Intimidator 1000cc Kohler Diesel Owner'S Manual Download

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OWNER’S

MANUAL

1000cc Kohler Diesel

750 EFI Kohler Gas

UTVRevised 12-16-2013

2014

Summary of Contents for 1000cc Kohler Diesel

Page 1: ...OWNER S MANUAL 1000cc Kohler Diesel 750 EFI Kohler Gas UTVRevised 12 16 2013 2014...

Page 2: ...__________________ Purchasing Date _____________________________ Type ______________________________________ Pin Number ________________________________ Special Notice ______________________________ K...

Page 3: ...Riding Gear Page 15 Features Controls and Operation Pages 16 32 New Vehicle Break in Page 33 Service and Maintenance Pages 34 61 Storing and Maintaining Appearance Pages 62 63 Transporting your Intim...

Page 4: ...NGER A Danger indicates a hazardous situation that if not avoided may result in serious injury or death WARNING A Warning indicates a situation that if not avoided may result in property damage Notice...

Page 5: ...our part to prevent Injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid drivers license Do not let people drive or ride after using alcohol or drugs Do...

Page 6: ...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 Plan Ahead If you think or feel the vehicle ma...

Page 7: ...200 lb Inflate tire pressure to pressures stated on tire pressure label Page 8 Secure cargo so that it will not shift affecting handling or cause the cargo to strike occupants Keep cargo weight center...

Page 8: ...URE AND SIZE CHART Clutch Cover Warning some 750EFI models only Located on the CVT clutch cover WARNING Cover can become hot during and after operation Vehicle Size Load Air Top Speed Rating Max Posit...

Page 9: ...ential rule if in doubt remove the machine from service and contact the ROPS FOPS manufacturer for assistance Certain conditions will absolutely render the ROPS FOPS unusable examples are Permanent de...

Page 10: ...ssing Damaged mounting hardware must be replaced with proper specification hardware before placing the ROPS FOPS back in service Properly maintained seatbelts are essential to compliment the operator...

Page 11: ...helmet and eye protection Reduce speed and use extra caution while carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden br...

Page 12: ...source of flames or sparks Gasoline is very flammable Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting Exhaust system components are ve...

Page 13: ...turn Always follow turning procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Never abruptly accelerate while turning Jumps and Stunts Attempting wheelies jumps an...

Page 14: ...he safety labels Equipment Modifications We strongly recommend that consumers do not install any after market equipment that may increase the speed or power of the vehicle or to make any other modific...

Page 15: ...lways wear a helmet that meets or exceeds established DOT U S Department of Transportation safety standards Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Always wear shat...

Page 16: ...engine turn the ignition on and wait three seconds before cranking the engine Starting the Kohler 750 EFI For the best throttle response and performance allow the gas engine to idle for one minute af...

Page 17: ...ions Per Minute Odometer Displays the overall distance traveled by the vehicle Engine Hours Displays the overall hours the engine has operated Menu Adjust LCD screen brightness To adjust the LCD backl...

Page 18: ...s the left side of the rocker switch to turn on the low beam lights Press the right side of the rocker switch to turn on the low and high beam lights Standard Intimidator models are equipped with low...

Page 19: ...is off In some situations the front differential may remain locked after turning the 4wd switch off If this occurs you may continue to notice increased steering effort and some vehicle speed restrict...

Page 20: ...d press and hold the right side of the rocker switch Quickly release the switch when the bed is down or the actuator starts to make the same clicking sound ELECTRICAL Accessory 12V Electrical Outlet T...

Page 21: ...st or replace the shifter cable Your Intimidator is equipped with a Park gear in the gearbox While your vehicle is in Park both rear wheels will lock serving as your Parking Brake Your vehicles transm...

Page 22: ...y or death Always avoid operating in a manner that could result in vehicle rollover Do not grab or hold ROPS while vehicle is moving If a rollover occurs holding to the roll cage could crush your hand...

Page 23: ...installed cab nets increases the risk of serious injury or death in the event of an accident or overturn They must be used by both operator and passengers at all times Make sure all latches are secur...

Page 24: ...e Intimidator is equipped with a gear selection icon shown on the instrument clusters digital display The brake pedal must be applied in order to start the vehicle and should be applied while shifting...

Page 25: ...passenger accessories cargo loads and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity Reduce speed and allow greater distances for braking...

Page 26: ...argo dump box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes Place the gearbox in Park 3 Dismount the vehicle 4...

Page 27: ...open the tailgate twist the latch on the middle of the tailgate then pull The tailgate is supported by a lever on each side of the cargo bed Do not remove the levers DANGER To avoid personal injury do...

Page 28: ...faster than 10 MPH when hauling or towing loads on a level surface 4 Vehicle speed should never exceed 5 MPH when hauling or towing loads on uneven surfaces rough terrain cornering or while ascending...

Page 29: ...100 lbs 1 000 lbs 200 lbs 300 lbs 10 mph 16 kph 5 mph 8 kph Crew Series 750 EFI 2 100 lbs 1 000 lbs 200 lbs 300 lbs 10 mph 16 kph 5 mph 8 kph Truck Series 750 EFI 2 100 lbs 1 000 lbs 200 lbs 300 lbs 1...

Page 30: ...bers have multiple mounting positions to further adjust the stiffness of the ride by changing the angle in which the shocks are mounted With heavy loads the shocks can be mounted in a near vertical po...

Page 31: ...r purchase to avoid deterioration in gasoline quality or add fuel stabilizer to keep fuel fresh and stabilized Gasoline blend differs from season to season for the best seasonal engine performance To...

Page 32: ...el to expand Immediately clean up spillage during refueling NOTICE High sulfur content in fuel may cause engine wear Kohler 1000 Diesel Fuel Type For best results use only clean fresh commercial grade...

Page 33: ...hanical feeding pump 5 Do NOT manually operate the fuel pump with the engine running 6 After bleeding the system tighten the union bolt on the fuel filter securely NEW VEHICLE BREAK IN The break in pe...

Page 34: ...m your certified Intimidator dealer Maintenance intervals in the following chart pages 36 37 are based upon average riding conditions and an average vehicle speed of approximately ten miles per hour V...

Page 35: ...gle of Operation full oil level 25 degrees Filter capacity not included Always check the dipstick before operation Kohler 1000 Diesel Engine Specifications Cylinders 3 Bore 75 mm 2 95 in Stroke 77 6 m...

Page 36: ...el change yea Engine oil after initial 50 hour break in GAS 100 hr 12 Months Inspect level often chan Lubricate front suspension 100 hr 12 Months Lubricate polyurethane j Lubricate rear suspension 100...

Page 37: ...hs Inspect level often change yearly hr 12 Months Lubricate polyurethane joints hr 12 Months Lubricate polyurethane joints hr 12 Months Inspect lubricate adjust hr 12 Months Inspect lubricate hr 12 Mo...

Page 38: ...VI 700 ml Fuse and Relay Kohler 750 EFI Fuses can be found in three locations a main fuse next to the battery on the passenger side of the engine and under the front hood in a fuse block Fuse Block F...

Page 39: ...main fuses on the driver side of the engine and in a fuse block under the front hood Fuse Block Fuse Chart Main fuse battery 80 amp Glow plugs 50 amp Differential Lock 10 amp Fan 20 amp Headlight Low...

Page 40: ...e the cause or see your dealer Oil Check The oil dipstick and fill tube is located on the top of the engine 1 Position the vehicle on level surface Shift the transmission into P Park and turn the vehi...

Page 41: ...ches 7 Reinstall the drain plug and torque to 10 ft lbs 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 9 Using a clean dry cloth cl...

Page 42: ...e fill tube is located behind the driver s seat between the bed and cab 1 Position the vehicle on level surface Shift the transmission into P Park and turn the vehicle off 2 Remove the seat 3 Locate a...

Page 43: ...rench turn the filter counterclockwise to remove it 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the o ring on the new filter with a film of fresh engine oi...

Page 44: ...osits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and service The tip should not be white A white insulator tip indicates overheating caused by...

Page 45: ...anding heated coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the...

Page 46: ...fan is on a temperature switch and will automatically turn on when needed Periodically check the fuse and fan to be sure it is working properly Air Filter Always change the air filter at intervals ou...

Page 47: ...the bottom of the level check fill plug hole threads 1 Position the vehicle on a level surface 2 Remove the level check fill plug Check the oil level 3 Add the recommended oil as needed Pages 65 66 4...

Page 48: ...linkage bracket on top of the skid plate on the passenger side of the gearbox 2 Depending on which way the shifter needs to be adjusted loosen one of the jam nuts and then tighten the other jam nut u...

Page 49: ...he gearbox in Park 3 Remove the fill plug Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Differential Oil Change On the front differential the drain plug is located...

Page 50: ...Do not modify any components of the CVT system Doing so may reduce its strength so that a failure may occur at high speeds The CVT system has been precision balanced Any modification will cause the sy...

Page 51: ...cover if equipped 4 Remove all debris wrapped in and around the CVT system and air duct passage 5 Check for signs of damage to seals on the transmission and engine See your dealer promptly for servic...

Page 52: ...r 4 If possible drain and replace engine oil 5 Remove the spark plugs Kohler 750 EFI only Turn the engine over several times by using the ignition key 6 Dry the spark plugs then reinstall or if possib...

Page 53: ...ngine side and the foot pedal side Adjust the two jam nuts on the cable conduit A The full throttle stop and the idle stop for the pedal are adjusted by the 5 16 bolts in the mount assembly B Kohler 1...

Page 54: ...tery Notice The battery requires maintenance Check the battery terminals and distilled water levels monthly Do not allow any battery cell to run dry Keeping the battery terminals coated with dielectri...

Page 55: ...ause burns and produce hydrogen gas which is highly explosive Take care not to touch the positive and negative cables together while connected to the battery Do not lean over the battery Do not connec...

Page 56: ...two way or three way switch in the dash The outside headlights are driving lights The inside set of lights are high beam lights if equipped The height and angle of the headlights can be adjusted by Ti...

Page 57: ...omes contaminated or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface and place transmission in P Park 2 View the brake fluid level at the rese...

Page 58: ...linder as shown in the picture below Picture 1 Brake pressure switch pictured Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3...

Page 59: ...ame inflation pressure on each axle DANGER Installation of non standard tires use of oversized tires or use of different tread patterns can change or impair the handling of the vehicle and may void yo...

Page 60: ...ound drive straight forward for 30 feet This is easiest done by driving on a painted line next to a wall or next to any other straight object 2 Stop the vehicle Place the transmission in P Park 3 Remo...

Page 61: ...een centerline to centerline forward front of the tires at hub height 5 Measure the distance between centerline to centerline behind rear the tires at hub height 6 Front distance should be 0 inches to...

Page 62: ...icle Clean vehicle with automotive soap and water NOTICE Mud can stain the vehicles seat and plastic Immediately wash mud off vehicle with mild soap and water Tips Avoid the use of harsh cleaners as t...

Page 63: ...ble wire 8 Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures See page 55 for further information 9 Tie a plastic bag over the exhaust pi...

Page 64: ...smission in Park AND secure the vehicle to the trailer by tying the frame of the Intimidator to the trailer with suitable straps or chains Do not attach a strap or chain to the suspension arms ACCESSO...

Page 65: ...ing Air Circulation with Electric Fan Starting Electric Start MAX Horsepower 25HP MAX Torque Engine 40 4 FT LB 2800 RPM Fuel Type 87 Octane Gasoline 10 Ethanol Max Engine Oil Type SAE10 30W Engine Lub...

Page 66: ...ing Air Circulation with Electric Fan Starting Electric Start MAX Horsepower 25HP MAX Torque Engine 40 4 FT LB 2800 RPM Fuel Type 87 Octane Gasoline 10 Ethanol Max Engine Oil Type SAE10 30W Engine Lub...

Page 67: ...D Selection Cooling Air Circulation with Electric Fan Starting Electric Start MAX Horsepower 25HP MAX Torque Engine 40 4 FT LB 2800 RPM Fuel Type 87 Octane Gasoline 10 Ethanol Max Engine Oil Type SAE1...

Page 68: ...lation with Electric Fan Ignition Electric Start MAX Horsepower Approximately 24HP Fuel Type Diesel meets ASTM D 975 1D or 2D EN590 or equivalent Engine Oil Type SAE15 40 Engine Lubricant Speed Up To...

Page 69: ...quid Pump Circulation with Electric Fan Ignition Electric Start MAX Horsepower Approximately 24HP Fuel Type Diesel meets ASTM D 975 1D or 2D EN590 or equivalent Engine Oil Type SAE15 40 Engine Lubrica...

Page 70: ...iquid Pump Circulation with Electric Fan Ignition Electric Start MAX Horsepower Approximately 24HP Fuel Type Diesel meets ASTM D 975 1D or 2D EN590 or equivalent Engine Oil Type SAE15 40 Engine Lubric...

Page 71: ...___________________ ____________________________________________________________ ____________________________________________________________ __________________________________________________________...

Page 72: ...maged Air filter is clogged Spark plug defective Kohler 750 only Engine oil viscosity is wrong Battery becomes weak and the engine does not turn over quick enough Brake pedal is not engaged Parking Br...

Page 73: ...pending on ambient temperatures Clean battery cables and terminals Charge the battery In cold weather always remove the battery from the engine charge and store it indoors Install it on the machine on...

Page 74: ...ts Engine diagnostic light comes on Engine will not idle Difficult to shift Cause Spark plug defective Kohler 750 only Engine just started and had not warmed up Engine is cold High tension cord defect...

Page 75: ...p or replace it Allow the engine to run for a few minutes Allow the engine to run for a few minutes Allow time for engine to warm before driving Consult your authorized dealer Clean or replace fuel li...

Page 76: ...and heat up Battery electrolyte Cause Battery overused until lights are dim Battery has not been recharged Poor terminal connection Battery life expired Insufficient charging Battery was used with an...

Page 77: ...lace battery Clean the terminal and tighten securely Replace battery Consult your authorized dealer Preventive measure Charge battery properly Keep the terminal clean and tight Apply grease and treat...

Page 78: ...ED WARRANTY Intimidator 4x4 will at its option repair or replace without charge any part covered by the warranty which is found to be defective in material and or workmanship within 6 months after dat...

Page 79: ...repairs made by an unauthorized repair center Warranty does not apply to wearable items or items considered being part of normal maintenance Wearable items and normal maintenance components include b...

Page 80: ...covered by the warranty which is found to be defective in material and or workmanship within 6 months after date of sale to the original retail purchaser of a new Intimidator 4x4 gasoline model This...

Page 81: ...unauthorized repair center Warranty does not apply to wearable items or items considered being part of normal maintenance Wearable items and normal maintenance components include but are not limited...

Page 82: ...eter Reading ______________________________ Dealer Stamp ___________________________________ 2nd Service Date __________________________________________ Hour Meter Reading ____________________________...

Page 83: ..._______________________________ 6th Service Date __________________________________________ Hour Meter Reading ______________________________ Dealer Stamp ___________________________________ 7th Servi...

Page 84: ...OF PURCHASE_________________________ DEALER__________________________________ PURCHASER LAST NAME_______________________________ FIRST NAME______________________________ ADDRESS_______________________...

Page 85: ...ays be extra careful when riding on unfamiliar terrain steep slopes or when encountering obstacles _____ I have read the above warnings and I understand that SEVERE INJURY OR DEATH can result from ign...

Page 86: ...For additional information please see us at www intimidatorUTV com Intimidator Inc 1 Bad Boy Blvd Batesville Arkansas 72501 855 307 0933 OWNER S MANUAL 1000cc Kohler Diesel 750 EFI Kohler Gas...

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