Owners Manual
Page 12
... and operating a battery-powered vehicle. This vehicle is an ADULT VEHICLE ONLY. INTRODUCTION WARNING Failure to follow the warnings contained in this vehicle only on public or private roads where speed limits 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 safety warnings, precautions and operating...
... and operating a battery-powered vehicle. This vehicle is an ADULT VEHICLE ONLY. INTRODUCTION WARNING Failure to follow the warnings contained in this vehicle only on public or private roads where speed limits 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 safety warnings, precautions and operating...
Owners Manual
Page 27
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 23
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 23
Owners Manual
Page 35
.... SAFETY Operator Safety Precautions During Maintenance WARNING! Always follow all safety instructions 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 in the battery pack is properly immobilized before beginning any maintenance. • Always block the chassis securely before working under the vehicle. • Turn the key off the main disconnect switch before servicing...
.... SAFETY Operator Safety Precautions During Maintenance WARNING! Always follow all safety instructions 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 in the battery pack is properly immobilized before beginning any maintenance. • Always block the chassis securely before working under the vehicle. • Turn the key off the main disconnect switch before servicing...
Owners Manual
Page 37
Electrical Components Electrical wiring, circuit boards and components are located under and behind the upper and lower console. ON OFF Optional Accessory Switches Electrical Access Panel (Fuses/Main Disconnect Switch) 33 Press the bottom of the headlight switch to turn the headlights and taillights on. NOTICE: Liquids can damage electrical components and the circuit board. Handle liquids with care. Do not spray water directly into the upper or lower console. FEATURES AND CONTROLS Console Headlight Switch Press the top of the switch to turn the lights off.
Electrical Components Electrical wiring, circuit boards and components are located under and behind the upper and lower console. ON OFF Optional Accessory Switches Electrical Access Panel (Fuses/Main Disconnect Switch) 33 Press the bottom of the headlight switch to turn the headlights and taillights on. NOTICE: Liquids can damage electrical components and the circuit board. Handle liquids with care. Do not spray water directly into the upper or lower console. FEATURES AND CONTROLS Console Headlight Switch Press the top of the switch to turn the lights off.
Owners Manual
Page 71
... motor. Never use the chassis or body as a ground connection. • Make sure vent caps are grounded directly to a 12-volt auxiliary outlet or terminal board. (continued on next page) 67 It does not disable the battery pack. FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING! See page 52. Do not work in or near the battery compartment or on the terminal board. Always turn...
... motor. Never use the chassis or body as a ground connection. • Make sure vent caps are grounded directly to a 12-volt auxiliary outlet or terminal board. (continued on next page) 67 It does not disable the battery pack. FEATURES AND CONTROLS Batteries Battery Handling Precautions WARNING! See page 52. Do not work in or near the battery compartment or on the terminal board. Always turn...
Owners Manual
Page 83
.... Install the desired accessory back onto the mounting brackets. Keep the rear latch in a locked position when operating or transporting the vehicle. Secure the safety strap. Always lock the release handle with the ignition key after changing accessory backs. 79 Test to make sure the latches are secure. CAUTION! Remove the safety strap and carefully remove the existing accessory back. FEATURES AND CONTROLS Rear Accessory Backs (Option) 5. 6. 7. 8. 9. The rear accessory could fall and...
.... Install the desired accessory back onto the mounting brackets. Keep the rear latch in a locked position when operating or transporting the vehicle. Secure the safety strap. Always lock the release handle with the ignition key after changing accessory backs. 79 Test to make sure the latches are secure. CAUTION! Remove the safety strap and carefully remove the existing accessory back. FEATURES AND CONTROLS Rear Accessory Backs (Option) 5. 6. 7. 8. 9. The rear accessory could fall and...
Owners Manual
Page 103
... Check headlights, horn, turn signals, windshield wiper and brake lights for leaks. 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 secured Check tires for correct air pressure and wear Check brake fluid reservoir for proper brake fluid level. Check steering wheel freeplay...
... Check headlights, horn, turn signals, windshield wiper and brake lights for leaks. 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 secured Check tires for correct air pressure and wear Check brake fluid reservoir for proper brake fluid level. Check steering wheel freeplay...
Owners Manual
Page 107
Position the vehicle on a level surface. 2. MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation. 1. There should be 0.8-1.0 inch (20-25 mm) of freeplay at the outer rim of the steering wheel. 3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by your authorized GEM dealer. 103 Lightly turn the steering wheel left and right.
Position the vehicle on a level surface. 2. MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation. 1. There should be 0.8-1.0 inch (20-25 mm) of freeplay at the outer rim of the steering wheel. 3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by your authorized GEM dealer. 103 Lightly turn the steering wheel left and right.
Owners Manual
Page 112
Never place any part of the vehicle, use automotive jack stands to support the vehicle on a dry, firm, level surface. 2. Position the vehicle on a firm, level surface, or see your body under an elevated vehicle. Turn the key off. Jack Points 108 Frame viewed from bottom 1. If you need access to the bottom of your authorized GEM dealer for service. A falling vehicle can cause serious injury or death. Set the park brake. 3. MAINTENANCE Tires Wheel Removal WARNING!
Never place any part of the vehicle, use automotive jack stands to support the vehicle on a dry, firm, level surface. 2. Position the vehicle on a firm, level surface, or see your body under an elevated vehicle. Turn the key off. Jack Points 108 Frame viewed from bottom 1. If you need access to the bottom of your authorized GEM dealer for service. A falling vehicle can cause serious injury or death. Set the park brake. 3. MAINTENANCE Tires Wheel Removal WARNING!
Owners Manual
Page 113
... crossmember. MAINTENANCE Tires Wheel Removal 4. NOTICE: Jacking at the point where the tub or floor panel support and the main frame rail are welded. For example, if the right front tire is located diagonally opposite the jacking position. Alternative locations include the rear frame rail and the center of the tire that is being changed, block the left rear wheel. 5. Use a small floor style jack or low...
... crossmember. MAINTENANCE Tires Wheel Removal 4. NOTICE: Jacking at the point where the tub or floor panel support and the main frame rail are welded. For example, if the right front tire is located diagonally opposite the jacking position. Alternative locations include the rear frame rail and the center of the tire that is being changed, block the left rear wheel. 5. Use a small floor style jack or low...
Owners Manual
Page 114
Be sure the valve stem is toward forward rotation. 3. See your authorized GEM dealer for service. 1. Do not service axle nuts that all nuts are torqued to specification. Place the wheel in serious injury or death. Carefully lower the vehicle to specification. Always ensure that have a cotter pin installed. Set the park brake. 2. MAINTENANCE Tires Wheel Installation WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
Be sure the valve stem is toward forward rotation. 3. See your authorized GEM dealer for service. 1. Do not service axle nuts that all nuts are torqued to specification. Place the wheel in serious injury or death. Carefully lower the vehicle to specification. Always ensure that have a cotter pin installed. Set the park brake. 2. MAINTENANCE Tires Wheel Installation WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
Owners Manual
Page 115
... can be replaced. Headlight Replacement If a headlight fails to work properly, the entire assembly must be replaced. If your vehicle is equipped with optional high/low beam headlights, an expired front turn signal fails to work properly, the entire assembly must be replaced. If your authorized GEM dealer for best visibility. MAINTENANCE Lights Poor lighting can be replaced. Always make sure lights are adjusted properly for service. See your vehicle is equipped...
... can be replaced. Headlight Replacement If a headlight fails to work properly, the entire assembly must be replaced. If your vehicle is equipped with optional high/low beam headlights, an expired front turn signal fails to work properly, the entire assembly must be replaced. If your authorized GEM dealer for best visibility. MAINTENANCE Lights Poor lighting can be replaced. Always make sure lights are adjusted properly for service. See your vehicle is equipped...
Owners Manual
Page 116
Apply dielectric grease to the socket before installing the new lamp. 4. Brake Lights 1. Remove the brake light lens. 2. Remove the expired lamp. 3. MAINTENANCE Lights Rear Turn Signal Light Replacement 1. Test the light for proper operation. Remove the expired lamp. 3. Test the light for proper operation. 112 Apply dielectric grease to the socket before installing the new lamp. 4. Remove the rear turn signal lens. 2.
Apply dielectric grease to the socket before installing the new lamp. 4. Brake Lights 1. Remove the brake light lens. 2. Remove the expired lamp. 3. MAINTENANCE Lights Rear Turn Signal Light Replacement 1. Test the light for proper operation. Remove the expired lamp. 3. Test the light for proper operation. 112 Apply dielectric grease to the socket before installing the new lamp. 4. Remove the rear turn signal lens. 2.
Owners Manual
Page 117
Measure the distance from a wall. 2. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) 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) 113 MAINTENANCE Lights Headlight Beam Adjustment 1.
Measure the distance from a wall. 2. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) 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) 113 MAINTENANCE Lights Headlight Beam Adjustment 1.
Owners Manual
Page 118
... the headlight, and tighten the screw. 7. Repeat steps 4-6 until the lamp is equipped with both high and low beam headlights, place the headlights on the seat while performing the following step. 4. If the vehicle is properly adjusted. 114 The most intense part of a rider on high beam for this step. 5. Apply the brakes. Observe the headlight aim. MAINTENANCE Lights Headlight Beam...
... the headlight, and tighten the screw. 7. Repeat steps 4-6 until the lamp is equipped with both high and low beam headlights, place the headlights on the seat while performing the following step. 4. If the vehicle is properly adjusted. 114 The most intense part of a rider on high beam for this step. 5. Apply the brakes. Observe the headlight aim. MAINTENANCE Lights Headlight Beam...
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 bench seat, 3 in rear spat 4 under bench seat, 2 in rear bed 4 under bench seat, 2 in rear bed 3 under rear bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed Optional 8-Volt...
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 bench seat, 3 in rear spat 4 under bench seat, 2 in rear bed 4 under bench seat, 2 in rear bed 3 under rear bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed 3 under bench seat, 3 in rear bed Optional 8-Volt...
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: 36 psi (248 kPa) / 14-inch: 36 psi (248 kPa) GEM e4 GEM eS Features Gauge Auxiliary power (option) Seat belts Direction switch Headlights Taillights/brake lights Horn / Turn Signals Hazard Signals Mirrors LCD...
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: 36 psi (248 kPa) / 14-inch: 36 psi (248 kPa) GEM e4 GEM eS Features Gauge Auxiliary power (option) Seat belts Direction switch Headlights Taillights/brake lights Horn / Turn Signals Hazard Signals Mirrors LCD...
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... 14-inch: 36 psi (248 kPa) Features Gauge Auxiliary power (option) Seat belts Direction switch Headlights Taillights/brake lights Horn / Turn Signals Mirrors LCD Display 12-volt accessory outlet Automotive-style 3-point seat belts High/Low/Reverse Single beam 40-watt LED Standard Rear view, interior, left side view 141
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... 14-inch: 36 psi (248 kPa) Features Gauge Auxiliary power (option) Seat belts Direction switch Headlights Taillights/brake lights Horn / Turn Signals Mirrors LCD Display 12-volt accessory outlet Automotive-style 3-point seat belts High/Low/Reverse Single beam 40-watt LED Standard Rear view, interior, left side view 141
Owners Manual
Page 150
... for export. Please work with your original selling dealer's authorized location. THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY. If any warranty issues. WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must present your copy of the Warranty Registration form to the dealer. Should your dealer require any GEM Servicing Dealer to Safety Recalls. 146
... for export. Please work with your original selling dealer's authorized location. THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY. If any warranty issues. WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must present your copy of the Warranty Registration form to the dealer. Should your dealer require any GEM Servicing Dealer to Safety Recalls. 146
Owners Manual
Page 159
... Switch...52-53 Tires...106-110 Tire Pressure ...106 Tread Depth ...107 Wheel Installation...110 Wheel Nut Torque ...107 Wheel Removal ...108-109 S Transporting the Vehicle...96-97 Trip Meter ...38-39 Turn Signal ...36 Turn Signal Light, Front ...111 Turn Signal Light, Rear...112 Vehicle Information Label ...9-11 Warning Symbols ...7 Washing, Windshield/Sunroof . . 130 Weight Capacity ...22-23 Wheel Installation ...110 Wheel Nut Torque...107 Wheel Removal ...108-109 Windshield Washer ...86 Windshield Wiper ...37 Zero Speed Detection Feature...
... Switch...52-53 Tires...106-110 Tire Pressure ...106 Tread Depth ...107 Wheel Installation...110 Wheel Nut Torque ...107 Wheel Removal ...108-109 S Transporting the Vehicle...96-97 Trip Meter ...38-39 Turn Signal ...36 Turn Signal Light, Front ...111 Turn Signal Light, Rear...112 Vehicle Information Label ...9-11 Warning Symbols ...7 Washing, Windshield/Sunroof . . 130 Weight Capacity ...22-23 Wheel Installation ...110 Wheel Nut Torque...107 Wheel Removal ...108-109 Windshield Washer ...86 Windshield Wiper ...37 Zero Speed Detection Feature...