle until all occupants are seated with seat belts fastened.
• Avoid sharp turns an inclines and at high speeds (may cause rollover).
• Reduce speed on wet and slippery surfaces and in turns.
• Do not leave children unattended in vehicle.
• Set handbrake before leaving the vehicle.
• Remove key when leaving vehicle unattended.
• Stop vehicle before reversing direction.
• Be aware of small children and objects behind you before reversing direction.
• ALWAYS DRIVE SAFELY. FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN
SERIOUS OR FATAL INJURY.
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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 occupants within the vehicle or to protect against injury during an accident.
WEAR SEAT BELTS AT ALL TIMES.
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SAFETY
Safety Labels and Locations
High Voltage Warning
High voltage warning labels are located in two places on your vehicle: near the battery compartment and under the hood near the motor controller.
WARNING
HIGH VOLTAGE
You could be seriously or fatally injured by electric shock if you attempt to open, repair,
test, inspect or adjust. Only qualified technicians should open and service. Consult service
manual.
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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 noncompliance will void warranty.
CARGO WARNING (eL XD)
• Maximum cargo capacity of this bed should never exceed 1100 lbs. (499 kg).
• Distribute weight equally over axle.
• No passengers permitted.
• Abuse or noncompliance will void warranty.
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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 16 to oper-
ate this vehicle and never allow anyone
without a valid driver's license to operate
this vehicle.
• Never permit a guest to operate this vehi-
cle unless the guest has read this manual
and all product labels.
• Always make sure the seat belts are
secured for operator and all passengers
before operating.
• Never exceed the maximum occupant
capacity of your vehicle:
GEM e2 2 occupants
GEM e4 4 occupants
GEM eS 2 occupants
GEM eL 2 occupants
GEM eL XD 2 occupants
®
GEM e6
6 occupants
SAFETY
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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. Avoid situations that could result in a rollover.
• Always be sure there are no obstacles or
people behind your vehicle when operating in reverse. When it's safe to proceed
in reverse, move slowly. Avoid turning at
sharp angles in reverse.
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• 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.
Operator Safety
• Never carry loads on the roof of the vehicle. 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 cargo.
Allow a greater distance for braking.
• Always set the park brake and remove the
key when leaving the vehicle unattended.
SAFETY
• The voltage in the battery pack is sufficient 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.
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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.
• Never consume alcohol or drugs before
or while operating this vehicle.
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• Never operate at excessive speeds.
Always travel at a speed proper for the
traffic, visibility and operating
conditions, and your experience.
• Never attempt jumps, doughnuts or other
stunts.
• Always inspect your vehicle 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.
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 dealer if it has been
involved in an accident.
SAFETY
• Always be alert for obstacles when operating this vehicle. Never attempt to operate over obstacles.
• Always be careful of skidding or sliding.
On slippery surfaces such as ice, travel
slowly and exercise caution to reduce the
chance of skidding or sliding out of control.
• Never operate this vehicle on steep hills.
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SAFETY
Operator Safety
Gross Vehicle Weight Rating (GVWR)
WARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling
and could cause loss of control. NEVER exceed the GVWR of your vehicle.
The maximum payload capacity of your vehicle is the maximum weight you may add to
your vehicle without exceeding the GVWR. 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.
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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 in or on apparel
• weight of any options or accessories and their contents
• weight of any additional cargo on the vehicle
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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 on your vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been
made to the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
GEM-approved accessories, and familiarize yourself with their function and effect on the
vehicle.
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SAFETY
WARNING
Operator Safety
Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn,
which may result in serious injury or death. Heed all safety warnings outlined in this section of the
owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Age Restrictions
This vehicle is an ADULT
VEHICLE ONLY. NEVER
operate this vehicle if you
are under age 16 and
NEVER operate without a
valid driver’s license.
Seat Belts
Riding in this vehicle without wearing the seat
belt increases the risk of serious injury in the
event of an accident or sudden stop. Occupants
must wear seat belts at all times. Always make
sure the seat belts are secured for operator and
all passengers before operating. See page 71.
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SAFETY
Operator Safety
Operating Without Instruction
Operating this vehicle
without proper instruction
increases the risk of an
accident. The operator
must understand how to
operate the vehicle
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.
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Ventilation When Charging Batteries
Failure to provide adequate ventilation while
charging batteries can result in an explosion.
Volatile hydrogen gas is emitted during charging
and may accumulate in pockets at the ceiling.
• Always ensure a minimum of 5 air changes per
hour in the charging area.
• Always remove any storage covers from the
vehicle and open any cab doors (if equipped)
before charging.
Operator Safety
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in
safe operating condition before operating
increases the risk of an accident. Always inspect
the vehicle before each use to make sure it's in
safe operating condition. Always follow all
inspection and maintenance procedures and
schedules described in the owner's manual.
SAFETY
Using Alcohol or Drugs
Operating the vehicle after
consuming alcohol or drugs
could adversely affect
operator judgment, reaction
time, balance and
perception. Never drink
alcohol or use drugs or
medications before or while
operating this vehicle.
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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 system.
Operating at Excessive Speeds
Operating this vehicle at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate for
the traffic, the visibility and operating conditions,
your skills and your passengers’ skills.
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Exhibition Driving
Exhibition driving increases the risk of an
accident or overturn. Never attempt wheelies,
jumps, doughnuts or other stunts. Avoid
exhibition driving.
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 at faster speeds.
Vehicle Rollover
Vehicle rollover could cause serious injury or
death. The cab frame is not designed or intended
to provide rollover protection. Always make sure
the seat belts are secured for operator and all
passengers before operating. Avoid situations
that could result in a rollover. Avoid sharp turns
and abrupt steering maneuvers.
SAFETY
Carrying Cargo
Carrying loads on the roof could damage the roof
and affect vehicle handling, which could result in
an accident or overturn. Never carry loads on the
roof of the vehicle.
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