Intimidator UTV Part Manual

Transcription

1 Intimidator UTV Part Manual 00cc 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...0 Radiator Assembly... Parts List... Engine only Assembly... Parts List... Engine in Frame Assembly... Rear Suspension Assembly... Parts List... Rops Assembly... Safety Net Assemblies... Bed Assembly ( of )...0 Parts List... Bed Assembly ( of )... Parts List... Decals...

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

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

5 Lights and Brake Assemblies 0 A B 0 0 DETAIL B DETAIL A

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

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

8 Seat, Dash, and Grill Assembly ITEM QTY PART NUMBER DESCRIPTION cc Single Cab Main Frame Assembly Dash Support Assy Seat Frame Assy, 00cc Steering Wheel Large UTV Steering Wheel Cap-Hurricane Tilt Steering Gas Spring Front Receiver Tube Mtg Tube Front Receiver Tube Plate Front Receiver Gusset Intimidator Front Receiver Bottom Tube Intimidator --00 Hitch Pin Front Grill insert Brush Guard Mtg Brkt-Left --00 Brush Guard Mtg Brkt-Right Intimidator Bumper Seat Pin Latch Assembly Shift Lever Knob 00cc /" - X -/" Hex Bolt -0-0 /-0 x / Button Socket C/S /-0 Nylon Insert Locknut BL /- Nylon Insert Locknut Seat Bottom-Large UTV /-x/ Carriage Bolts Zinc /- Hex Flange Nuts Zinc w/serations /- x Carriage Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon /" - X -/" Hex Hd Cap Screw /"- x -/" Carriage Bolt /- Nylock Flange Nut /- X GR Hex Bolts Zinc / ID x / Plastic Washer / x -/ G Zn Hex Bolt /-, Right Hand Thread Heim /-0 Nylon Insert Locknut Zinc Orange Nylon /-0 x Grade Hex bolts Zinc Overflow Bottle Spacer /"x-/" Black Tube Plug /" Round Tubing Plug /- x -/ Grade Hex Bolt Rivnut /-0 Steel -0-0 /-0 X Button Socket C/S Black Hood Rest Bumper-Lg UTV Gear Shift Cable-00cc Classic Steering Column Bearing Brush Guard Skid Plate /" - /" Ind Hex Washr Hd - Type F /- x GR Hex Bolt Zinc /- Nylon Insert Locknut Volt Cube Relay /- Hex Nut Zinc / inch Loop Clamp / x Hex Head Tek Screw cc Shifter Spring Bushing, Oil Impregnated cc Transmission Shift Lever Assy cc Dash Shifter Indicator Plate Mounting Brkt -0-0 /-0 X Button Socket C/S Black /-0 Cage Nut /- Nylock HEX Nut /- x Carriage Bolt cc Dash indicator Plastic Plate cc Dash Shifter Metal Brkt Rotary Latch Bracket-Frame 00cc /- x / GR Hex bolt Zinc

9 Plastics Assembly DETAIL B 0 DETAIL A 0 0 B A 0 0

10 ITEM QTY 0 Plastics Assembly PART NUMBER DESCRIPTION /- Nylon Insert Locknut /" - X -/" Hex Hd Cap Screw -0-0 /-0 Nylon Insert Locknut BL -0-0 /-0 X Button Socket C/S Black /" - /" Ind Hex Washr Hd - Type F --00 Upper Radiator Mounting Brkt Upper Front Fender Flare-Left Front Firewall-Large UTV-Black Center Seat Panel-Large UTV-Or Hood Large UTV-Orange Upper Front Fender Flare-Right Dash-Large UTV Seat Panel Left-Large UTV-Blk Seat Panel Right-Large UTV-Blk Lower Front Fender Flare-Right Lower Front Fender Flare-Left /-0 x Grade Hex bolts Zinc Speedometer/Display Gauge Ignition Switch Floor Board-Large UTV-Black Head Light Hi/off/Low Beam Sw WD Switch / Flat Washer Black Hood Hinge M-. x 0 Pan Phil M/S Zinc Differential Lock Switch Panel Plug-Eaton Blank Switch --0 Firewall Mount Brkt Buttom Bumper-Tailgate Dump Bed Up/Down Switch -0-0 /-0 X-/" BH Socket Scr Blk / flat Washer - SS AUEVCO P/N HOLE PLUG BLACK / x Hex Head Tek Screw Front Grill-Large UTV-Black 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 cc Single Cab Main Frame Assembly /-0 Nylon Insert Locknut Zinc Orange Nylon /-0 Hex Flange Nuts Zinc W/Serrations Upper Hood Support Brkt-Diesel-Weber cc Classic Wiring Harness Glovebox Center Seat Panel-Large UTV-Gr Center Seat Panel-00-Camo Center Seat Panel-00-Charo Hood Large UTV-Gr Hood Large UTV- Camo Hood Large UTV-Blk Front Grill-UTV (Base Model Only) Indicator Light Intimidator Left Inner Fender Intimidator Right Inner Fender

11 DETAIL A Radiator Assembly A 0 0

12 Parts List ITEM QTY PART NUMBER DESCRIPTION Upper Hood Support Brkt-Diesel-Weber /" - /" Ind Hex Washr Hd - Type F --00 Lower Radiator Mounting Brkt /- x Carriage Bolt /- Nylock HEX Nut Radiator Grommets RadiatorAssy-Large MTV 00cc Fan / Over Temperature Switch, Includes Contacts and Boot (M THREADS) Upper Radiator Mounting Brkt ID Plastic Washer /" - X -/" Hex Bolt /- Nylon Insert Locknut Coolant Hose /" ID ABA -mm x mm Wide Hose Clamp Radiator Overflow Bottle /-0 Nylon Insert Locknut Zinc Orange Nylon / x Hex Head Tek Screw / Flat Washer Black Zinc /-0 x Grade Hex bolts Zinc /" Hose - High Temp Hose Clamp No. - / - / / inch Loop Clamp / EPDM Cushion Clamp /-0 X Button Socket C/S Black -0-0 /-0 Nylon Insert Locknut BL mm Screw Clamp 00cc Engine Skid Plate 00cc Classic Front Skid Plate /" - x -/" G Carriage Bolt

13 0 Engine only Assembly 0 Engine Assembly ITEM 0 0 QTY PART NUMBER DESCRIPTION Water Pump Housing Impeller-Water Gasket Paper Cylinder Front Oil Dipstick Silent Chain.Px Chain Guide Chain Guide Chain Tension Guide Chain Tensioner Plunger PTO Cover 00cc Engine Intake Manifold Hose Spring Driving Wheel Driving Wheel VBelt Chain Tensioner Housing Valve Cover Variator Cover CVT Air Guide

14 DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E A B C D E Engine in Frame Assembly

15 ITEM QTY 0 Parts List PART NUMBER DESCRIPTION cc Rectifire Module Bracket Voltage Regulator cc Air Filter Bracket cc Starter Relay Bracket Seat Frame Assy, 00cc Exhaust System Assembly, 00cc cc CVT Air Inlet Hose cc CVT Air Outlet Hose cc Coil Mount Bracket cc Shift Cable Bracket cc Engine Throttle Body Intake Hose CVT Plenum Bezel CVT Plenum Filter Media cc Upper Engine Mount Assembly Lower Fuel Tank Support Brkt /" - /" Ind Hex Washr Hd - Type F Fuel Tank Cap-Lg UTV-Gas / Lockwasher Zinc /- x / GR Hex bolt Zinc / USS Flat Washer Zinc Upper Fuel Tank Support Brkt /" x -/" Hex Hd Cap Scr Fuel Sender x /" Indented hex Head machine Screw Front Drive Shaft 00cc Single Cab Gas Tank Heat Shield Classic & Cew / x Hex Head Tek Screw cc Muffler Mounting Bracket Assembly cc Muffler Frame Bracket Gas Tank, Weber/00CC Engine /- Nylock HEX Nut / Fuel Line - Low Perm Rear Drive shaft 00cc /- x " GR Hex bolt /" - X -/" Carriage Bolt /- X GR Hex Bolts Zinc /- Nylon Insert Locknut /-0 x -/ Grade Hex bolts Zinc /-0 Nylon Insert Locknut Zinc Orange Nylon Volt Battery /-0 x Carriage Bolt Zinc /-0 Wing Nut Zinc /-0 x Grade Hex bolts Zinc /-0 Hex Flange Nuts Zinc W/Serrations Filter Restriction Switch cc UTV Battery Box Large MTV A-Arm Bushing /" - X-/" Hex Bolt Gr /- Nylon Insert Locknut / Lock Washer Zinc / to - / Hose Clamp / to - / Hose Clamp CVT Enclosure Bracket -0-0 /-0 Nylon Insert Locknut BL -0-0 /-0 X Button Socket C/S Black /" ID Hose M0 x. x 0mm Hex Cap Bolt mm - mm x mm ABA 0 Clamp mm - mm Two Ear Clamp mm-mm Two Ear Clamp M0 x. x MM tap bolt M x.0 x Flange Hex Bolt Fuel Filter/Regulator cc Fuel Pump Mount /" Female Fuel line Quick Disconnect /" Male Fuel Line Quick Disconnect /" Female Fuel Line Quick Disconnect -0-0 /-0 x Button C/S Black M-. Hex Toplock Nut-Zinc " Battery Cable Gauge Fuel Tank Heat Shield Insulation Electric Fuel Pump, Weber/00CC ENGINE Pillow Block Bearing Brkt single Cab 00cc Assy Pillow Block Bearing /- x -/ Hex Bolt GR /" - X -/" Hex Hd Cap Screw /- Nylock Flange Nut

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

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

18 Rops Assembly Parts List ITEM 0 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 /-0 x -/" Hex Bolt /-0 Nylon Insert Locknut /-0 x -/ GR Hex Cap Screw /-0 x / GR Shoulder Bolt

19 Safety Nets Assemblies 0 0 DETAIL A A Net Assemblies ITEM 0 QTY PART NUMBER DESCRIPTION /"-X-/" Gr C/S /- Serrated Flange Nut Front Side Not Female Buckle Mount Brkt 0 /-0 X" (GRS) Carriage Bolt /-0 Nylon Insert Locknut BL Seat Panel Left-Large UTV-Blk Seat Panel Right-Large UTV-Blk Side Net - Right Side Side Net - Left Side /- Nylon Insert Flange Nut Zinc Orange Nylon / x -/ G Zn Hex Bolt Spacer,. O.D. x.00 I.D. x.00"l

20 DETAIL A A Bed Assembly 0

21 Bed Assembly ITEM 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 /-0 Cage Nut /-0 x / Button Socket C/S /-0 X" Button Hd Black /-0 Nylon Insert Locknut BL Spacer,. IDx.0 ODx. L /-0 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 0 x / Pan Philips Tek Screw Dump Bed Tail gate Actuator Buttom Bumper-Tailgate-00 Push Pin Rivet-Bed Seal Striker Post Fender Washer

22 DETAIL A A Bed Assembly

23 ITEM QTY Bed Assembly PART NUMBER DESCRIPTION /- Nylock HEX Nut Srandard Bed Bottom 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 /-0 Cage Nut / Flat Washer Black -0-0 /-0 x / Button Socket C/S -0-0 /-0 Nylon Insert Locknut BL -0-0 /-0 X Button Socket C/S Black Dump Bed Latch Push Rod Latch Push Rod Retainer Clip Dump Bed Gas Spring-Large UTV "X-/" Shoulder Bolt /"x -/" Shoulder Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon /-0 x Grade Hex bolts Zinc Dump Bed Rotary Latch Spacer,. IDx.0 ODx. L Pedal Spring Spacer LRG UTV -/ spacer Dump Bed Actuator-00 Series (XD Models Only) /" X " Shoulder Bolt (XD Models Only) /- X GR Hex Bolts Zinc (XD Models Only) /- Nylock Flange Nut (XD Models Only) Standard Bed Frame Assy

24 00cc Left Orange Gray O.D. Green 00cc Right Orange -0-0 Gray -0-0 O.D. Green Decal Warning Cluster Load Rating Decal X Left Orange -0-0 Gray -0-0 O.D. Green XD Right Orange -0-0 Gray -0-0 O.D. Green X Right Orange -0-0 Gray -0-0 O.D. Green XD Left Orange -0-0 Gray -0-0 O.D. Green Dash Intimidator Orange Gray O.D. Green Tailgate Intimidator Orange -0-0 Gray -0-0 O.D. Green Muffler Hot Warning Label ROPS Helmet Logo Decal Camo x Decal Camo XD Decal -0-00