Intimidator UTV Part Manual
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1 Intimidator UTV Part Manual GCK Revision Date --
2 Table of Contents Front Suspension Assembly... Parts List... Steering, Dash and Brake Assemblies... Parts List... Seat 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... ROPs Assembly... Bed Assembly... Parts List...0 Decals...
3 DETAIL A A Front Suspension Assembly
4 ITEM QTY Front Suspension Assembly PART NUMBER DESCRIPTION Rack & Pinion, Large MTV Left Front Upper A-arm Assy Left Front Lower A-Arm Assy Front Shock-Kohler Lg UTV (Stage only) Elka Stage Front Shock Aluminum Body (Stage and only) Right Front Lower A-Arm Assy Right Front Upper A-Arm Assy Spindle, Left Front-Large UTV Ball Joint-Spindle-Upper High Strength Ball Joint-Spindle-Lower Spindle Bearing LRG UTV Retaining Ring-Spindle Bearing Rotor - Large UTV Hub-Large UTV Half-Shaft - Front Large UTV Hayes Titan x mm Front Left Caliper Hayes Titan x mm Front Right Caliper --00 Hayes Front Caliper Brkt --00 Hayes Front Caliper Mounting Brkt mm copper crush washer Brake Line Front Left-Lg UTV Banjo Bolt M 0mm x Left A Frame Guard Right A Frame Guard Retaining Ring-Lg MTV Ball Jt / ID / OD Hose / Spring Hose Clamp Breather Plug Threaded Large MTV A-Arm Bushing Large MTV A-Arm Bushing Sleeve /" - X-/" Hex Bolt Gr /- Nylon Insert Locknut /- x GR Hex Bolt Zinc Rear Hub Castle Nut Rear Hub Castle Nut Cotter Pin /- X GR Hex Bolts Zinc /- Nylock Flange Nut M X. Castle Nut /- X / GR Hex Bolts Zinc /- Hex Flange Nuts Zinc w/serations /- x / GR Hex bolt Zinc /-0 x -/ Grade Hex bolts Zinc / USS Flat Washer - SS / Lockwasher Zinc /- x -/ Hex Bolt GR M0 x. x 0MM Tap Bolt M0 DIN B SPLIT LOCKWASHER ZINC /-0 Nylon Insert Locknut Zinc Orange Nylon / inch Loop Clamp Front Wheel Assembly (Stage only) --00 Wheel Assembly ( with x0x0.0r tire mounted) (Stage only) Wheel Assembly ( with 0x0x0.0R tire mounted) (Stage only) / Lug Nut-0- Front --00 Half Shaft CV Boot Kit Hayes Titan Front Caliper Replaced Pad Kit with Pads
5 DETAIL A 0 0 Steering, Dash and Brake Assemblies 0 A 0 B 0 0 DETAIL B
6 ITEM QTY 0 0 Steering, Dash and Brake Assemblies PART NUMBER DESCRIPTION /- X GR Hex Bolts Zinc /- Nylon Insert Locknut /" - X -/" Hex Hd Cap Screw --00 Lower Shift Cable Bracket / ID x / Plastic Washer Tilt Steering Gas Spring /- Nylon Insert Flange Nut Zinc Orange Nylon / x -/ G Zn Hex Bolt Intimidator Steering Wheel, GCK and Envy Steering Column Bearing Shift Lever Knob-Large UTV Gear Shift Cable-00cc Classic /-, Right Hand Thread Heim / Housing /-0 Nylon Insert Locknut Zinc Orange Nylon Steering Shaft Assembly-Large UTV Steering Wheel Cap-Hurricane PMW Controller, Team Rear Diff Steering Shaft Wheel Nut /- x -/ Grade Hex Bolt Rivnut /-0 Steel /- Hex Nut Zinc -0-0 /-0 X Button Socket C/S Black Hood Rest Bumper-Lg UTV / Flat Washer Black Zinc Steering Column Assy- Large UTV TGB Shifter Adapter TGB 000 ECU Mount Assembly ID X. OD X. Spacer 0Y ECU Starter Solenoid 00cc -0-0 /-0 x / Button Socket C/S -0-0 /-0 Nylon Insert Locknut BL Pull Rod Assy Shift Lever /- x / GR Hex bolt Zinc /- Nylock HEX Nut TGB 000 Intimidator Dash Support Assembly /- X / Hex C/S GR Zinc /- X -/ Hex Coupling Nut Zinc /" - X -/" Carriage Bolt 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 TGB Brake Pedal Left Mounting Bracket / IDx / x / OIB Bushing "X-/" Shoulder Bolt Pedal Spring Spacer LRG UTV -/ spacer Bow Tie Clip TGB Brake Pedal Right Mounting Bracket Spring-Accelerator Pedal TGB Brake Pedal Assy TGB Accelerator Pedal Assy. Complete /-0 x Grade Hex bolts Zinc /" x /" Soc. Shoulder Bolt /"- Nyloc Jam Nut /- Hex Flange Nuts Zinc w/serations UTV Electric Power Steering Unit (Stage only) --00 Power Steering Brkt (Stage only) TGB GPS Puck Mount (Stage only) UTV GPS Puck for use with " display (Stage only)
7 Seat and Grill Assemblies A DETAIL A
8 ITEM 0 0 QTY PART NUMBER A Seat and Grill Assemblies DESCRIPTION /- X GR Hex Bolts Zinc /- Nylon Insert Locknut /- x Carriage Bolt /" - /" Ind Hex Washr Hd - Type F Floor Board Support Assy /" - X -/" Hex Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon Brush Guard Skid Plate GCK Seat Bottom /- Nylock Flange Nut Front Receiver Gusset Intimidator Front Receiver Bottom Tube Intimidator Front Receiver Tube Mtg Tube -/"x-/" Black Tube Plug Seat Pin Latch Assembly "x" Black Tube Plug / - X " Carriage Bolt 000 TGB Classic Main Frame TGB 000 Seat Frame Assembly EPS Rectifier Assembly /-0 Nylon Insert Locknut BL /-0 x Button C/S Black 000 TGB Bumper Lower Section Assy. 000 TGB Front Bumper Upper Section Assy.(Stage and only) GCK Front Reciver Assembly 000 TGB Front Bumper Driver Brace 000 TGB Front Bumper Passenger Brace
9 DETAIL A DETAIL B DETAIL C A B C Plastics Assembly
10 Plastics Assembly ITEM QTY 0 PART NUMBER DESCRIPTION 0 UTV Left Quarter Panel 0 UTV Right Quarter Panel 0 UTV Left Fender 0 UTV Right Fender 0 UTV Floor Panel 0 UTV Front Grill 0 UTV Dash 0 UTV Left Door Panel Left Door Outer Trim Panel-Orange Left Door Outer Trim Panel-OD Green Left Door Outer Trim Panel-Camo Left Door Outer Trim Panel-Gun Metal Gray 000 TGB Door Latch 000 TGB Latch 000 TGB Door Handle Mounting Bracket 000 TGB Left Door Inner Trim Panel 000 TGB Driver Door Latch Mounting Bracket 0 UTV Right Door Panel Right Door Outer Trim Panel-Orange Right Door Outer Trim Panel-OD Green Right Door Outer Trim Panel-Camo Right Door Outer Trim Panel-Gun Metal Gray TGB 000 Door Hinge 0 UTV Seat Frame Center Cover-Orange 0 UTV Seat Frame Center Cover-OD Green 0 UTV Seat Frame Center Cover-Camo 0 UTV Seat Frame Center Cover-Gun Metal Gray /-0 X-/" BH Socket Scr Blk / Flat Washer Black /-0 Nylon Insert Locknut BL 0- / Button Stainless Bolt 0- Nylon Insert Locknut /" x -/" Hex Hd Cap Scr. Striker Post Fender Washer AUEVCO P/N HOLE PLUG BLACK /-0 X Button Socket C/S Black / Fender Washer (" OD) /- x / GR Hex bolt Zinc / USS Flat Washer Zinc /- x -/ Grade Hex Bolt /-0 x Button C/S Black 0 UTV Key Switch Panel Stage and 0 Key Switch Panel Stage 0 UTV Glovebox Door 000 TGB Glove Box Hinge /-0 x / Button Socket C/S 000 TGB Hood Striker Mount GCK Under Hood Shock Mounting Brkt. GCK Hood Rack /-0x/ Carriage Bolts Black Envy Seat Hinge Basket Latch Striker Post Hexagon socket countersunk and button head screws - Metric series /- Nylon Insert Flange Nut Zinc Orange Nylon 000 TGB Glove Box Latch 000 TGB Mesh Grill Insert Differential Lock Switch 0 Vertical Mount Dump Bed Up/Down Switch 0 Vertical Mount WD Switch 0 Vertical Mount Panel Plug-Eaton Blank Switch Head Light Hi/Off/Lo Beam Switch Vertical Mount Headlight Assembly Left MY0 Headlight Assembly Right MY0 Ignition Switch USB Port Stage and Remote USB Port GCK Stage /- / Socket C/S Plain Intimidator 0 Grill Logo TGB " x " Display for MY0 Stage and UTV " x " Display Stage 0 UTV. x. Display Mounting Plate Stage and 0 UTV x Display Moutning Plate Stage 0 UTV Hood-Orange 0 UTV Hood-OD Green 0 UTV Hood-Camo 0 UTV Hood-Gun Metal Gray 0- x / Button Socket C/S - SS 000cc Wiring Harness 0 TGB Park/Neutral Bypass Jumper 000 TGB PV0 Display Jumper Cable 000 TGB PV0 Display Jumper Cable
11 Radiator Assembly DETAIL B 0 DETAIL A A B 0 0
12 ITEM QTY Radiator Assembly PART NUMBER DESCRIPTION TGB Lower Radiator Mounting Bracket Mahindra 000 TGB Battery Box Assembly --00 Battery Box Stiffener Bracket Radiator Assembly Radiator Grommets V AGM Starter Battery Mower Positive Battery Cable " long Mower Negative Battery Cable " long -- Battery Hold Down ID Plastic Washer /" - X -/" Hex Bolt /- Nylon Insert Locknut /- Nylock Flange Nut Radiator Overflow Bottle /-0 x / Button Socket C/S -0-0 /-0 Nylon Insert Locknut BL / Flat Washer Black /-0 x Grade Hex bolts Zinc /-0 Hex Flange Nuts Zinc W/Serrations /" - /" Ind Hex Washr Hd - Type F Coolant Hose /" ID Hose Clamp No. - / - / /" Hose - High Temp /- Nylock HEX Nut /- x Carriage Bolt TGB Front Skid Plate TGB Rear Skid Plate /" - x -/" G Carriage Bolt /-0 Wing Nut Zinc /-0 Nylon Insert Locknut Zinc Orange Nylon M x. x omm Phillips Head Machine Screw, Zinc / x Hex Head Tek Screw TGB Hood Hinge Bracket -0-0 /-0 X Button Socket C/S Black Buttom Bumper-Tailgate TGB Upper Radiator Mounting Bracket UTV Hood Release Rod Tailgate Rotary Latch-Right
13 Engine Assembly 0 ITEM 0 QTY Engine Assembly PART NUMBER DESCRIPTION TST0000P 000cc V Twin Engine Assembly 00 Oil/Air Seprator nd Inlet Tube 0 st Inlet Tube 0 Outled Box 0 st Inlet Tube Adapter st Inlet Tube Adapter nd Inlet Tube Adapter nd Inlet Tube Adapter 0 st Oulet Tube Adapter 0 nd Outlet Tube Adapter Air Cleaner Assembly
14 DETAIL A DETAIL B A B Engine in Frame Assembly
15 ITEM QTY Engine in Frame Assembly PART NUMBER DESCRIPTION TST0000P 000cc V Twin Engine Assembly TGB 000 Seat Frame Assembly TGB Bolt on Enging Mount Assembly TGB Lower Fuel Tank Mounting Bracket --00 Fuel Tank for use with In-Tank Pump Upper Fuel Tank Support Brkt TGB Shifter Cable Bracket TGB Muffler Mount Bracket TGB Air Box Mounting Bracket TGB Exhaust Header Heat Shield TGB Muffler Heat Shield UTV Gas Cap Non-Venting --00 M x 0MM DIN Hex C/S --00 M-. X 0MM DIN Hex C/S M-. Din Nylock Nut /-, Right Hand Thread Heim / Housing Gear Shift Cable-00cc Classic / x Hex Head Tek Screw /"- x -/" Carriage Bolt /- Nylock Flange Nut /" - /" Ind Hex Washr Hd - Type F In tank Fuel pump for 000cc engine 00 kpa regulator /" ID Hose Throttle Cable TGB /" - X -/" Carriage Bolt /- Nylon Insert Flange Nut Zinc Orange Nylon Bush Cake / Lockwasher Zinc /- x / GR Hex bolt Zinc / USS Flat Washer Zinc /" x -/" Hex Hd Cap Scr /- Nylock HEX Nut /- x -/ Grade Hex Bolt ID X. OD X. Spacer 0 Muffler Assy Rear Shaft Drive Set Front Drive Shaft with universal joints M0 x. x 0MM Tap Bolt / x -/ G Zn Hex Bolt /" - x -/" G Carriage Bolt /" x -/" Hex C/S Gr / flat Washer - SS TGB Coil Mounting Bracket U Bolt Upper Air Intake Box Lower Air Intake Box -0-0 /-0 x / Button Socket C/S TGB 000 Air Box Plate Air Intake Box Cover Plate Air Intake Box Cover
16 DETAIL B DETAIL A B A 0 Rear Suspension Assembly
17 ITEM QTY Rear Suspesion Assembly PART NUMBER DESCRIPTION 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 Retaining Ring-Spindle Bearing Spindle Bearing LRG UTV XD Lug Nut Rotor - Large UTV mm copper crush washer Banjo Bolt M 0mm x Brake Line Left Rear-Lg UTV Half-Shaft - Rear Large UTV Rear Hub Castle Nut Cotter Pin Rear Hub Castle Nut Rear Shock-Lg. UTV-Gas & Diesel Elka Stage Rear Shock Aluminum Body (Stage and ony) /- x GR Hex Bolt Zinc Rear Differential, Large MTV --00 Extended Right Rear Upper A-arm assy --00 Extended Right Rear Lower A-Arm Assy Brake Line Right Rear-Lg UTV Brake Line Tee-Rear-Lg UTV Brake Line-MC to Rear T-Lg UTV / x Hex Head Tek Screw Rear Diff Lock Solenoid Rear Wheel Assembly, XD (Stage only) --00 Wheel Assembly ( with x0x0.0r tire mounted) (Stage only) Wheel Assembly ( with 0x0x0.0R tire mounted) (Stage only) /- Nylock Flange Nut IRS Lower Spacer IRS Upper Spacer --00 Half Shaft CV Boot Kit / Lockwasher Zinc /" - x " Hex Cap Screw Gr /- x -/ Hex Bolt GR Break Line Anchor--/" / ID / OD Hose Breather Plug Threaded / Spring Hose Clamp --00 Left Rear Fender Well 00cc Right Lowered Rear Fender Well Hayes Stinger mm Rear Right Caliper Hayes Stinger mm Rear Left Caliper Hayes Stinger Rear Caliper Replaced Pad Kit with Pads --00 Hayes Rear Caliper Brkt Hayes Rear Caliper Mounting Brkt --00 M0-. X MM DIN HEX TAP BOLT CL.. ZINC M0 DIN B SPLIT LOCKWASHER ZINC TGB Rear Diff Skid Plate /"- x -/" Carriage Bolt Rear Diff Cage Top Brace / x /" GR Carr Bolts Zinc /- x / Carriage Bolts /- Nylon Insert Flange Nut Zinc Orange Nylon
18 0 Rops Assembly ITEM QTY PART NUMBER Rops Assembly DESCRIPTION ROPS K Brace Assy For Seat Back w/ Integral Headrest ROPS Front Cross Brace Assy ROPS Rear Cross Brace Assy TGB Left Rops Hoop Assembly TGB Right Rops Hoop Assembly --00 GCK Cage Shim /" - x Gr. Hex bolt Cs /- Serrated Flange Nut / x /" GR Carr Bolts Zinc /- Nylock Flange Nut / Lock Washer Zinc GCK Seat Back Stage Head Rest Stage Head Rest Stage Head Rest Seat Belt Latch /" - x -/" G Carriage Bolt / USS Flat Washer Zinc /"-X-/" Gr C/S Three Point Seat Belt Assembly Driver Seat with Switch Three Point Seat Belt Assembly Center Three Point Seat Belt Assembly Right Heyco Hole Plug Spacer,. O.D. x.00 I.D. x.00"l -0-0 /-0 x -/" Hex Bolt /-0 Nylon Insert Locknut /-0 x -/ GR Hex Cap Screw /-0 x / GR Shoulder Bolt --00 STEALTH- ULTRA HD-B Stage " Pipe Clamp Stage
19 Bed Assembly 0 0 A 0 DETAIL A
20 ITEM QTY 0 PART NUMBER Bed Assembly DESCRIPTION TGB 000 Bed Frame Assembly 0 UTV Cargo Bed 000 TGB Bed Mounting Bracket /- x / GR Hex bolt Zinc 000 TGB Bed Heat Shield / x Hex Head Tek Screw 000 TGB Bed Tie Down /-0 x / Button Socket C/S / Flat Washer Black 0 UTV Left Bed Panel Insert-Orange 0 UTV Left Bed Panel Insert-OD Green 0 UTV Left Bed Panel Insert-Camo 0 UTV Left Bed Panel Insert-Gun Metal Gray 0 UTV Right Bed Panel Insert-Orange 0 UTV Right Bed Panel Insert-OD Green 0 UTV Right Bed Panel Insert-Camo 0 UTV Right Bed Panel Insert-Gun Metal Gray 000 TGB Right Bed Stiffener 000 TGB Bed Left Stiffener Basket Latch Striker Post 0 UTV Cargo Bed Tailgate Dump Bed Tail Gate Latch, Non-Locking, with Actuator Plate 0 UTV Bed Tailgate Latch Plate Tailgate Rotary Latch, Right Tailgate Rotary Latch, Left 0 UTV Left Tailgate Latch Mounting Bracket 0 UTV Left Tailgate Mounting Bracket Tailgate Rod 0 UTV Bed Tailgate Stiffener Dump Bed Actuator-00 Series /" ID X /" OD X /" LENGTH FLANGE BUSHING /- X -/ HEX C/S GR ZINC /- NYLON INSERT FLANGE LOCKNUT ZC YELLOW /"-x-/ Gr Hex Cap Scr /- Nylon Insert Jam Locknut " X " Shoulder Bolt /- Nylock Flange Nut Pedal Spring Spacer LRG UTV -/ spacer
21 --00 GCK Bed Decal Orange GCK Decal --00 EPA Label for Intimidator 000cc TGB Engine Power Restriction Warning Label ANSI_ROHVA Compliance Label GCK Tire Inflation Decal Warning Cluster 00cc and 000cc --00 Clean Filters Decal --00 EPA Hang Tag Intimidator 000cc
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