Intimidator UTV Part Manual

Transcription

1 Intimidator UTV Part Manual Kohler Gas 0 EFI 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... Kohler Engine Assembly... Parts List... Rear Suspension Assembly... Parts List... Rops Assembly... Safety Net 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 0 0 Lights and Brake Assemblies Only on XD Model

6 ITEM 0 0 QTY Lights and Brake Assemblies PART NUMBER DESCRIPTION /- Hex Flange Nuts Zinc w/serations --00 /" - X -/" Carriage Bolt /- Nylock HEX Nut Master Cylinder, Dual Cylinder --00 Banjo Bolt-Double-mm Brake Switch-Banjo mm copper crush washer Brake Line-MC to Rear T-Lg UTV Brake Line Front Right-Lg UTV Brake Line Front Left-Lg UTV /- x Carriage Bolt /- x -/ Carriage bolt --00 Brake Pedal Bracket-Right Brake Pedal Assy-Large UTV Accel Pedal Lever Assy Brake Pedal Bracket Left /" x /" Soc. Shoulder Bolt "X-/" Shoulder Bolt / IDx / x / OIB Bushing Pedal Spring Spacer LRG UTV -/ spacer /"- Nyloc Jam Nut Bushing, Oil Impregnated /- Hex Flange Nuts Zinc w/serations --00 /" x -/" Hex C/S Gr /- Nylon Insert Locknut Zinc Orange Nylon /- x / Grade Hex bolts Zinc Spring-Accelerator Pedal Clevis Pin, /" x /" Bow Tie Clip /- x Grade Hex bolts Zinc -0-0 /- Nylon Insert Locknut BL --0 /- X-/" BH Socket Scr Blk --0 /- x -/" Hex Bolt /- Hex Flange Nuts Zinc W/Serrations Spring- Accelerator Pedal Assy Accelerator Pedal Assy-LG UTV ID x.00 OD x.0 Thick TFE Washer Spring-Park Brake Headlight-Low Beam-Large UTV Headlight-High Beam-Large UTV Head Light Bracket-Right Head Light Bracket Brace-Right Head Light Bracket Brace-Left Head Light Bracket-Left --00 /" x -/" Hex Hd Cap Scr Skid Plate - Kohler 0 EFI & DIESEL --00 /" - /" Ind Hex Washr Hd - Type F --00 Brake Fluid DOT. Quarts

7 DETAIL A DETAIL B DETAIL C A B C 0 0 Seat, Dash, and Grill Assemblies 0 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 Steering Column Assy Shift Lever Assembly 00 Series Floor Board Support Assy --00 /"- x -/" Carriage Bolt Rotary Latch Bracket-Frame (Base Model Only) --00 /" - X -/" Hex Bolt --0 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 Volt Cube Relay Steering Wheel Cap-Hurricane PMW Controller, Team Rear Diff Steering Shaft Wheel Nut Seat Frame Assy Kohler / to - / Hose Clamp ft. Flex Hose --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 -0-0 Front Receiver Gusset Intimidator Front Receiver Bottom Tube Intimidator / EPDM Cushion Clamp /" OD x /" ID x " Long Nylon Spacer Blk Turn Signal Pod / EPDM Loop Clamp /"x-/" Black Tube Plug /- x -/ Grade Hex Bolt /" Round Tubing Plug Rivnut /- Steel Fuse Block Cover, 0 EFI /- Hex Nut Zinc --00 CVT Plenum Filter Media Seat Pin Latch Assembly --0 /- X Button Socket C/S Black Hood Rest Bumper-Lg UTV --00 Hitch Pin CVT Plenum Bezel

9 DETAIL A DETAIL B A B Plastics Assembly 0 0

10 ITEM QTY Plastics Assembly PART NUMBER DESCRIPTION /- Nylon Insert Locknut --00 /" - X -/" Hex Hd Cap Screw -0-0 /- Nylon Insert Locknut BL --0 /- X Button Socket C/S Black --00 /" - /" Ind Hex Washr Hd - Type F --00 Upper Radiator Mounting Brkt 0-- Upper Front Fender Flare-Left 0-- Front Firewall-Large UTV-Black Center Seat Panel-Large UTV-Or Hood Large UTV-Orange 0-- Upper Front Fender Flare-Right Dash-Large UTV 0-0- Seat Panel Left-Large UTV-Blk 0-- Seat Panel Right-Large UTV-Blk 0-0- Lower Front Fender Flare-Right 0-- Lower Front Fender Flare-Left --00 Upper Hood Support Brkt-Kohler/Electirc /- x Grade Hex bolts Zinc /- Hex Flange Nuts Zinc W/Serrations --00 Speedometer/Display Gauge Ignition Switch --00 Volt Auxilliary Plug 0-- Floor Board-Large UTV-Black --00 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 Engine Fault Indicator Light Filter Plugging Ind. Light Panel Plug-Eaton Blank Switch --0 Firewall Mount Brkt Self Adheasive Bumper --00 Dump Bed Up/Down Switch --0 /- X-/" BH Socket Scr Blk / flat Washer - SS AUEVCO P/N HOLE PLUG BLACK / x Hex Head Tek Screw -0-0 /- x / Button Socket C/S 0-0- Front Grill-Large UTV-Black Hood Lid-large UTV --00 Wiring Harness_LG UTV-Gas Glovebox 0-- Center Seat Panel-Large UTV-Gr 0--0 Center Seat Panel-00-Camo 0--0 Center Seat Panel-00-Charo -00- Hood Large UTV-Gr Hood Large UTV- Camo Hood Large UTV-Blk 0-- Front Grill-UTV (Base Model Only) --00 Dash Light Blank Panel Seat Pin Frame Guard-x." Break Pedal Boot-Lg UTV Shift Lever Boot-Large UTV Kohler 0 CVT Cover Instualton /"x-/" Black Tube Plug --00 Hitch Pin Female Push on Terminal

11 DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E A B C D E Kohler Engine Assembly

12 ITEM QTY Kohler Engine Assembly PART NUMBER DESCRIPTION --00 Lower Transmission Mounting Brkt --0 Lower Shift Cable Bracket --00 /- Serrated Flange Nut --00 /" - X -/" hex C/S-Gr /- x -/ Hex Bolt Zinc /- Nylon Insert Flange Nut Zinc Orange Nylon --00 / - X " Hex Bolt /- Nylon Insert Locknut /" Zn Lock Washer / Lockwasher Zinc /- X GR Hex Bolts Zinc /- x / GR Hex bolt Zinc Kohler 0 EFI Engine Package Fuel Sender Air Filter Air Box Cap Air Box Assembly Intake Adapter Hose-0 EFI Kohler Air Canister Clamp Air Filter Bracket Transmission --00 Front Drive Shaft-Lg UTV 0 EFI --00 Rear Drive Shaft-Gas Lg UTV's Kohler & Weber / to - / Hose Clamp --00 /" - /" Ind Hex Washr Hd - Type F --00 Muffler Mount Bracket AGM Starter Battery /- x " GR Hex bolt --00 /- x Carriage Bolt Zinc /- Wing Nut Zinc --00 Battery Hold Down " Battery Cable Gauge /- x Grade Hex bolts Zinc /- Hex Flange Nuts Zinc W/Serrations Throttle Cable-0-EFI Kohler CVT Belt-Kohler 0 EFI --00 Gas Tank-Kohler 0 EFI --00 Lower Fuel Tank Support Brkt ft. / Fuel Line - Low Perm Hose Clamp No. - / - / --0 Upper Fuel Tank Support Brkt --00 /" x -/" Hex Hd Cap Scr Fuel Tank Cap-Lg UTV-Gas --0 Team Trans Shift Lever Ext Gear Shift Cable-Large UTV --00 /" X Quick Disc. Rod End /- Nylon Insert Locknut Zinc Orange Nylon /- Hex Nut / Lock Washer Zinc -0-0 /-x/ Carriage Bolts Black Zinc /- Hex Flange Nuts Zinc w/serations Muffler-Kohler EFI & Diesel CVT Driver Pulley-Kohler CVT Driven Pulley-Kohler --00 Rain Cap- Air Filter Motor/Transmission Bracket /-x/ Carriage Bolts Zinc /- Nylock HEX Nut Fuel Sender Exhaust Mainfild-Kohler - EFI Exhaust Hdr Gasket-Diesel/Muff Spark Arrestor Kit for Muffler --0 CVT Backplate Stiffener, Kohler EFI CVT Backing Plate, Kohler EFI --00 Motor/Transmission Bracket Upper Brkt-0EFI CVT Cover Kohler 0 EFI / X / hex head tri-lobe thread forming bolt --00 /- x -/ Hex C/S GR Zinc / Flat Washer Black Zinc --00.ODx.IDx."L Spacer / USS Flat Washer Zinc Gas Tank Heat Shield Classic & Cew / x Hex Head Tek Screw Mx.xmm Hex Washer Hd MS -0-0 /- Nylon Insert Locknut Black Zinc --00 Muffler Rear Mounting Brkt --00 Exhaust Pipe Heat Shield -0-0 /- x Carriage Bolt Black /- x -/" Carriage Bolt --00 Muffler Heat Shield-Al x /" Indented hex Head machine Screw CVT Shim CVT Shim CVT Shim --00 /- x -/ GR Hex Bolt --00 /"-x-/" Hex Hd Cap Scr Male Push on Terminal w 0 Motor Oil. quarts

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

14 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

15 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

16 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

17 DETAIL A A 0 Bed Assembly

18 Bed Assembly ITEM 0 QTY PART NUMBER DESCRIPTION Bed Side Support-Left Bed Side Support-Right Standard Bed Tailgate Tailgate Rotary Latch-Left Tailgate Rotary Latch-Right Tailgate Support Bracket (Left) Tailgate Support Bracket (Right) Tailgate Support Arm-00 Top Tailgate Guard Left TG Side Cover Right TG Side Cover 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 Serrated Flange nut x / Pan Philips Tek Screw Dump Bed Tail gate Actuator Buttom Bumper-Tailgate-00 Push Pin Rivet-Bed Seal Striker Post Fender Washer

19 DETAIL A A 0 Bed Assembly

20 ITEM 0 QTY Bed Assembly PART NUMBER DESCRIPTION /- Nylock HEX Nut Srandard Bed Bottom -00- Srandard Bed Front Right Bed Corner Cover Lower Bed Cover 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 GR Hex Bolts Zinc (XD Models Only) --00 /- Nylock Flange Nut (XD Models Only) Standard Bed Frame Assy

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

22 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

23 0cc Left --00 Orange -- Gray -- O.D. Green 0cc Right --00 Orange -- Gray -- O.D. Green Decal Warning Cluster Decal Warning Cluster Crew-Series --00 X Left --00 Orange -- Gray -- O.D. Green 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

24 Muffler Hot Warning Label E Fuel Warning Label --00 ROPS --00 Versabed XD Left Orange 0-- Gray 0-- O.D. Green Versabed Left Orange 0-- Gray 0-- O.D. Green Versabed XD Right Versabed Right Orange 0-- Gray 0-- O.D. Green Orange 0-- Gray 0-- O.D. Green Versabed Tailgate Orange 0-- Gray 0-- O.D. Green