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... Engine in Frame Assembly... Parts List... Rear Suspension Assembly... Parts List... Roll Cage Assembly... Parts List... Safety Net Assemblies...0 Bed Assembly ( of )... Parts List... Bed Assembly ( of )... Parts List... Decals...-

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

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 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 XD Front Tire Tie Rod End-Intimidator XD Front Wheel Base Model Front Wheel --00 Base Model Front Tire -0-0 Caliper Brake Mount Spacer XD Wheel Center Cap Base Wheel Center Cap -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 Brake Caliper Brkt-Ausco-Elect

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

6 Parts List ITEM QTY PART NUMBER DESCRIPTION /- Hex Flange Nuts Zinc w/serations /" - X -/" Carriage Bolt /- Nylock HEX Nut Master Cylinder, Dual Cylinder Banjo Bolt-Double-0mm-.0 Brake Switch-Banjo-0 0 mm copper crush washer Brake Line-MC to Rear T-Lg UTV Brake Line Front Left-Lg UTV Brake Line Front Right-Lg UTV /-x/ Carriage Bolts Zinc /- x -/ Carriage bolt Brake Pedal Bracket-Right-00 Brake Pedal Assy-Large UTV Brake Pedal Bracket Left-00 / 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 Accel Pedal Lever Accel Pedal Spring Anchor Accel Pedal Spacer Headlight-High Beam-Large UTV Head Light Bracket-Right LED Headlight Head Light Bracket Brace-Right Head Light Bracket Brace-Left Head Light Bracket-Left /" x -/" Hex Hd Cap Scr. Break Fluid DOT. quarts /-0 x Grade Hex bolts Zinc /-0 Hex Flange Nuts Zinc W/Serrations /-0 Nylon Insert Locknut Zinc Orange Nylon /" x /" Soc. Shoulder Bolt /"- Nyloc Jam Nut /" x -/" Hex C/S Gr /-0 x -/" Hex Bolt /-0 X-/" BH Socket Scr Blk /-0 Nylon Insert Locknut BL. ID x.00 OD x.0 Thick TFE Washer Spring-Accelerator Pedal Assy /-0 x / Grade Hex bolts Zinc

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

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

9 DETAIL A DETAIL B DETAIL C A B C Plastics Assembly

10 Parts List ITEM QTY PART NUMBER DESCRIPTION /-0 x Grade Hex bolts Zinc Floor Board-Large UTV-Black Rear Floor Board Crew Cab Left Rear Lower Kick Panel, Crew Cab Hood Large UTV-Orange XD Front Grill-Large UTV-Black Lower Front Fender Flare-Left Lower Front Fender Flare-Right /-0 X Button Socket C/S Black / Flat Washer Black /-0 Nylon Insert Locknut BL Hood Hinge Upper Front Fender Flare-Right Upper Front Fender Flare-Left Passenger Front Kick PNL. PSG Driver Front Kick PNL. PSG Front Seat Back Crew Cab Front Firewall-Large UTV-Black M-. x 0 Pan Phil M/S Zinc /-0 X-/" BH Socket Scr Blk Upper Hood Support Brkt-Kohler/Electirc /" - /" Ind Hex Washr Hd - Type F Firewall Mount Brkt Speedometer/Display Gauge Ignition Switch Volt Auxilliary Plug WD Switch Head Light Hi/off/Low Beam Sw. Differential Lock Switch Dump Bed Up/Down Switch Panel Plug-Eaton Blank Switch Upper Radiator Mounting Brkt /" - X -/" Hex Hd Cap Screw /- Nylon Insert Locknut Buttom Bumper-Tailgate-00 Right Rear Lower Kick Panel, Crew Cab Front Seat Box Seater Wiring Harness- 00CC Crew Cab / flat Washer - SS /-0 x / Button Socket C/S AUEVCO P/N HOLE PLUG BLACK Center Seat Panel-Large UTV-Gr Center Seat Panel-00-Camo Hood-OD Green Hood-Camo Hood-Metallic Black Glovebox Base Model Front Grill Seat Pin Frame Guard-x." Shift Lever Boot-Large UTV Break Pedal Boot-Lg UTV Kohler 0 CVT Cover Instualton -/"x-/" Black Tube Plug Hitch Pin Center Seat Panel-Large UTV-Or /-0 Nylon Insert Locknut Zinc Orange Nylon Indicator Light Intimidator Left Inner Fender / x Hex Head Tek Screw Intimidator Right Inner Fender

11 DETAIL A A Radiator Assembly

12 Radiator Assembly ITEM QTY PART NUMBER DESCRIPTION Upper Hood Support Brkt-Diesel-Weber /" - /" Ind Hex Washr Hd - Type F Lower Radiator Mounting Brkt /- x Carriage Bolt /- Nylock HEX Nut Radiator Grommets RadiatorAssy-Large MTV Upper Radiator Mounting Brkt 00cc Fan / Over Temperature Switch, Includes Contacts and Boot (M THREADS).ID Plastic Washer /" - X -/" Hex Bolt /- Nylon Insert Locknut Coolant Hose /" ID ABA -mm x mm Wide Hose Clamp Radiator Overflow Bottle-00 /-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 Nylon Insert Locknut BL -mm Screw Clamp 00cc Engine Skid Plate 00cc Classic Front Skid Plate 00cc Crew Cab Mid Skid Plate /-0 Cage Nut /-0 x / Buttonhead Socket C/S - SS Dashboard Upper Heat Shield without PWR Steering Dashboard Lower Heat Shield without PWR Steering

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 Assembly 0

15 ITEM QTY 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 Crew Cab Bearing Pillow Block 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 Pillow Block Bearing Front Drive Shaft 00cc Crew 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 -- Battery Hold Down /-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 / Washer Zinc / to - / Hose Clamp --00 Hex Bolt mm Nylon Insert Locknut / 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 Electric Fuel Pump, Weber/00CC ENGINE /- x -/ Hex Bolt Zinc / - X " Hex Bolt -0-0 /-0 X-/" BH Socket Scr Blk --00 Spacer for shifter cable at transmission cc Exhaust Pipe Heat Shield Exhaust Pipe Band Clamp Exhaust Pipe Heat Shield Clamp / Flat Washer Black Zinc Muffler Hanger 00 Engine Starter Solenoid, 00cc Engine Air Box to Frame Hose, -/"L x " ID

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

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 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 XD Rear Wheel Base Rear Wheel XD Rear Tire Base Rear Tire XD Wheel Center Cap Base 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 Tee-Rear-Lg UTV /- Nylon Insert Locknut XD Lug Nut Base 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 /- x -/ Hex C/S GR Zinc Brake Caliper Brkt-Ausco-Elect

18 Crew Cab Roll Cage Assembly

19 Parts List ITEM QTY PART NUMBER DESCRIPTION Front Seat Frame Assembly Crew Cab ROPS K Brace Assy For Seat Back w/ Integral Headrest ROPS Front Cross Brace Crew Cab Rear Side Net Latch Bracket left Crew Cab Rear Side Net Latch Bracket Right / Lock Washer Zinc / x /" GR Carr Bolts Zinc /"- Nyloc Jam Nut /- Nylock Flange Nut /- x -/ Carriage Bolt / USS Flat Washer Zinc /- Serrated Flange Nut /"-X-/" Gr C/S /" - x Gr. Hex bolt Cs / - X Flange Bolt BLK Gr. Seat Bottom-Large UTV Seat Back-Large UTV ROPS X-Brace Assembly Crew Cab ROPS Left Rear Hoop Assy Crew Cab ROPS Right Rear Hoop Assy Crew Cab ROPS Left Front Hoop Assy Crew Cab ROPS Right Front Hoop Assy Crew Cab Crew Cab Rear Handhold Assy Seat Belt Assy- Point-Front Drivers Side Seat Belt Assy- Point-Center Seat Belt Assy- Point-Passangers Side Seat Belt Assy- Point-Rear Drivers Side Seat Pin Latch Assembly /-0 x -/" Hex Bolt Spacer,. O.D. x.00 I.D. x.00"l /- x -/ Hex Cap Screw GR /-0 x -/ GR Hex Cap Screw /-0 x / GR Shoulder Bolt /-0 Nylon Insert Locknut

20 0 Crew Cab Safety Nets Assemblies DETAIL B B A 0 ITEM 0 QTY PART NUMBER Parts List DESCRIPTION /"-X-/" Gr C/S /- Serrated Flange Nut Side Net - Left Side Side Net - Right Side /-0 Nylon Insert Locknut BL /-0 X" (GRS) Carriage Bolt Rear Side Net - Left Side Intimidator Rear Side Net - Right Side Intimidator Spacer,. O.D. x.00 I.D. x.00"l Front side net female buckle Mounting Brkt 0 DETAIL A

21 DETAIL A A Bed Assembly 0 0

22 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 Standard Bed Right Side Bed Dust Seal Dump Bed Handle Assy /- Nylon Insert Jam Locknut /-0 Cage Nut / Flat Washer Black /-0 x / Button Socket C/S /-0 X" Button Hd Black /-0 Nylon Insert Locknut BL /-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 Basket Latch Striker Post Serrated Flange nut 0 x / Pan Philips Tek Screw Spacer,. IDx.0 ODx. L Dump Bed Tail gate Actuator Buttom Bumper-Tailgate-00 Push Pin Rivet-Bed Seal Striker Post Fender Washer

23 DETAIL A A Bed Assembly 0

24 ITEM QTY Bed Assembly PART NUMBER DESCRIPTION /- Nylock HEX Nut Standard Bed Bottom Standard 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 /- 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 Bronze Bushing - SF Dump Bed Actuator-00 Series (XD Models Only) /" X " Shoulder Bolt (XD Models Only) /- X GR Hex Bolts Zinc (XD Models Only) Standard Bed Frame Assy / x / x / Spacer

25 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

26 EPA/CARB Label --00 EPA/CARB Hang Tag --00 General Warning Tag --00 RHOVA Decal -0-00