Intimidator UTV Part Manual
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1 Intimidator UTV Part Manual Crew Cab 000cc Diesel 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 CVT and Radiator Assembly... Parts List... Engine Assembly Only... Engine Assembly in Frame... 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 0
4 Front Suspension Assembly ITEM QTY 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 --00 /- 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 --00 /- 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-Larg UTV Tie Rod End-Intimidator XD Front Wheel XD Front Tire XD Wheel Center Cap Base Wheel Center Cap 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 /-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 --00 / 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 Hayes Titan x mm Front Left Caliper --00 Hayes Front Caliper Brkt --00 Hayes Front Caliper Mounting Brkt Hayes Titan x mm Front Right Caliper M0 x. x 0MM Tap Bolt Hayes Titan Front Caliper Replaced Pad Kit with Pads M0-. X MM DIN HEX TAP BOLT CL.. ZINC M0 DIN B SPLIT LOCKWASHER ZINC
5 DETAIL A A 0 0 Lights and Brake Assemblies 0 0 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 Brake Pedal Bracket-Right-0 Brake Pedal Assy-Large UTV Brake Pedal Bracket Left-0 / 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 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.0 OD x.0 Thick TFE Washer Spring-Accelerator Pedal Assy /-0 x / Grade Hex bolts Zinc 0 Uniq Headlight Left Mounting Bracket Assembly 0 Uniq Headlight Right Mounting Bracket Assembly Headlight Assembly Left MY0 Headlight Assembly Right MY0 /-0 X Button Socket C/S Black /" x -/" Hex Hd Cap Scr. /- Nylon Insert Flange Nut Zinc Orange Nylon
7 DETAIL A DETAIL B A B Seat, Dash, and Grill Assemblies
8 ITEM QTY Seat, Dash, and Grill Assemblies PART NUMBER DESCRIPTION Crew Cab Rear Frame Assy-Diesel Front Frame-Truck/Crew Cab Dash Support Assy 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 --00 /- 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 Shaft Assembly-Large UTV --00 Steering Wheel Cap-Hurricane Steering Shaft Wheel Nut Steering Wheel Large UTV /" - X -/" Hex Hd Cap Screw --0 Upper Shift Cable Bracket /- Nylon Insert Locknut Bushing, Oil Impregnated / IDx / x / OIB Bushing --00 /- x GR Hex Bolt Zinc Shift Lever Knob-Large UTV /-0 x Grade Hex bolts Zinc /-0 Nylon Insert Locknut Zinc Orange Nylon Gear Shift Cable-0 TRK SERIES & CREW CAB /-, Right Hand Thread Heim Brush Guard Skid Plate /" - /" Ind Hex Washr Hd - Type F Volt Cube Relay / x Hex Head Tek Screw PMW Controller, Team Rear Diff /-0 x / Carriage Bolt Truck Series Skid Plate /-0 Cage Nut /-0 x / Buttonhead Socket C/S - SS Skid Plate - Kohler EFI & DIESEL Truck Series Skid Plate Front Brkt / - X " Carriage Bolt --00 /- Nylock Flange Nut Intimidator 0 Front Bumper Assembly / EPDM Cushion Clamp Front ReceiverAssembly Front Receiver Bottom Tube Intimidator /"-x-/ Gr Hex Cap Scr /"x-/" Black Tube Plug /- x -/ Grade Hex Bolt /" Round Tubing Plug Rivnut /-0 Steel /- Hex Nut Zinc Hood Rest Bumper-Lg UTV -0- /-0 X Button Socket C/S Black /- x / Carriage Bolts --00 Hitch Pin -00- / Flat Washer Black Zinc /- x / GR Hex bolt Zinc Steering Column Assy- Large UTV Shift Lever Assembly 0 Series TGB 000 Front Bumper Left Frame Mounting Bracket Assembly TGB 000 Front Bumper Right Frame Mounting Bracket Assembly Front Bumper Left Frame Mounting Bracket Assembly Front Bumper Right Frame Mounting Bracket Assembly
9 DETAIL A DETAIL B A B 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 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 /-0 Hex Flange Nuts Zinc W/Serrations Firewall Mount Brkt Ignition Switch Volt Auxilliary Plug WD Switch Head Light Hi/off/Low Beam Sw. Differential Lock Switch Dump Bed Up/Down Switch Upper Radiator Mounting Brkt /" - X -/" Hex Hd Cap Screw /- Nylon Insert Locknut Buttom Bumper-Tailgate-0 Right Rear Lower Kick Panel, Crew Cab Wiring Harness-Diesel Truck & Crew / flat Washer - SS /-0 x / Button Socket C/S AUEVCO P/N HOLE PLUG BLACK Center Seat Panel-Large UTV-Gr Center Seat Panel-0-Camo Center Seat Panel-0-Charco Hood-OD Green Hood-Camo Hood-Matallic Black Seat Pin Frame Guard-x." Shift Lever Boot-Large UTV Break Pedal Boot-Lg UTV -/"x-/" Black Tube Plug Hitch Pin /-0 Nylon Insert Locknut Zinc Orange Nylon Glove Box Latch Assembly 0 Front Grill Intimidator 0 Grill Plate Intimidator 0 Grill Logo 0- x / Button Socket C/S - SS 0- Nylon Insert Locknut Small Display Dash "x" Display 0
11 Crew Cab Diesel CVT Assembly 0
12 Parts List ITEM QTY PART NUMBER DESCRIPTION /- Nylon Insert Locknut /- x Carriage Bolt Transmission Diesel/CVT Plate Mx.x0mm Hex Washer Hd MS /- x " GR Hex bolt Lower Radiator Mounting Brkt /- Nylock HEX Nut Intimidator Diesel Skid Plate RadiatorAssy-Large MTV CVT Enclosure Rear-Diesel Coolant Hose Passenger Side, Crew/Truck Series /" - /" Ind Hex Washr Hd - Type F CVT Enclosure Bolt CVT Enclosure Front Cover CVT Enclosure Outlet Nozzle CVT Gasket Radiator Grommets Upper Radiator Mounting Brkt /" - X -/" Hex Hd Cap Screw Diesel Seat Frame Radiator Overflow Bottle-0 Upper Hood Support Brkt-Diesel-Weber. ft. /" Hose - High Temp Hose Clamp No. - / - / /"- x -/" Carriage Bolt /- x / GR Hex bolt Zinc Rotary Latch Bracket-Frame (Base Model Only) Rear Drive Shaft Lg UTV-Diesel EFI/ Diesel Ext Bed TRK Series CVT Clutch Fan CVT Inlet Hose-Diesel CVT Outlet Hose-Diesel CVT Driven Pulley-Diesel CVT Driver Pulley-Diesel CVT Belt-Diesel / Lockwasher Zinc Crew Cab Rear Frame Assy-Diesel Front Frame-Truck/Crew Cab /- Nylon Insert Locknut /-0 X Button Socket C/S Black /-0 Nylon Insert Locknut BL /"-x-/ Gr Hex Cap Scr Coolant Hose Drivers Side, Crew/Truck Series CVT Plenum Hose Clamp CVT Enclousre Hose Clamp Piezeoelectric Buzzer CVT Plenum Filter Media.0" ID x." Nord-Loack Washer, CVT Clutch. CVT Shim.00 CVT Shim / x / Pan Head Hex Head Machine Screw - Hex Nut CVT Plenum Bezel ABA -mm x mm Wide Hose Clamp Anitfreeze-Premix. gallons ABA -mm x mm Wide Hose Clamp CVT Enclosure Bracket CVT Fan Inside Spacer Washer CVT Centrifugal Fan Spacer Washer CVT Secondary Spacer Washer
13 Kohler Diesel Engine ITEM 0 QTY PART NUMBER Parts List DESCRIPTION Diesel Engine Dipstick Brkt Throttle Cable-Kohler Diesel /- x / GR Hex bolt Zinc /- Nylock HEX Nut Diesel Engine Package Alternator Oil Filter Belt Fuel Lift Pump Temperature Water Sender-Lg UTV Diesel Temp Sd/Sw Crush Washer M-.0 Hex Flange Nut w/ Serrations Diesel Oil Fill Adapter Diesel Oil Fill Grommet AWG Insulated Standard Copper Wire Cable Stop Assembly 0W 0 Motor Oil. quarts 0
14 DETAIL A DETAIL B DETAIL C DETAIL D A B C D Diesel Engine Assembly
15 Diesel Engine Assembly- ITEM QTY ED000-S PART NUMBER DESCRIPTION Left Diesel Engine Arm Assy Diesel/Transmission Bracket/Assy Upper Transmission Mount Tab Team Trans Right Mounting M X. X MM Hex Tap Bolt. IDx. ODx 0. Washer /- Nylon Insert Locknut /- x Carriage Bolt /- X GR Hex Bolts Zinc / Flat Washer Black Zinc /- Nylon Insert Locknut Bushing, Oil Impregnated /" ID /- Serrated Flange Nut /" - X -/" hex C/S-Gr Diesel Rear Motor Arm Assembly Transmission /" - X-/" Hex Bolt Gr / Washer Zinc Mx.x0mm Hex Washer Hd MS / Lock Washer Zinc Mx.xmm Hex Tap Bolt Lower Shift Cable Bracket / - X " Hex Bolt /-0 x Grade Hex bolts Zinc Team Trans Shift Lever Ext /" X Quick Disc. Rod End / Lock Washer Zinc /- Hex Nut /-0 Nylon Insert Locknut Zinc Orange Nylon Volt Battery-Diesel Positive Battery Cable Ga. Negative Battery Cable, Ga. Diesel Batt Strap / x /" GR Carr Bolts Zinc Diesel Engine Package ABA -mm x mm Wide Hose Clamp Coolant Hose " ID X. OD Intake Adapter Hose-Diesel -/ to -/ Hose Clamp Air Filter Air Box Cap Air Box Assembly Air Canister Clamp Air Filter Bracket /" - /" Ind Hex Washr Hd - Type F /- x / GR Hex bolt Zinc /- Nylon Insert Flange Nut Zinc Orange Nylon Rain Cap- Air Filter Diesel Engine Fuel Filter ft.-/ Fuel Line - Low Perm Hose Clamp No. - / - / ft.-/" Hose Muffler Mount Bracket Fuel Tank-Diesel Engine Lower Fuel Tank Support Brkt Diesel Gas Cap Upper Fuel Tank Support Brkt /" x -/" Hex Hd Cap Scr. / Lockwasher Zinc /- x " GR Hex bolt Muffler-Kohler EFI & Diesel Exhaust Mainfold-Diesel-Black Spark Arrestor Kit For Muffler Engine Vibration Mount /-x/ Carriage Bolts Black Zinc /- Hex Flange Nuts Zinc w/serations Fuel Sender Gear shift Cable-Large UTV /- X -/ Hex C/S GR zinc.odx.idx."l Spacer ED-s /- Nylock Flange Nut /-x." Hex Tap Bolt Diesel Transmission Washer Filter Restriction Switch / ID / OD Hose Breather Plug Threaded / Spring Hose Clamp 0- x /" Indented hex Head machine Screw / EPDM Cushion Clamp / x Hex Head Tek Screw Male Push on Terminal " Battery Cable Gauge Remote Oil Filter Kit Diesel Remote Oil Filter Bracket
16 DETAIL A DETAIL B DETAIL C A B C Rear Suspension Assembly 0 0
17 Rear Suspesion Assembly ITEM QTY 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 /- X GR Hex Bolts Zinc 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 --00 /- 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 --00 /- Nylon Insert Locknut Brake Line-MC to Rear T-Lg UTV / x Hex Head Tek Screw Rear Diff Lock Solenoid XD Rear Tire XD Rear Wheel --00 /- Nylock Flange Nut /"- x -/" Carriage Bolt IRS Lower Spacer XD Wheel Center Cap IRS Upper Spacer Base Wheel Center Cap --00 Base Rear Tire 0-0- 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 --00 / Lockwasher Zinc /" - x " Hex Cap Screw Gr / x /" GR Carr Bolts Zinc --0 Right Rear Differential Mount /- X -/ Hex C/S GR Zinc /- x -/ Hex Bolt GR Break Line Anchor--/" / ID / OD Hose Breather Plug Threaded / Spring Hose Clamp --00 Left Lowered Rear Fender Well Right Lowered Rear Fender Well -00- / Flat Washer Black Zinc 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 M0-. X MM DIN HEX TAP BOLT CL.. ZINC M0 DIN B SPLIT LOCKWASHER ZINC
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.0"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.0"l Front side net female buckle Mounting Brkt 0 DETAIL A 0
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-0 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-0 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 x / Button Socket C/S -0- /-0 Nylon Insert Locknut BL -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 --00 Bronze Bushing - SF Dump Bed Actuator-0 Series (XD Models Only) /" X " Shoulder Bolt (XD Models Only) --00 /- X GR Hex Bolts Zinc (XD Models Only) Standard Bed Frame Assy / x / x / Spacer
25 000cc Left Orange -0-0 Gray -0-0 O.D. Green 000cc Right Orange -0-0 Gray -0-0 O.D. Green Decal Warning Cluster X Right Orange -0-0 Gray -0-0 O.D. Green XD Right Orange -0-0 Gray -0-0 O.D. Green X Left 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 Load Rating Label, Crew Camo XD Decal Camo x Decal Helmet Logo Decal -0-00
26 RHOVA Decal ROPS Decal General Warning Tag --00
Intimidator UTV Part Manual
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FDSB5 : 00 - CABINET BOTTOM ASSY [/] Page of FDSB5 : 00 - CABINET BOTTOM ASSY [/] Page of Ref # Part Number Qty. Description 5 7 9 0 5 7 9 0 5 7 F0959 PD00 K09 PK90 G9 PC90 PM000 PB000 K090 PM909 PA9700
POS QTY PARTNUMBER BESKRIVELSE DESCRIPTION
Model: Premium 5390 TR/W 4-speed Part Number: 90066569 Year: 2018 A-1 1 433243 KOBLINGSHÅNDTAG CLUTCH LEVER A-2 1 433228 STOP HÅNDTAG BRAKE LEVER A-3 1 428853 BESLAG MED STOP FOR BØJLER BRACKET A-5A 1