Intimidator GC 1K Owner'S Manual Download

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FAILURE TO FOLLOW SAFE OPERATING PRACTICES MAY RESULT IN

SERIOUS INJURY OR DEATH.

REMEMBER - YOUR MACHINE IS ONLY AS SAFE AS THE OPERATOR!

HAZARD CONTROL AND ACCIDENT PREVENTION ARE DEPENDENT UPON THE

AWARENESS, CONCERN, PRUDENCE, AND PROPER TRAINING OF THE

PERSONNEL INVOLVED IN THE OPERATION, TRANSPORT, MAINTENANCE, AND

STORAGE OF THE EQUIPMENT.

WARNING

Read this manual in its entirety before attempting to operate the Intimidator

Off-Road Vehicle.

This manual provides procedures for minor maintenance, but major repair information

can be found in the Intimidator Off-Road Vehicle Service Manual. Major repair should

only be performed by an authorized Intimidator Service Dealer.

Updated 9/6/2019

Summary of Contents for GC 1K

Page 1: ...2020 OWNER S MANUAL...

Page 2: ...OF THE PERSONNEL INVOLVED IN THE OPERATION TRANSPORT MAINTENANCE AND STORAGE OF THE EQUIPMENT WARNING Read this manual in its entirety before attempting to operate the Intimidator Off Road Vehicle Th...

Page 3: ...ork hard to provide the highest quality of products parts and accessories at the best possible price We strive to create a unique experience for our customer that will differentiate Intimidator Off Ro...

Page 4: ...ar Differential 16 Electric Dump Bed if equipped 16 Electrical 17 Parking Brake 18 Stand Alone Parking Brake 18 Shifting Gears 19 Rollover Protective Structure ROPS 20 Seatbelts and Half Doors 20 Tilt...

Page 5: ...ance 51 Troubleshooting 52 CVT Troubleshooting 53 Battery Troubleshooting 54 Storage 55 Transporting Your Intimidator 56 Accessories 56 Specifications 57 GC1K Base 57 GC1K Base Crew 58 GC1K Stage 1 59...

Page 6: ...ons in this manual can result in severe injury or death Product Identification Number PIN Your machine s PIN is located between the seat back and cargo bed Figure 1 PIN Label Definitions Danger Indica...

Page 7: ...n before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid side hilling ridin...

Page 8: ...able to sit with back against seat feet flat on floor and foot rests and have hands on steering wheel or handhold s where equipped Stay completely inside the vehicle Be Sure Riders Pay Attention and...

Page 9: ...rturn or other accidents Never carry passengers in the cargo bed Maximum cargo bed capacity is 1200 lb gas diesel 700 lb electric and 1000 lb GC1K Cargo bed loading may affect handling and stability o...

Page 10: ...h if installed o Reduce speed when making turns o Avoid steep inclines and tough terrain Read your owner s manual before loading towing or pulling objects Tilt Cargo Bed Warning Located near the handl...

Page 11: ...oubt remove the machine from service and contact the ROPS manufacturer for assistance Certain conditions will absolutely render the ROPS unusable Examples are Permanent deformation or twisting Missing...

Page 12: ...oads or paved surfaces With more than two passengers five for crew models With any passenger who cannot reach the grab handles With passengers in the cargo box With non approved accessories or modific...

Page 13: ...well ventilated and free of any source of flames or sparks Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting Exhaust system components a...

Page 14: ...mb a hill or drive down a hill with a slope of more than 15 degrees Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Always maintain a steady...

Page 15: ...cteristics of the vehicle Use only factory approved accessories and familiarize yourself with their function and effect on the vehicle Safe Riding Gear Always wear appropriate clothing when riding the...

Page 16: ...ded that the transmission is placed in Park before attempting to start the engine For the best throttle response and performance allow the engine to idle for at least one minute after each cold start...

Page 17: ...Seat Belt Use Indicator Current Time Basic Navigation Features All display features are easily accessed through buttons touch point commands and menus Touch any button and all of the button controls w...

Page 18: ...screen of the display gauge or under the diagnostics screen Under diagnostics you will find all of the error codes that you ve received Engaging and Disengaging 4 Wheel Drive 4WD Warning Do not drive...

Page 19: ...of the switch The switch light will turn on meaning the differential lock is engaged If one of the rear wheels should slip press the switch to turn on the differential lock Both wheels with then turn...

Page 20: ...the OFF position 12V Accessory Port Warning Do not use the 12V accessory port to heat a cigarette lighter Some models are equipped with a 12V accessory port The port is activated when the key is swit...

Page 21: ...wheels will lock Your vehicle s transmission should be set in Park at all times when not in use If you have hauling or towing heavy loads always park on level ground To engage the parking brake stop t...

Page 22: ...Operate the vehicle normally Shifting Gears Figure 14 Gear Shift Lever Warning Do not attempt to shift gears while the vehicle is in motion Always come to a complete stop and hold the brake before at...

Page 23: ...ANSI standards and OSHA standards for rollover performance requirements Always have an authorized Intimidator dealer thoroughly inspect the ROPS if it ever becomes damaged in any way Seatbelts and Hal...

Page 24: ...cated on the steering column directly behind the steering wheel Hauling Cargo Danger Always follow these precautions when hauling cargo Refer to the cargo bed safety warning label located in the cargo...

Page 25: ...xtreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require braking downhill Allow extra distance for braking Cargo Bed Danger Do not sit or stand on the tai...

Page 26: ...ed 3 Dismount the vehicle 4 Ensure that the cargo is positioned evenly in the cargo box 5 Lower the tailgate 6 Position yourself next to the cargo box release lever located on the driver s side of the...

Page 27: ...actuator starts to make a clicking sound Towing Figure 20 2 Receiver Hitch Danger Always follow these precautions when towing a load Never load more than 300 lb tongue weight on the rear towing bracke...

Page 28: ...position of the left and right shock absorbers equal Uneven adjustments can cause loss of control Notice A special tool is required to adjust the shock spring Authorized Intimidator dealers are equipp...

Page 29: ...use unleaded gasoline with an index rating of 90 or higher The effects of old stale or contaminated fuel are not covered by warranty Use fuel within 30 days of purchase to avoid deterioration in gasol...

Page 30: ...gine overheating must be avoided 0 10 Hours Avoid prolonged operation above throttle Vary the speed of the UTV regularly Do not operate at one set throttle position 10 20 Hours Avoid prolonged operati...

Page 31: ...ust be inspected and serviced more frequently Severe Use Definition Extended idle Short trip cold weather operation Prolonged low speed heavy load operation Frequent or prolonged operation in dusty en...

Page 32: ...Maintenance o Ignition System perform maintenance and check when continuous abnormal ignition misfire after burn or overheating occur o Carbon Deposit Removal remove carbon deposits in cylinder head p...

Page 33: ...25hr 3 months Inspect Service Air Filter 25hr 3 months Inspect clean replace if necessary Battery 25hr 3 months Check terminals Transmission Gearbox Oil 25hr 3 months Inspect level change yearly Rear...

Page 34: ...0hr 24 months Adjust Exhaust System 250hr 24 months Inspect for leaks operation Brake Fluid 350hr 36 months Drain change fluid CVT Clutch 350hr 36 months Inspect clean replace worn parts Wheel Bearing...

Page 35: ...tion Sensor 1 Short Circuit Battery 18 P0131 Lambda sensor 0 diagnosis Short Circuit Ground 19 P0132 Lambda sensor 0 diagnosis Short Circuit Battery 20 P0133 Lambda sensor 0 diagnosis Open Circuit 21...

Page 36: ...ort Circuit Battery Engine Oil Your machine is factory filled with Intimidator SYN 10W 40 This is the recommended engine oil Always check and change the oil at intervals outlined in the periodic maint...

Page 37: ...and discard the gasket ring 7 Remove the dipstick and allow oil to drain completely from the crankcase Note Observe the condition of the oil It gives insight into the health of the engine If there is...

Page 38: ...k plugs 5 Reinstall the plug by inserting it into its housing and rotating it clockwise until tight Cooling System Danger Radiator coolant is under pressure when the vehicle is hot Escaping steam can...

Page 39: ...w bottle filled to the recommended level Air Intake Screen Figure 23 Air Intake Screen Notice Use of a pressure washer to clean the air intake screen may cause damage to the screen If the screen is da...

Page 40: ...ntrolled by a temperature switch and will automatically turn on when needed Periodically check the fuse and fan to ensure its proper operation Air Filter Always change the air filter at intervals outl...

Page 41: ...tions Adjusting the Shifter Linkage Warning Your vehicle s gearshift lever comes properly adjusted from the factory so that the Park gear is fully engaged and will not slip During every pre ride inspe...

Page 42: ...the shift lever Heim under the hood directly to the left of the steering column as viewed from the front of the machine Figure 26 Shift Lever Heim 3 Remove the Heim from the shifter lever assembly by...

Page 43: ...the check fill plug is located on the passenger side facing the wheel To check the differential oil 1 Ensure that the vehicle is safely parked on a flat surface 2 Place the gearbox into Park 3 Remove...

Page 44: ...odify any components of the CVT system Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt Notic...

Page 45: ...ove the CVT drain bolt 3 Allow all water to drain from the CVT 4 Reinstall the drain bolt Figure 28 CVT Drain Bolt Location Note If any debris entered the CVT the CVT must be cleaned and inspected 5 A...

Page 46: ...h new ones 7 Attempt to start the engine If it does not start repeat the drying procedure 8 Immediately take the vehicle to your dealer for service Throttle System If the throttle pedal has excessive...

Page 47: ...grease or petroleum jelly will prolong battery terminal life span When connecting the battery connect the red lead first and then the black lead Reversing the leads will harm your machine Battery Cha...

Page 48: ...r battery and jumper cables may be used to start the engine To jump start your machine 1 Ensure that the dead vehicle and the donor vehicle are parked within jumper cable range safely with both engine...

Page 49: ...in the dash The LED light strips are daytime running lights The outside set of lights are low beams while the inside set are the high beams CV Joint Boots Figure 30 Joint Boot In accordance with the...

Page 50: ...ntimidator The brake pressure switch is located on the master cylinder Brake Inspection To inspect the brake system 1 Check all hoses and fittings for fluid leaks 2 Check the brake pedal for excessive...

Page 51: ...steering wheel 1 Ensure that the vehicle is safely parked on a flat surface 2 Lightly turn the steering wheel left and right There should be no more than of free play 3 If there is excessive free play...

Page 52: ...rn ono for one second and then turn off when the engine is started b If the light remains on there is an incorrect connection in the system refer to the Fault Diagnosis Table below c If there is a mal...

Page 53: ...is Content Suggestions Solutions 21 Main torque sensor disconnection 1 Unplug and re plug all wires 2 Check voltage of each wire by multimeter 3 Test with new ECU 1 Ensure proper wire connections 2 Re...

Page 54: ...vehicle clean will not only improve its appearance but it can also extend the life of various components Below are some guidelines for keeping your Intimidator clean Avoid the use of harsh or abrasive...

Page 55: ...oper viscosity Weak battery Clean battery cables terminals charge battery remove the battery for storage Brake pedal not engaged Apply pressure to brake when starting Brake pressure switch malfunction...

Page 56: ...e will not idle Defective spark plug Adjust spark plug gap replace spark plug Cold engine Allow time for engine to warm Dirty fuel injectors Consult your dealer Difficult to shift Engine RPM too high...

Page 57: ...onnections Terminals appear white Insufficient electrolyte Add distilled water to proper level charge battery Overused battery Charge replace battery Recharging is impossible Expired battery Replace b...

Page 58: ...under the tire to keep moisture away from the rubber 6 Lubricate throttle cable 7 Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures 8 T...

Page 59: ...Below are some considerations while transporting your machine Use extra caution with any and all activities involved with loading securing transporting and unloading your machine Make sure that the t...

Page 60: ...lectronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsepow...

Page 61: ...ctronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsepower...

Page 62: ...Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsepower 83Hp 61 9 k...

Page 63: ...ic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsepower 83Hp...

Page 64: ...onic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsepower 83...

Page 65: ...Electronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Electric Start MAX Horsep...

Page 66: ...io 10 2 1 Carburetor Electronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Elect...

Page 67: ...atio 10 2 1 Carburetor Electronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Starting Ele...

Page 68: ...ression Ratio 10 2 1 Carburetor Electronic Fuel Injected Throttle Body Final Drive Shaft Driven Automatic CVT Low High Neutral Reverse Park Drive System 2WD Electronic 4WD Selection Cooling Liquid Sta...

Page 69: ...als if found to be defective in material and or workmanship within one 1 year after date of sale to the original retail purchaser of a new Intimidator 4x4 UTV model This limited warranty is non transf...

Page 70: ...midator UTVs comply with U S EPA emissions regulations Intimidator provides the same warranty coverage to all motorcycle owners regardless of where the UTV is registered Your Warranty Rights and Oblig...

Page 71: ...istance If you are not satisfied with the way in which a warranty claim is resolved by Intimidator you may write directly to Director of Field Operations Support Division EI4 397F Environmental Protec...

Page 72: ...rranted part is not available within thirty 30 days or when an authorized Intimidator facility is unable to complete a repair within thirty 30 days In an emergency situation the repair of emission con...

Page 73: ...2 3 4 5 6 7 8 Intimidator Inc Utility Vehicle Owner s Registration and Training Certificate Keep original copy on file at your dealership VIN PIN Model Date of Purchase Dealer Purchaser Last Name Fir...

Page 74: ...ion o Ensure that the gear selector operates properly o Inspect safety belts for wear or damage Lights o Make sure lights high and low beams operate properly as well as brake lights Oil and Fluids o O...

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