Intimidator UTV Part Manual
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- Magdalene Vestergaard
- 4 år siden
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1 Intimidator UTV Part Manual Kohler Diesel Truck Series Revision Date --
2 Table of Contents Front Suspension Assembly... Parts List... Lights and Break Assemblies... Parts List... 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... Safety Net Assemblies... Bed Assembly...0 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 Dash & Grill Assemblies DETAIL C DETAIL B 0 0 DETAIL A 0 A C B 0 0
8 ITEM QTY 0 0 Dash & Grill Assemblies PART NUMBER DESCRIPTION /- Nylon Insert Locknut /- X GR Hex Bolts Zinc --00 /- x GR Hex Bolt Zinc --00 /- Nylon Insert Locknut /" - X -/" Hex Hd Cap Screw /- x Carriage Bolt /" - /" Ind Hex Washr Hd - Type F Bushing, Oil Impregnated Dash Support Assy Floor Board Support Assy /"- x -/" Carriage Bolt /" - X -/" Hex Bolt --0 Upper Shift Cable Bracket / ID x / Plastic Washer / IDx / x / OIB Bushing Tilt Steering Gas Spring /- Nylon Insert Flange Nut Zinc Orange Nylon / x -/ G Zn Hex Bolt Steering Wheel Large UTV Steering Column Bearing /-0 x Grade Hex bolts Zinc Shift Lever Knob-Large UTV /-, Right Hand Thread Heim /-0 Nylon Insert Locknut Zinc Orange Nylon Brush Guard Skid Plate Steering Shaft Assembly-Large UTV / x Hex Head Tek Screw Volt Cube Relay --00 Steering Wheel Cap-Hurricane PMW Controller, Team Rear Diff Steering Shaft Wheel Nut Brush Guard Mtg Brkt-Right Gear Shift Cable-0 Ext Bed --00 /- Nylock Flange Nut Front Receiver Assembly -0-0 Front Receiver Gusset Intimidator Front Receiver Bottom Tube Intimidator / EPDM Cushion Clamp /"x-/" Black Tube Plug Rivnut /-0 Steel /- Hex Nut Zinc -0- /-0 X Button Socket C/S Black Hood Rest Bumper-Lg UTV --00 Hitch Pin -00- / Flat Washer Black Zinc TGB 000 Front Bumper Left Frame Mounting Bracket Assembly Front Bumper Left Frame Mounting Bracket Assembly Front Bumper Right Frame Mounting Bracket Assembly / - X " Carriage Bolt Intimidator 0 Front Bumper Assembly
9 DETAIL A DETAIL B A B Flat Bed Plastics Assembly
10 Flat Bed Plastics Assembly ITEM QTY PART NUMBER DESCRIPTION --00 Passenger Side Tool Box Shelf --00 Driver Side Tool Box Shelf Storage Door left Left Rear Fender Storage Door Right Right Rear Fender Passenger Side Tool Box Stop --00 Driver Side Tool Box Stop Lower Front Fender Flare-Left Lower Front Fender Flare-Right Seat Panel Left-Large UTV-Blk Seat Panel Right-Large UTV-Blk Hood Large UTV-Orange Upper Front Fender Flare-Right Upper Front Fender Flare-Left Floor Board-Large UTV-Black Front Firewall-Large UTV-Black Center Seat Panel-Large UTV-Or -0- /-0 X Button Socket C/S Black 0-0- /-0 Nylon Insert Locknut BL / Flat Washer Black /-0 x Grade Hex bolts Zinc /-0 Hex Flange Nuts Zinc W/Serrations --0 Firewall Mount Brkt Ignition Switch Head Light Hi/off/Low Beam Sw WD Switch Volt Auxilliary Plug Differential Lock Switch Dump Bed Up/Down Switch Wiring Harness-Diesel Truck & Crew Buttom Bumper-Tailgate /" - /" Ind Hex Washr Hd - Type F Hood Hinge M-. x 0 Pan Phil M/S Zinc Truck Bed Tool box Hinge Driver Storage Box Passenger Storage Box Tool Box Striker Plate / x Hex Head Tek Screw AUEVCO P/N HOLE PLUG BLACK / flat Washer - SS -0- /-0 x / Button Socket C/S 0-0- /-0 X-/" BH Socket Scr Blk Hood-OD Green Hood-Camo Hood-Matallic Black Center Seat Panel-Large UTV-Gr Center Seat Panel-0-Camo Center Seat Panel-0-Charco /"x-/" Black Tube Plug x / Button Socket C/S - SS x / Button Socket C/S - SS Nylon Insert Locknut Shift Lever Boot-Large UTV Break Pedal Boot-Lg UTV Seat Pin Frame Guard-x." Latch Compression Hinge --00 Hitch Pin /-0 Nylon Insert Locknut Zinc Orange Nylon Glove Box Latch Assembly Front Grill Intimidator 0 Grill Plate Intimidator 0 Grill Logo Small Display Dash "x" Display
11 CVT and Radiator Assemblies 0 0
12 ITEM QTY 0 0 PART NUMBER ED-s Parts List DESCRIPTION /- Nylon Insert Locknut /- x Carriage Bolt Diesel/CVT Plate Mx.x0mm Hex Washer Hd MS /- x " GR Hex bolt /" Zn Lock Washer Lower Radiator Mounting Brkt /- Nylock HEX Nut Intimidator Diesel Skid Plate RadiatorAssy-Large MTV CVT Enclosure Rear-Diesel ABA -mm xmm Wide Hose Clamp Coolant Hose " ID X. OD /" - /" Ind Hex Washr Hd - Type F CVT Enclosure Bolt CVT Enclosure Front Cover CVT Gasket Radiator Grommets Upper Radiator Mounting Brkt /" - X -/" Hex Hd Cap Screw Radiator Overflow Bottle-0 Upper Hood Support Brkt-Diesel-Weber. ft.-/" Hose - High Temp Hose Clamp No. - / - / Seat Bottom-Large UTV Rear Drive Shaft Lg UTV-Diesel EFI/ Diesel Ext Bed TRK Series CVT Clutch Fan CVT Driven Pulley-Diesel CVT Driver Pulley-Diesel CVT Belt-Diesel / Lockwasher Zinc /- Nylon Insert Locknut Frame Assy-Truck Series-Diesel Seat Frame Assembly Diesel Truck Truck Series Skid Plate Skid Plate - Kohler EFI & DIESEL. ft.-" Flex Hose " X " Hose Reducer /-0 Cage Nut /-0 x / Buttonhead Socket C/S - SS Truck Series Skid Plate Front Brkt CVT Enclosure Hose Clamp / - X " Carriage Bolt /-0 X Button Socket C/S Black /-0 Nylon Insert Locknut BL /"-x-/ Gr Hex Cap Scr Seat Pin Latch Assembly CVT Plenum Filter Media Piezeoelectric Buzzer. CVT Shim.0 CVT Shim.0" ID x." Nord-Loack Washer, CVT Clutch CVT Plenum Bezel /- x / Carriage Bolts / x / Pan Head Hex Head Machine Screw - Hex Nut Antifreeze-Premix. gallons Coolant Hose, Drivers side, Crew/Truck Series ABA -mm x xmm Wide Hose Clamp / x Hex Head Tek Screw Diesel Remote Oil Filter Bracket /- x -/ Hex C/S GR Zinc Remote Oil Filter Kit CVT Crush Tube CVT Enclosure Bracket /- Nylon Insert Flange Nut Zinc Orange Nylon /- x -/ Grade Hex Bolt CVT Fan Inside Spacer Washer CVT Centrifugal Fan Spacer Washer CVT Secondary Spacer Washer
13 Kohler Diesel Engine Parts List ITEM 0 QTY PART NUMBER 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 AWG Insulated Standard Copper Wire Cable Stop Assembly 0W 0 Motor Oil. quarts 0
14 DETAIL A DETAIL B DETAIL C A B C 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 Brkt 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-0 Ext Bed /- X -/ Hex C/S GR Zinc.ODx.IDx."L Spacer /- Nylock Flange Nut CVT Crush Tube 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
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 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 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-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.0"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 /-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.0"l Front side net female buckle Mounting Brkt 0
20 DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E A B C D E Flat Bed Assembly
21 Flat Bed Assembly ITEM QTY 0 0 PART NUMBER DESCRIPTION Truck Right Bed Panel Assy Truck Left Bed Panel Assy Truck Bed Floor Panel-AL Truck Bed Tailgate Assembly Door Latch-Right Door Latch-Left Truck Bed Eng. Access Door-AL Truck Bed Taillight Panel-AL Extended Bed Hinge /- X -/" Shoulder Bolt /-0 Nylon Insert Locknut BL /-0 x / Button Socket C/S /-0 x Button C/S Black Truck Bed Side Gate Brkt Rubber Stops Tail/Brake Light Assembly Truck Bed Taillight Bracket 0- Nylon Insert Locknut 0- / Button Stainless Bolt /-0 x " Carriage Bolt /-0 x / Carriage Bolt Door Latch /-0 X Button Socket C/S Black /- Nylon Insert Flange Nut Zinc Orange Nylon / /x / Bend U-Bolt GR Zinc Truck Bed U-Bolt Brkt Buttom Bumper-Tailgate-0 Truck Bed Side Panel Gusset Right Truck Bed Side Panel Gusset Left /-0 Nylon Insert Locknut Zinc Orange Nylon Access Door Latch Pin & Grommet Truck Bed Engine Access Door Brkt Truck Bed Engine Access Door Brkt Extended Bed Latch Grip Headlight Recept. Pin Tail-Brake Light Receptical WP Deutsch Receptcal Wedge Truck Series Bed Frame Assembly_0 Truck Front Panel Assembly
22 Decal Warning Cluster cc Left Orange -0-0 Gray -0-0 O.D. Green 000cc Right Orange -0-0 Gray -0-0 O.D. Green 0 Truck Series Left Orange -0-0 Gray -0-0 O.D. Green 0 Truck Series Right Orange -0-0 Gray -0-0 O.D. Green Tailgate 0 Truck Series Orange -0-0 Gray -0-0 O.D. Green Dash Intimidator Orange Gray O.D. Green Load Rating Decal Muffler Hot Warning Label ROPS Helmet Logo Decal -0-00
23 Camo x Decal Camo XD Decal General Warning Tag --00 RHOVA Decal -0-00
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