Intimidator UTV Part Manual
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1 Intimidator UTV Part Manual 00cc XD Sport Revision Date --
2 Table of Contents Front Suspension Assembly... Parts List... Lights and Break Assemblies... Parts List... Seat and Grill Assemblies... Parts List... Dash Assembly... Parts List...0 Plastic Assembly... Parts List... Radiator Assembly... Parts List... Engine only Assembly... Engine in Frame Assembly... Parts List... Rear Suspension Assembly... Parts List... ROPs Assembly...0 Safety Net Assemblies... Bed Assembly ( of )... Parts List... Bed Assembly ( of )... Parts List... Decals...-
3 DETAIL A A Front Suspension Assembly 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 ELKA Front Shock 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 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 Front Wheel Assembly XD Sport Wheel Center Cap 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 Warn Vantage 000 lb. Winch Brake Caliper Brkt-Ausco-Elect Caliper Brake Mount Spacer Hydraulic Caliper Brake Pad
5 DETAIL A DETAIL B A B Lights and Brake Assemblies 0
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 Left-Lg UTV Brake Line Front Right-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 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 -0-0 /-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 DETAIL A A Seat and Grill Assemblies
8 ITEM QTY Parts List PART NUMBER DESCRIPTION cc Single Cab Main Frame Assembly Seat Frame Assy, 00cc Front Receiver Tube Mtg Tube Front Receiver Assembly 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 Seat Pin Latch Assembly /" - X -/" Hex Bolt -0-0 /-0 x / Button Socket C/S -0-0 /-0 Nylon Insert Locknut BL /- Nylon Insert Locknut King Ranch Seat Bottom /-x/ Carriage Bolts Zinc /- Hex Flange Nuts Zinc w/serations /- x Carriage Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon /"- x -/" Carriage Bolt /- Nylock Flange Nut /- X GR Hex Bolts Zinc /"x-/" Black Tube Plug /- x -/ Grade Hex Bolt Brush Guard Skid Plate /" - /" Ind Hex Washr Hd - Type F / inch Loop Clamp / x Hex Head Tek Screw Rotary Latch Bracket-Frame 00cc /- x / GR Hex bolt Zinc Intimidator XD Sport Front Bumper Assembly --00 Intimidator XD Sport Front Bumper Top Left Mounting Bracket Intimidator XD Sport Front Bumper Top Right Mounting Bracket --00 Intimidator XD Sport Front Bumper Skid Plate / - X " Carriage Bolt
9 Dash Assembly A DETAIL A
10 Dash Assembly ITEM QTY PART NUMBER DESCRIPTION Dash Support Assy Steering Wheel Large UTV Steering Wheel Cap-Hurricane Tilt Steering Gas Spring Shift Lever Knob 00cc /- Nylon Insert Locknut /- Nylon Insert Flange Nut Zinc Orange Nylon /" - X -/" Hex Hd Cap Screw /- 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 Gear Shift Cable-00cc Classic Steering Column Bearing /- x GR Hex Bolt Zinc /- Nylon Insert Locknut Volt Cube Relay /- Hex Nut Zinc 00cc Shifter Spring Bushing, Oil Impregnated 00cc Shift Lever Assy 00cc Transmission Shift Lever Assy 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 Power Steering Power Steering Brkt /" - X -/" Carriage Bolt / Flat Washer Black Zinc Steering Column Assy- Large UTV Upper Shift Cable Bracket
11 DETAIL A DETAIL B A B Plastics Assembly
12 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 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-00-Charo Hood Large UTV-Blk Front Grill-UTV (Base Model Only) Indicator Light Intimidator Left Inner Fender Intimidator Right Inner Fender
13 DETAIL A Radiator Assembly 0 A 0 0
14 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 Dashboard Lower Heat Shield PWR Steering Dashboard Upper Heat Shield PWR Steering
15 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
16 DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E A B C D E Engine in Frame Assembly 0 0
17 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 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 / 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 00cc Single Cab /" - X -/" Hex Hd Cap Screw /- Nylock Flange Nut /- x -/ Hex Bolt Zinc -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 Muffler Hanger 00 Engine Starter Solenoid, 00cc Engine Air Box to Frame Hose, -/"L x " ID cc Carrier Bearing Mounting Bracket cc Carrier Bering Bracket Classic / - X " Carriage Bolt
18 DETAIL A DETAIL B DETAIL C A B C Rear Suspension Assembly 0 0
19 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 ELKA Shock Rear Rear Differential, Large MTV 00cc Rear Diff Skid Plate 00cc Rear Differential Bracket Left Rear Fender Well 00cc Rear Wheel Assembly XD Sport 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 /"- 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
20 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 King Ranch Seat Back 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-Front Drivers Side Seat Belt Assy- Point-Center Seat Belt Assy- Point-Passengers Side 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
21 Safety Nets Assemblies 0 0 DETAIL A A ITEM 0 QTY PART NUMBER Net Assemblies DESCRIPTION /"-X-/" Gr C/S /- Serrated Flange Nut /-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 Spacer,. O.D. x.00 I.D. x.00"l Front side net female buckle Mounting Brkt 0
22 DETAIL A A Bed Assembly 0 0
23 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
24 Bed Assembly 0 0 DETAIL A 0 0 A
25 ITEM 0 0 QTY Bed Assembly PART NUMBER DESCRIPTION /- Nylock HEX Nut Standard Bed Bottom Standard Bed Front Right Bed Corner Cover Lower Bed Cover 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 /- GR Hex Bolts Zinc /- Nylon Insert Flange Nut Zinc Orange Nylon Pedal Spring Spacer LRG UTV -/ spacer Dump Bed Actuator-00 Series /" X " Shoulder Bolt Standard Bed Frame Assy Bronze Bushing - SF- 0-
26 00cc Left Gray 00cc Right -0-0 Gray Decal Warning Cluster Load Rating Decal XD Sport Bed Decal Right --00 XD Sport Bed Decal Left --00 Dash Intimidator Gray ROPS Tailgate Intimidator -0-0 Gray Muffler Hot Warning Label Helmet Logo Decal EPA/CARB Label --00 EPA/CARB Hang Tag --00
27 General Warning Tag --00
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