Polaris eM 1400 - Manual

4 INTRODUCTION The GEM eM 1400 is a utility vehicle. Never operate on public roads. This vehicle does not meet National Highway Traffic Safety Administration (NHTSA) regulations for operation on public streets, roads and highways. Familiarize yourself with all laws and regulations con-cerning the op...

6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided below. The Vehicle Identification Number (VIN) indicates the model year, model type and serial number of your vehicle. The VIN is stamped on the left rear frame. The VIN i...

7 SAFETY 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 instructio...

8 SAFETY Safety Labels and Locations Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver’s license. 7175566 Discretionary Warning...

9 SAFETY Safety Labels and Locations Battery Caution CAUTION • Do not drive through water above the floor of the vehicle. Battery damage will occur.• Batteries require regular maintenance.• Failure to maintain batteries in accordance with the owners manual can result in battery damage, vehicle malfu...

10 SAFETY Personal Protective Equipment Always wear the proper clothing when operating or riding in this vehicle. All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding...

11 SAFETY Operator Safety • Never modify this vehicle through improper installation or use of non-GEM-approved accessories. • Always set the park brake and remove the key when leaving the vehicle unattended. • The voltage in the battery pack is sufficient to cause death by electrocution. With the ex...

12 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...

13 SAFETY Operator Safety Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, 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 f...

15 SAFETY Operator Safety Operating on Public Roads This vehicle does not meet National Highway Traffic Safety Administration (NHTSA) regulations for operation on public streets, roads and highways. Operating this vehicle on public streets, roads or highways could result in a collision with another ...

16 FEATURES AND CONTROLS Component Locations Console Hip Bar Cargo Box Headlights Front Bumper/Brush Guard Tailgate Latch Releases Receiver Hitch Tailgate Taillight Reflector Charge Receptacle

17 FEATURES AND CONTROLS Console 1. Steering Wheel 2. Indicator Lights 3. Key Switch 4. Direction Selector 5. Headlight Switch 6. Charge Status Indicator 7. Battery Discharge Indicator 8. Hour Meter 9. Glove Box/Storage Compartment 10. Beverage Holder11. 12V Auxiliary Outlet12. Park Brake Lever13. T...

18 FEATURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the gauge will display 100%. The charge status indicator will be solid green (see page 19). Av...

19 FEATURES AND CONTROLS Console Park Brake Lever To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents opera...

20 FEATURES AND CONTROLS Console Indicator Panel Lights The indicator lights activate when the key is in the ON position. Indicator Status Indicates Malfunction Steady Electrical malfunction (flash sequence on controller indicates type; see troubleshooting guide on page 21) Accelerator pedal is pres...

21 FEATURES AND CONTROLS Malfunction Indicator Troubleshooting Guide The malfunction codes will blink on the controller. The code definitions provided here are for informational purposes only. Tip: If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault ...

22 FEATURES AND CONTROLS Batteries This vehicle is equipped with eight 6-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 55 for battery access instructions. Always observe all battery safety warnings and safe handling procedures ...

23 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases. Ambient Temperature Implications on Batteries 1. Battery range decreases as ambient temp...

24 FEATURES AND CONTROLS Main Power Connector NOTICE: Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components. When disconnect...

25 FEATURES AND CONTROLS Brake Pedal Push the brake pedal toward the floor to slow or stop the vehicle. Apply the brakes before turning the key on. Accelerator Pedal The accelerator pedal will function only when the key is ON and the direction selector switch is set to either forward or reverse. To ...

26 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Pre-Ride Inspection Failure to inspect an...

27 OPERATION Driving Procedure 1. Disconnect the charging cable (if connected). 2. All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. 3. Sit in the driv...

28 OPERATION Driving On Slippery Surfaces Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control....

29 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose s...

30 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5...

31 OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determinin...

32 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 10 MPH (16...

33 OPERATION Dumping the Cargo Box If equipped, use the electric dump box switch to raise the cargo box and dump cargo. 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Set the park brake. 4. Place the dire...

34 OPERATION Transporting the Vehicle When transporting the GEM eM 1400 for a long distance or on public streets, always use a trailer with an approved load rating greater than the GEM eM 1400’s curb vehicle weight of 1700 lbs. (771 kg) plus any installed accessories or cargo. Follow these guideline...

35 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may...

37 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all wi...

38 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT in...

39 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, de...

41 WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your w...

42 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or D...

43 WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable....

44 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace par...

46 MAINTENANCE Transaxle Transaxle Specifications Chart Transaxle Oil Change This gearbox uses a lifetime fluid. Checking the fluid level and changing the fluid is not required. Please see your authorized GEM dealer for any transaxle-related concerns. Do NOT add fluid to the transaxle unless changin...

47 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 25. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid,...

48 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 44. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. There should ...

49 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this ma...

50 MAINTENANCE Tires Wheel Removal 1. Apply the brakes. Set the park brake. Turn the key off. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Set the park ...

51 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight i...

52 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the key to the ON position. 2. Apply the brakes. If the light doesn't come on, check the wiring, the brake switch or the tail light assembly. Indicator Pane...

53 MAINTENANCE Fuse Replacement If you experience electrical failure for a specific component (such as indicator lamps or headlights) a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse box is located under the hood....

55 MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger. The battery charge receptacle is located on the left side panel below the driver’s seat. WARNING! Failure to provide adequate ventilation while charging batteries can result in an explosion. ...

56 MAINTENANCE Batteries Battery Cleaning Always keep battery terminals and connections free of corrosion. To clean, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat batt...

57 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your GEM vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. GEM recommends washing the vehicle by hand or with a garden hose, usin...

58 MAINTENANCE Cleaning and Storage Polishing the Vehicle GEM recommends the use of common household aerosol furniture polish for polishing the finish on your GEM vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the f...

59 MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 57. 2. Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic M...

60 SPECIFICATIONS GEM eM 1400 Dimensions Dry Weight 1500 lbs. (680.4 kg) Ground Clearance 8 in. (20.3 cm) Length 114.5 in. (291 cm) Width 56.5 in. (143.5 cm) Height 52.5 in. (133.3 cm) Cargo Box (Inside) 51.5 x 41.75 in. (130.8 x 106 cm) Wheelbase 79 in. (200.7 cm) Turning Radius (GVW) Left: 175 in....

61 SPECIFICATIONS TROUBLESHOOTING Vehicle Will Not Operate GEM eM 1400 Brake System Brakes 4-Wheel hydraulic disc w/dual bore front calipers Park Brake Lever-activated mechanical park brake Suspension Front suspension Independent Macpherson struts w/5 in. (12.5 cm) travel Rear suspension Dual A-Arm ...

62 WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO-YEAR, 8,000-MILE (12,900-km) or 750-HOUR, whichever comes first, LIMITED WARRANTY on all components (except batteries) of your GEM vehicle against defects in material or workmanship. Mileage is unlimited ...

63 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear an...

64 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES The exclusive remedy for breach of this warranty shall be, at POLARIS’ sole option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FO...

65 WARRANTY Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export...

66 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

68 INDEX A Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 25Auxiliary 12-Volt Terminal Board . . . . . . . . . . . 18Auxiliary Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 18Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 49 B Batteries Accessing ....

PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH For your nearest GEM dealer, call 855-RIDEGEM (855-743-3436)or visit www.gemcar.comPolaris Sales Inc.2100 Hwy. 55Medina, MN 55340 Part No. 9924949 Rev 0 2 Printed in USA ALL RIDERS MUST WEAR APPROVED PROTECTIVE GEAR. NEVER USE...