DFK INTIMIDATOR XD 4 Installation Instructions Manual Download

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INSTALLATION INSTRUCTIONS

INTIMIDATOR

XD 4

Summary of Contents for INTIMIDATOR XD 4

Page 1: ... INSTALLATION INSTRUCTIONS INTIMIDATOR XD 4 ...

Page 2: ...protective gloves if necessary Always keep your assembly area clean uncluttered and well lit Keep visitors and children a safe distance away from the assembly area Visitors should wear the same safety equipment described under Never operate your UTV with the cab doors open Failure to properly latch the doors before moving the vehicle could result in serious injury Dress for safety DO NOT wear loos...

Page 3: ...s about 1 time per month or according to the actual degree of pollution Do not use detergents that could scratch the surface plates abrasives harsh fabrics etc Do not use solvents or alkaline detergents or cleaners with ammonia ammonium hydroxide Do not remove the impurities from the surface of the razor blades or other sharp items Do not clean cab when the polycarbonate plates are heated by the s...

Page 4: ...A INC 630 324 8585 4 TOOLS NEEDED Not included Ratchet handle Socket beg 17 mm Socket beg 13 mm 0 67 in 0 51 in For tightening straps Socket beg 8 mm Metric wrench 13mm 17mm Utility knife 0 31 in Hex key 5mm 6 mm and 8mm Hole saw 76 mm Drill ø 2 5 4mm 3 in 0 1 0 16 in ...

Page 5: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 5 Drill ø 8mm Drill ø 12 mm Drill ø 21mm 0 31 0 33 in 0 5 in 0 83 in ...

Page 6: ...K AMERICA INC 630 324 8585 6 PREPARATION FOR INSTALLATION Uninstall all additional systems from the roller cages work lights rear mirrors drink holders etc Uninstall the safety nets from the UTV s body and roller cage Don t cut nets you can use these in future ...

Page 7: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 7 CAB PREVIEW ...

Page 8: ...IMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 8 LEFT DOOR BASE RIGHT DOOR BASE Uninstall the originall screw in red circle from the UTV s body and save these carefully ...

Page 9: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 9 Place the right door base onto the roller cage to correct position ...

Page 10: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 10 Fix the door base with the UTV s body by original screw and incuded washers ...

Page 11: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 11 Adjust the door base to best position gently ...

Page 12: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 12 Place the right door base upper holder onto the door base and onto the roller cage ...

Page 13: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 13 Fix the holder with the base to the roller cage by screws washers nuts and covers ...

Page 14: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 14 Place the door base holder Ω onto the door base and onto the roller cage ...

Page 15: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 15 Fix the door base with the holder to the roller cage by screws washers nuts and covers ...

Page 16: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 16 Place the door base middle right holder onto the door base and onto the roller cage ...

Page 17: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 17 Fix the door base with the holder to the roller cage by screws washers nut and covers ...

Page 18: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 18 Place the base upper holder onto the door base and onto the roller cage ...

Page 19: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 19 Fix the holder with the base to the roller cage by screw washer nut and cover ...

Page 20: ...CHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 20 The left door base installation is similar with the right door base just repeat previous steps with left parts Tighten all nuts and screws on door base assemblies hard ...

Page 21: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 21 REAR PANEL Place the rear window holders onto the door base holder s welded screws ...

Page 22: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 22 Fix the window holders with the base holders by nuts washers and covers on both sides ...

Page 23: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 23 Uninstall the originall screws in red circles from the UTV s body ...

Page 24: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 24 Place the rear bottom ledge onto the forklift frame and adjust to best position ...

Page 25: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 25 Place the rear ledge holder onto the rear ledge and onto the roller cage ...

Page 26: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 26 Fix the rear bottom ledge with the holders to the roller cage by nuts washers and covers ...

Page 27: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 27 Fix the bottom rear ledge with the UTV s body by washer 10 and original screws ...

Page 28: ... 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 28 Take out the protective films from the rear window Place the rear window with sealing onto the roller cage and move that to the bottom ledge ...

Page 29: ...OR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 29 Adjust the rear window holders to best position and fix the holders with the window by screws washers nuts and covers on both sides ...

Page 30: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 30 Adjust the rear assembly to best position and tighten all screws and nuts hard ...

Page 31: ...door stop holder with the door stop assembly onto the correct front ledge holder left or right Fix the door stop holder with the front ledge holder by screws washers nuts and covers Use the right door stop holder and right front ledge holder on picture on right side of the roller cage YOU CAN T MAKE MISTAKE BETWEEN LEFT AND RIGHT PARTS IF YOU MAKE MISTAKE YOU ARE GOING TO HAVE BIG PROBLEM WITH DOO...

Page 32: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 32 Uninstall the originall screws in red circles from the roller cage and save these See next page ...

Page 33: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 33 Detail view ...

Page 34: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 34 Place the front bottom ledge onto the dashboard and onto the roller cage ...

Page 35: ...D 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 35 Fix the front bottom ledge with the roller cage by original screws on right side and repeat previous steps on left side of the roller cage ...

Page 36: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 36 Place the front ledge holder assemblies onto the front ledge and onto the roller cage on both sides ...

Page 37: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 37 Fix the holder with the ledge to the roller cage by screws washers nuts and covers on both sides ...

Page 38: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 38 Place the front ledge support holder onto the ledge welded holder and onto the front bottom ledge on both sides ...

Page 39: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 39 Fix the support holder with the ledge and with the ledge holder by nut washer and cover on both sides ...

Page 40: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 40 Place the upper front ledge onto the roller cage and adjust to best position ...

Page 41: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 41 Place the strap ring onto the front ledge and onto the roller cage ...

Page 42: ...MIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 42 Fix the strap ring with the front ledge to the roller cage by screws washers nuts and covers and tighten these correctly ...

Page 43: ... 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 43 ELECTROINSTALLATION WIPER SET 1 View onto the wiper motor with the cover and with the middle ledge Place the washer onto the wiper longer pin ...

Page 44: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 44 Place the washer onto shorter wiper pin View onto installed washers ...

Page 45: ... DFK AMERICA INC 630 324 8585 45 Place the wiper assembly onto the front glass from inner side Insert these washers onto the wiper s pins and onto the glass from outer side Fix the wiper motor with the front glass by included nuts and tighten these correctly ...

Page 46: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 46 FRONT PANEL Place the front window with the hinge to the front upper ledge ...

Page 47: ... 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 47 Fix the front window s hinges with the hhinge s bases to the front ledge by screws washers nuts and covers Tighten these screws and nuts hard ...

Page 48: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 48 ROOF Stick the self glued seal onto the roller cage ...

Page 49: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 49 Place the roof onto the roller cage and adjust to correct position ...

Page 50: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 50 Place the roof holders onto the roof onto the front upper ledge and onto the roller cage on both sides ...

Page 51: ... ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 51 Fix the roof with the front ledge and with the roof holders to the roller cage by screws washers nuts and covers Tighten these screws and nuts gently now ...

Page 52: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 52 Fix the rear window with the roof by screws washers nuts and covers ...

Page 53: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 53 Adjust the roof and the front upper ledge with front window to best position and tighten all screws and nuts ...

Page 54: ...R ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 54 FRONT PANEL Install the gas spring onto the gas spring holder on both sides It s necessary to install the gas springs in same position like on picture ...

Page 55: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 55 Open the window and install the gas spring into the gas spring metal holder ...

Page 56: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 56 Fix the gas spring with the gas spring metal holder by nuts and cover on both sides ...

Page 57: ...OR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 57 LEFT DOOR RIGHT DOOR Lubricate the hinge s pins and insert the washers onto the hinge s pins Insert the door onto the hinge s pins ...

Page 58: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 58 Loosen the door hinge s screws ...

Page 59: ...NC 630 324 8585 59 Adjust the door by hinges to best position If you have some gapes between the door seal and the roller cage or UTV s body you can insert more washers 10 onto the hinges or take out washer 10 from the hinges Tighten the hinge s screws and nuts correctly ...

Page 60: ...5 60 Adjust the door stop holder door stop assembly and if you need front ledge holder to best position If you close the door slowly and adjust the door stop correctly you can hear 2 clear metalic click After you adjusted the door stop to best position tighten all screws and nuts hard ...

Page 61: ... ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 61 If you have some gapes between the EPDM and UTV s body loosen the bottom ledge s nuts and adjust the EPDM to better position Tighten these nuts correctly ...

Page 62: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 62 Install the gas spring into the door base gas spring holder ...

Page 63: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 63 Fix the gas spring with the gas spring holder by nut washer and cover ...

Page 64: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 64 Place the gas spring holder onto the door frame ...

Page 65: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 65 Insert the gas spring into the holder and adjust the holder to best position ...

Page 66: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 66 Fix the gas spring holder with the door frame by TEX screws washers and TEX covers ...

Page 67: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 67 Fix the gas spring with the holder by nut washer and cover ...

Page 68: ...L QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 68 Uninstall the screws from the door and place the mirror washer and the right rear mirror onto the door panel Fix the mirror with the base to the door by screws from previous steps ...

Page 69: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 69 Repeat previous steps with the left door and left parts ...

Page 70: ...IDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 70 ELECTROINSTALLATION WIPER WASHER ASSEMBLY Parts needed Included Washer tube Switch wiper washer off Harness and washer tank ...

Page 71: ... the harness branch No 2 from the harness to the dasboard inner space Find the best place for wiper washer switch and cut rectangle hole for that Connect the harness branch No 2 with the swith and insert that into the hole Run the harness branch No 1 around the roller cage to the wiper motor Connect the harness branch No 1 with the wiper motor and stretch the washer hose through the bushing ...

Page 72: ...ication Find the original cable where is 12V after you turn on the main UTV s switch Connect the harness cables red to 12V original electrification and black to UTV s skelet If you don t find connection for connectors installed on harness branch you can use other connectors included Fill the washer liquide into the washer tank before first usage SEE NEXT PAGE ...

Page 73: ...on wiper switch and look on the larger wiper pin If you connect all harness connectors correctly pin is turning Find the ends of turning and install the wiper arm on correct position Fix the wiper arm with the wiper motor pin by included nut Insert plastic holder onto the wiper latch pin in correct position ...

Page 74: ... 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 74 View onto the installed plasstic holder Insert the wiper arm hook onto the wiper latch plastic holder and press it into the correct position ...

Page 75: ...TOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 75 View onto installed wiper arm hook Connect the washer hose from the harness with the washer hose from wiper arm by included tube ...

Page 76: ...SE CALL DFK AMERICA INC 630 324 8585 76 ELECTROINSTALLATION HEATER Parts needed included Heater with cover Bleeding valve Electric vent Tightening straps Air vent corner Air vent straight Small medium and large Hot air hose AL tape Y coupling 14 18 14 ...

Page 77: ...TIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 77 Y couplings El Vent switch Heater switch assembly Heater harness Hot water hose Air vent grill holder Air vent grill ...

Page 78: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 78 Exploded view to important parts ...

Page 79: ...INTIMIDATOR XD 4 FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 79 IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES ...

Page 80: ...A INC 630 324 8585 80 Install the heater with the heater holder to best position where you like these and fix these with the UTV s body by correct screws Connect harness branch No 3 with the heater connector Connect the harness branch No 4 with the electromagnetic vent ...

Page 81: ...IONS PLEASE CALL DFK AMERICA INC 630 324 8585 81 Drill 1 hole ø 11 5 14mm 0 45 0 55 in and 2 holes ø 2 5 4 mm 0 1 0 16 in into the dashboard in accordance with the ventilator switch base Be very carefull to find best place for switches 28 14 ...

Page 82: ... 2 from the heater to the UTV switch panel Connect the heater switch body with the harness branch No 1 Detail view Drill hole ø 21 mm for electromagnetic vent switch into the dashboard Pull the harness branch No 2 throught the hole from previous page bottom picture and connect the branch with the switch Detail of connection ...

Page 83: ...itch Connect the harness cables red to 12V original electrification and black to UTV s skelet If you don t find connection for connectors installed on harness branch you can use other connectors included Connect hot water hoses with the UTV s cooling circuit near the cooler by pair of Y coupling included If you have detailed information about engine cooling circuite and you are sure about correct ...

Page 84: ... 2 To achieve engine operating temperature depress the accelerator to increase The engine RPM This will increase the preasure and flow of the water pump forcing more coolant through the heater After operating temperature ceache turn of engine and open it Trapped air should come out from heater system throughout bleeding valve Repeat this procedure until heater cooling system is completely bleeded ...

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