Intimidator UTV Part Manual

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1 Intimidator UTV Part Manual Electric Revision Date --

2 Table of Contents Front Suspension Assembly... Parts List... Lights and Break Assemblies... Parts List... Seat, Dash, and Grill Assemblies... Parts List... Plastic Assembly... Parts List... Battery Assembly... Parts List... Electric Motor and Transmission Assembly... Parts List... Rear Suspension Assembly... Parts List... Rops Assembly... Safety Nets Assemblies... Bed Assembly ( of )... Parts List... Bed Assembly ( of )... Parts List... Versabed (Optional)... Parts List... Decals...-

3 DETAIL A A 0 Front Suspension Assembly 0 0 Includes Spacer on some models

4 ITEM QTY Front Suspension Assembly PART NUMBER DESCRIPTION --00 Left Front Upper A-arm Assy --00 Left Front Lower A-Arm Assy Large MTV A-Arm Bushing Sleeve /- Nylon Insert Locknut /" - X-/" Hex Bolt Gr Large MTV A-Arm Bushing /- x GR Hex Bolt Zinc Front Shock-Kohler Lg UTV --00 Half-Shaft - Front Large UTV --00 Spindle, Left Front-Large UTV Ball Joint-Spindle-Upper High Strength Spindle Bearing LRG UTV Retaining Ring-Spindle Bearing Hub-Large UTV --00 Rear Hub Castle Nut Cotter Pin --00 Rear Hub Castle Nut /- X GR Hex Bolts Zinc --00 /- Nylock Flange Nut M X. Castle Nut Ball Joint-Spindle-Lower Brake Caliper Brkt-Ausco-Elect --00 Hydraulic Caliper --00 Brake Pad Kit ( Pads per Kit) --00 mm copper crush washer Brake Line Front Right-Lg UTV --00 Banjo Bolt M mm x Rotor - Large UTV / Lug Nut-0- Front --00 Right Front Lower A-Arm Assy Right Front Upper A-Arm Assy --00 Spindle, Right Front-Large UTV Brake Line Front Left-Lg UTV Rack & Pinion, Large MTV /- X / GR Hex Bolts Zinc /- Hex Flange Nuts Zinc w/serations /- x / GR Hex bolt Zinc Front Differential-Larg UTV --00 Tie Rod End-Intimidator XD Front Wheel --00 XD Front Tire --0 Caliper Brake Mount Spacer XD Wheel Center Cap --00 Base Wheel Center Cap --00 Base Model Front Tire Base Model Front Wheel --0 Open End Lug Nut-Black (Base Model Only) Left A Frame Guard Right A Frame Guard /- x Grade Hex bolts Zinc /- Nylon Insert Locknut Zinc Orange Nylon --00 Half Shaft CV Boot Kit Retaining Ring-Lg MTV Ball Jt / Lockwasher Zinc /- x -/ Hex Bolt GR --00 / ID / OD Hose / Spring Hose Clamp --00 Breather Plug Threaded Break Line Anchor--/" --00 /-X " Hex Head Cap Screw

5 DETAIL A DETAIL B A B Only On XD Model

6 Parts List ITEM QTY PART NUMBER DESCRIPTION Main Frame-Electric Single Cab /- Hex Flange Nuts Zinc W/Serrations /- Nylon Insert Locknut Zinc Orange Nylon Brake Pedal Assy-Large UTV Accelerator Pedal Brkt-Elect Brake Pedal Bracket Left-00 /- x / Grade Hex bolts Zinc Bushing, Oil Impregnated /" x /" Soc. Shoulder Bolt / IDx / x / OIB Bushing /"- Nyloc Jam Nut Clevis Pin, /" x /" Bow Tie Clip Master Cylinder, Dual Cylinder mm copper crush washer Brake Line Front Left-Lg UTV Brake Line Front Right-Lg UTV Banjo Bolt-Double-mm-.0 Brake Line-MC to Rear T-Lg UTV Brake Switch-Banjo- Dash Support Assy /" - X -/" Carriage Bolt /- Nylock HEX Nut /" - X -/" Hex Hd Cap Screw /- Nylon Insert Locknut AMP Volt Dual Pro Charger Battery Charger Bracket-Right / x Hex Head Tek Screw Battery Charger Bracket-Left x / Pan Phillips T/S V To V Convertor Fuse Box Brkt-Electric /- X Button Socket C/S Black /- Nylon Insert Locknut BL /- Hex Flange Nuts Zinc w/serations Head Light Bracket Brace-Left /" x -/" Hex Hd Cap Scr. Head Light Bracket-Left /- x Carriage Bolt Headlight-Low Beam-Large UTV /" - X -/" Carriage Bolt Headlight-High Beam-Large UTV /- x -/ Carriage bolt Head Light Bracket Brace-Right Head Light Bracket-Right Accelerator Pedal Mount-Elect Electric Accelerator Pedal /- x Grade Hex bolts Zinc /- x " GR Hex bolt PMW Controller, Team Rear Diff Break Fluid COT. quarts

7 DETAIL A DETAIL B DETAIL C A B C 0 0 Seat, Dash, and Grill Assemblies 0 0

8 ITEM QTY Seat, Dash, and Grill Assemblies PART NUMBER DESCRIPTION /- Nylon Insert Locknut /- X GR Hex Bolts Zinc /- x / GR Hex bolt Zinc /- Hex Flange Nuts Zinc w/serations /- x GR Hex Bolt Zinc /- Nylock HEX Nut /- Nylon Insert Locknut --00 /" - X -/" Hex Hd Cap Screw /- x Carriage Bolt -0-0 /- x / Button Socket C/S -0-0 /- Nylon Insert Locknut BL --00 /" - /" Ind Hex Washr Hd - Type F Bushing, Oil Impregnated Dash Support Assy Floor Board Support Assy --00 /"- x -/" Carriage Bolt Rotary Latch Bracket-Frame (Base Model Only) --00 /" - X -/" Hex Bolt --00 Upper Shift Cable Bracket / ID x / Plastic Washer / IDx / x / OIB Bushing Tilt Steering Gas Spring /- Nylon Insert Flange Nut Zinc Orange Nylon --00 / x -/ G Zn Hex Bolt Steering Wheel Large UTV Steering Column Bearing /- x Grade Hex bolts Zinc Shift Lever Knob-Large UTV Gear Shift Cable-Large UTV /-, Right Hand Thread Heim /- Nylon Insert Locknut Zinc Orange Nylon --00 Brush Guard Skid Plate Steering Shaft Assembly-Large UTV Seat Bottom-Large UTV Front Grill insert / x Hex Head Tek Screw Steering Wheel Cap-Hurricane Steering Shaft Wheel Nut Seat Frame Assy- Electric --00 /- Nylock Flange Nut /-x/ Carriage Bolts Zinc --00 Brush Guard Mtg Brkt-Left --00 Brush Guard Mtg Brkt-Right Intimidator Bumper Front Receiver Tube Mtg Tube --00 Front Receiver Assembly Front Receiver Gusset Intimidator Front Receiver Bottom Tube Intimidator / EPDM Cushion Clamp Overflow Bottle Spacer Turn Signal Pod /"x-/" Black Tube Plug /" Round Tubing Plug Rivnut /- Steel /- Hex Nut Zinc --0 /- X Button Socket C/S Black Hood Rest Bumper-Lg UTV --00 Hitch Pin Seat Pin Latch Assembly

9 DETAIL A A 0 0 Plastics Assembly 0 0 0

10 Plastics Assembly ITEM QTY PART NUMBER DESCRIPTION /- Nylon Insert Locknut /" - X -/" Hex Hd Cap Screw /- Nylon Insert Locknut BL /- X Button Socket C/S Black /" - /" Ind Hex Washr Hd - Type F Upper Radiator Mounting Brkt Upper Front Fender Flare-Left Front Firewall-Large UTV-Black Center Seat Panel-Large UTV-Or Hood Large UTV-Orange Front Grill-Large UTV-Black Upper Front Fender Flare-Right Dash Seat Panel Left-Large UTV-Blk Seat Panel Right-Large UTV-Blk Lower Front Fender Flare-Right Lower Front Fender Flare-Left Upper Hood Support Brkt-Kohler/Electirc /- x Grade Hex bolts Zinc /- Hex Flange Nuts Zinc W/Serrations Speedometer/Display Gauge Ignition Switch Volt Auxilliary Plug Floor Board-Large UTV-Black Head Light Hi/off/Low Beam Sw. WD Switch / Flat Washer Black Hood Hinge M-. x Pan Phil M/S Zinc Hood Latch Differential Lock Switch Main Frame-Electric Single Cab Dash Display-Motor Controller Display Harness-AC Controller Wiring Harness-Lg UTV Electric AC Inlet Adapter Plate-Electric AC Inlet PLUG Hood Lid Large UTV-Orange Buttom Bumper-Tailgate-00 Self Adheasive Bumper Firewall Mount Brkt /- X-/" BH Socket Scr Blk /- x / Button Socket C/S / x Hex Head Tek Screw Center Seat Panel-Large UTV-Gr Center Seat Panel-00-Camo Center Seat Panel-00-Charco Hood-OD Green Hood-Camo Hood-Metallic Black Glovebox Base Model Front Grill Panel Plug-Eaton Blank Switch Dump Bed Up/Down Switch Dash Light Blank Panel Shift Lever Boot-Large UTV Seat Pin Frame Guard-x." Break Pedal Boot-Lg UTV -/"x-/" Black Tube Plug Hitch Pin

11 DETAIL A A Battery Assembly 0

12 Battery Assembly ITEM 0 QTY PART NUMBER DESCRIPTION Main Frame-Electric Single Cab Volt Battery Rear Battery Holder Battery Hold Down- Battery / -x Carriage Bolt /" -X -/" Carriage Bolt /- Nylock Flange Nut " Battery Cable Gauge " Battery Cable Gauge " Battery Cable Gauge Curtis Speed Controller (0) ( Passenger Only) /- Hex Flange Nuts Zinc W/Serrations /- x -/ Grade Hex bolts Zinc /- X Button Socket C/S Black 00 Amp Fuse Mounting Block Fast Acting Fuse-00 Amp Volt Relay x / Pan Phillips T/S Volt High Capacity Solenoid Solenoid Bracket Curtis Solenoid Bracket Curtis /- x Grade Hex bolts Zinc /- Nylon Insert Locknut Zinc Orange Nylon / flat Washer - SS /- Hex Nuts Zinc Battery Side Support-00 Elect Battery End Support-00 Elect Rubber Grammet-Rear Fire Wall Battery Tray Assy-Right Side Battery Tray Assy-Left Side /" - /" Ind Hex Washr Hd - Type F

13 Electric Motor & Transmission Assembly DETAIL A A 0

14 ITEM 0 QTY Electric Motor & Transmission Assembly PART NUMBER DESCRIPTION Main Frame-Electric Single Cab Transmission -- AC Motor-Extended Frame --00 M x.0 x Flange Hex Bolt --00 Upper Motor Mount-Electric --00 Lower Motor Mount-Electric --00 /"- x -/" Carriage Bolt --00 / - X " Carriage Bolt --00 /- Serrated Flange Nut /- Nylon Insert Locknut --00 /" - X -/" hex C/S-Gr --0 Team Trans Shift Lever Ext /- x Grade Hex bolts Zinc / Lock Washer Zinc /- Hex Nut /- Hex Flange Nuts Zinc W/Serrations Gear Shift Cable-Large UTV --00 /" X Quick Disc. Rod End --0 Trans Shift Cable Brkt-Elect --00 " Battery Cable Gauge --00 Front Drive Shaft-Lg UTV-Electric --00 Rear Drive Shaft-Lg UTV-Electric /- X GR Hex Bolts Zinc /" Zn Lock Washer --00 AC Transmision Adpater Elect. Motor Adpt. O-ring Elect. Motor Adpt. Seal Elect. Motor Adpt. O-ring / Lockwasher Zinc --00 / x -/ G Zn Hex Bolt Skid Plate-Gas /" - /" Ind Hex Washr Hd - Type F

15 DETAIL A DETAIL B DETAIL C A B C 0 0 Rear Suspension Assembly

16 ITEM QTY Rear Suspesion Assembly PART NUMBER DESCRIPTION --00 Left Rear Upper A-arm Assy --00 Left Rear Lower A-arm Assy Large MTV A-Arm Bushing Sleeve Large MTV A-Arm Bushing /- Nylon Insert Locknut /" - X-/" Hex Bolt Gr Independent Rear Suspension Flange BUSHING-Large UTV Hub-Large UTV /" - x." Hex Cap Screw Brake Caliper Brkt-Ausco-Elect /- X GR Hex Bolts Zinc Retaining Ring-Spindle Bearing Spindle Bearing LRG UTV XD Lug Nut Rotor - Large UTV --00 Hydraulic Caliper --00 Brake Pad Kit ( Pads per Kit) --00 mm copper crush washer --00 Banjo Bolt M mm x Brake Line Left Rear-Lg UTV --00 Half-Shaft - Rear Large UTV --00 Rear Hub Castle Nut Cotter Pin --00 Rear Hub Castle Nut --00 Rear Shock-Lg. UTV-Gas & Diesel /- x GR Hex Bolt Zinc Rear Differential, Large MTV --00 Right Rear Upper A-arm assy --00 Right Rear Lower A-Arm Assy Brake Line Right Rear-Lg UTV Brake Line Tee-Rear-Lg UTV /- Nylon Insert Locknut Brake Line-MC to Rear T-Lg UTV --00 Left Rear Fender Well / x Hex Head Tek Screw --00 Right Rear Fender Well Rear Diff Lock Solenoid XD Rear Tire XD Rear Wheel --00 /- Nylock Flange Nut --00 /"- x -/" Carriage Bolt --0 Caliper Brake Mount Spacer IRS Lower Spacer XD Wheel Center Cap IRS Upper Spacer --00 Base Wheel Center Cap --00 Base Rear Tire --0 Open End Lug Nut-Black (Base Model Only) Base Rear Wheel --00 Half Shaft CV Boot Kit Rear Diff Lock Solenoid Spring Rear Diff Cage Top Brace / Lockwasher Zinc --00 / x /" GR Carr Bolts Zinc --0 Right Rear Differential Mount --00 /- X -/ Hex C/S GR Zinc /- x -/ Hex Bolt GR Break Line Anchor--/" --00 / ID / OD Hose --00 Breather Plug Threaded / Spring Hose Clamp

17 Rops Assembly Parts List ITEM QTY PART NUMBER DESCRIPTION /" - x Gr. Hex bolt Cs /- Serrated Flange Nut / x /" GR Carr Bolts Zinc /- Nylock Flange Nut / Lock Washer Zinc Seat Back-Large UTV Seat Belt Latch ROPS Left Hoop Assy ROPS Right Hoop Assy ROPS K Brace Assy For Seat back w/ Integral Headrest ROPS Front Cross Brace Assy ROPS Rear Cross Brace Assy /" - x -/" G Carriage Bolt /"- Nyloc Jam Nut / USS Flat Washer Zinc /"-X-/" Gr C/S Seat Belt Assy- Point Outside Seat Belt Assy- Point-Middle Heyco Hole Plug Spacer,. O.D. x.00 I.D. x.00"l /- x -/" Hex Bolt /- Nylon Insert Locknut /- x -/ GR Hex Cap Screw --00 /- x / GR Shoulder Bolt

18 Safety Nets Assemblies C DETAIL C D DETAIL D DETAIL A A ITEM QTY Net Assemblies PART NUMBER DESCRIPTION /"-X-/" Gr C/S --00 /- Serrated Flange Nut --0 /- X" (GRS) Carriage Bolt -0-0 /- Nylon Insert Locknut BL 0-0- Seat Panel Left-Large UTV-Blk 0-- Seat Panel Right-Large UTV-Blk Side Net - Right Side Side Net - Left Side --0 Safety Net Bracket Left --0 Safety Net Bracket Right Side Net Clip Lock Pin --00 /- X-/" SS Butt Hd Scr Side Net Lower Clip Retainer_L Side Net Lower Clip Retainer_R Spacer,. O.D. x.00 I.D. x.00"l B DETAIL B

19 DETAIL A A Bed Assembly

20 Bed Assembly ITEM 0 QTY PART NUMBER DESCRIPTION Bed Side Support-Left Bed Side Support-Right Standard bed Tail Gate Panel With Cross Brace Assembly Tailgate Support Bracket (Left) Tailgate Support Bracket (Right) Tailgate Support Arm-00 Top Tailgate Guard-Aluminum Left TG Side Cover-Aluminum Right TG Side Cover-Aluminum Standard Bed Left Side-Steel Standard Bed Right Side-Steel Bed Dust Seal Dump Bed Handle Assy Tie Down Bracket /- Nylon Insert Jam Locknut /- Cage Nut /- x / Button Socket C/S /- X" Button Hd Black /- Nylon Insert Locknut BL Spacer,. IDx.0 ODx. L /- X Button Socket C/S Black /" - /" Ind Hex Washr Hd - Type F Tailgate Latch Push Rod Left /" x /" Soc. Shoulder Bolt / IDx / x / OIB Bushing Dump Bed Side-Right-Large UTV Dump Bed Side-Left-Large UTV Tailgate-Large UTV-Black Stop/Tail Light - Large UTV / Flat Washer Black Basket Latch Striker Post " ODx.0" IDx Flat Washer Serrated Flange nut x / Pan Philips Tek Screw Dump Bed Tail gate Actuator Buttom Bumper-Tailgate-00 Push Pin Rivet-Bed Seal

21 DETAIL A A 0 Bed Assembly

22 ITEM 0 QTY Bed Assembly PART NUMBER DESCRIPTION /- Nylock HEX Nut Srandard Bed Bottom Aluminum -00- Srandard Bed Front-Aluminum Right Bed Corner Cover-Aluminum Lower Bed Cover-Aluminum Rotary Latch Bracket-Bed (Base Model Only) Dump Bed Actuator Lever (Base Model Only) Dump Bed Handle Assy / x / Shoulder Bolt Bronze Bushing - SF /- Nylon Insert Jam Locknut /- x Carriage Bolt /- x / Carriage Bolts /- x -/ Carriage bolt /- Cage Nut / Flat Washer Black -0-0 /- x / Button Socket C/S -0-0 /- Nylon Insert Locknut BL --0 /- X Button Socket C/S Black Dump Bed Latch Push Rod Latch Push Rod Retainer Clip Dump Bed Gas Spring-Large UTV --00 "X-/" Shoulder Bolt --00 /"x -/" Shoulder Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon /- x Grade Hex bolts Zinc Dump Bed Rotary Latch Spacer,. IDx.0 ODx. L Pedal Spring Spacer LRG UTV -/ spacer --00 Dump Bed Actuator-00 Series (XD Models Only) /" X " Shoulder Bolt (XD Models Only) /- X -/ Hex C/S GR (XD Models Only) --00 /- Nylock Flange Nut (XD Models Only) Standard Bed Frame Assy

23 Versabed Assembly (Optional) DETAIL B DETAIL A DETAIL C DETAIL D C D B A

24 ITEM QTY 0 Parts List PART NUMBER DESCRIPTION Short Falt Bed Series Frame Assembly Short Flat BedTruck Right Bed Panel Assy Bed Front Assy Truck Bed Tailgate Panel-AL Door Latch Right Door Latch Left Short Flat Bed Left Bed Panel Assy Truck Bed Taillight Panel-AL --00 /- x " Carriage Bolt -0-0 /- Nylon Insert Locknut BL --00 Extended Bed Hinge -0-0 /- x / Button Socket C/S --0 /- X" (GRS) Carriage Bolt --00 /- x / Carriage Bolt Tail/Brake Light Assembly -0-0 Truck Bed Taillight Bracket / Button Stainless Bolt Nylon Insert Locknut Door Latch MTV --0 /- X Button Socket C/S Black --00 Truck Bed Side Gate Brkt Rubber Stops Buttom Bumper-Tailgate Intimidator Versa Bed Fender / x Hex Head Tek Screw Self Adheasive Bumper /- Hex Flange Nuts Zinc W/Serrations

25 0cc Right --00 Orange -- Gray -- O.D. Green 0cc Left --00 Orange -- Gray -- O.D. Green Decal Warning Cluster Decal Warning Cluster Crew-Series --00 X Left --00 Orange -- Gray -- O.D. Green Hot Charge Caution Label XD Right --00 Orange -- Gray -- O.D. Green X Right --00 Orange -- Gray -- O.D. Green XD Left --00 Orange -- Gray -- O.D. Green Dash Intimidator --00 Orange -- Gray -- O.D. Green Tailgate Intimidator --00 Orange -- Gray -- O.D. Green

26 Battery Charger Warning Label ROPS --00 Hot Motor Caution Label Versabed XD Left Orange 0-- Gray 0-- O.D. Green Versabed Left Orange 0-- Gray 0-- O.D. Green Versabed XD Right Orange 0-- Gray Versabed Right Orange 0-- Gray 0-- O.D. Green 0-- O.D. Green Versabed Tailgate Orange 0-- Gray 0-- O.D. Green

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