Intimidator 2500 EV Owner's Manual
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Intimidator 2500 EV Owner's Manual

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OWNER'S
MANUAL
2500 EV
Electric Vehicle
UTVRevised 6-17-2013

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Summary of Contents for Intimidator 2500 EV

  • Page 1 OWNER’S MANUAL 2500 EV Electric Vehicle UTVRevised 6-17-2013...
  • Page 2 Owner Memo Name: ____________________________________ Purchasing Date: ____________________________ Type: _____________________________________ Pin Number: _______________________________ Special Notice: _____________________________ Key Number: _______________________________ PAGE 2...

  • Page 3: Table Of Contents

    Safe Riding Gear ..........Page 15 Features, Controls and Operation ..... Page 16-30 Service and Maintenance ......Page 31-46 Storing and Maintaining Appearance ..Page 47-48 Transporting your Intimidator ......Page 48 Accessories ............Page 48 Specifications ..........Page 49 Troubleshooting ........Page 50-51 Warranties ..........

  • Page 4: Introduction

    INTRODUCTION READ THIS OWNER’S MANUAL. The Intimidator is an off- road vehicle and is not a toy. The Intimidator is an adult vehicle only and can be hazardous to operate. Failure to follow the warnings and instructions in this manual can result in severe injury or death.
  • Page 5 OWNER’S MANUAL DANGER: Improper Use of Off-Highway Vehicles Can Cause Severe Injury or Death Drive Responsibly Avoid loss of control and rollovers: Avoid abrupt maneuvers, sideways sliding, skidding, or • fishtailing, and never do donuts. Slow down before entering a turn. •...
  • Page 6 Improper Use of Off-Highway Vehicles Can Cause Severe Injury or Death. Be Prepared: Fasten seat belts. • Wear an approved helmet and protective gear. • Each rider must be 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.
  • Page 7 OWNER’S MANUAL Cargo Bed Safety Warning– Located in the cargo bed. Improper use of cargo bed or cage/frame can result in severe injury or death from loss of control, overturn or other accidents. Never carry passengers in the cargo bed. •...
  • Page 8 WARNING Keep hands, body, and other people away from pinch points when lowering bed. Do not hold the cage/frame while closing bed. Tire Pressure Chart TIRE PRESSURE AND SIZE CHART Vehicle Size Load Top Speed Rating Position Rating (lb) Pressure (psi) (mph) @ Max Load Payload Front...

  • Page 9: Rops And Fops Inspection Guide

    OWNER’S MANUAL Rollover Protective Structures (ROPS) Inspection Guide Falling Object Protective Structures (FOPS) Inspection ROPS and FOPS, like any other safety device, need to be periodically inspected to verify that the integrity of the device has not been compromised through normal machine use, misuse, age degradation, modifications, or roll-overs.
  • Page 10 Other conditions may require imminent service but may not render the unit immediately unusable, examples are: • Faded paint. • Faded, hard to read ROPS/FOPS label. • Slightly corroded mounting hardware. ROPS/FOPS must be inspected immediately after any type of collision, rollover or impact. If any damage is evident, the ROPS/FOPS must be removed from service, repaired and/or replaced.

  • Page 11: General Safety

    OWNER’S MANUAL GENERAL SAFETY Never Operate: If you are under age 16 or without a valid driver’s • license. At speeds too fast for your skills or conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees. •...
  • Page 12 Do not carry a passenger until you have at least two • hours of driving experience with the Intimidator. Always keep hands and feet inside the vehicle at all • times.
  • Page 13 OWNER’S MANUAL Operating on Pavement This vehicle’s tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces may cause quick tire wear and may adversely affect the handling of the vehicle and could result in loss of control, accident or overturn.
  • Page 14 The warranty of the Intimidator will be terminated if any unauthorized equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase the speed or power.

  • Page 15: Safe Riding Gear

    Helmet Wearing a helmet can prevent a severe head injury. Whenever riding the Intimidator or any Utility Vehicle, always wear a helmet that meets or exceeds established DOT (U.S. Department of Transportation) safety standards.

  • Page 16: Features, Controls And Operation

    If all keys are lost, a replacement ignition switch must be installed. Instrument Cluster Your Intimidator EV is equipped with a battery meter and an analog speedometer with a digital LCD screen. High pressure water or soap may damage components.
  • Page 17 OWNER’S MANUAL The LCD screen on the speedometer may display the following: • Seat belt reminder. • Gear Indicator – Displays the gear shifter position. P – Park R – Reverse N – Neutral L – Low Gear H – High Gear Odometer –...
  • Page 18 Standard Intimidator models are equipped with low beam headlights. Press the left side of the rocker switch to turn on the low beam lights. The right side of the rocker switch position is off.
  • Page 19 OWNER’S MANUAL Engaging and Disengaging 4WD WARNING: Do not drive in 4wd on a paved surface. • Do not engage 4wd while the rear wheels • are spinning without traction. This may cause severe drive-shaft and clutch damage. Always engage 4wd while the rear wheels have traction or are at rest.
  • Page 20 DANGER: Steering and vehicle performance will be altered with • the rear differential lock engaged. Do not operate faster than 10 mph. • Do not attempt to turn with the differential lock • engaged. Electric Dump Bed (if equipped) Press and hold the left side of the rocker switch to dump the cargo bed.

  • Page 21: Parking Brake

    To minimize the risk of damage to the vehicle, contact your authorized dealer. Parking Brake 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.
  • Page 22 The Rollover Protection Structure (ROPS) on this vehicle meets American National Standard Institute (ANSI) Standards and OSHA standards for rollover performance requirements. Always have authorize Intimidator, Inc., dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

  • Page 23: Seat Belts

    OWNER’S MANUAL Seat Belts DANGER: Falling from a moving vehicle could result in serious injury or death. Always fasten your seatbelt. DANGER: This vehicle is equipped with 3-point seat belts for occupants. Always make sure the seat belts are secured for all riders before operating.
  • Page 24 Tilt Steering Your Intimidator is equipped with tilt steering that can be adjusted by pulling the tilt-steering lever towards you, then lifting the steering wheel up or down. The tilt steering lever is located on the steering column, just behind the steering wheel.
  • Page 25 OWNER’S MANUAL Hauling Cargo DANGER: Always follow these precautions when hauling cargo: Driving with passengers in the cargo • box can result in severe injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.
  • Page 26 HEAVY LOADS CAN CAUSE BRAKING • AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require braking downhill. Allow yourself extra distance for braking. Front cargo tie-down point Rear cargo tie-down point Dumping the Cargo Box WARNING: If the cargo box is loaded to full weight capacity,...
  • Page 27 OWNER’S MANUAL Bed handle and lever to release Standard lift assist on dump box bed latch Electric actuator on dump box Cargo Bed Tailgate To 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.
  • Page 28 Towing Loads 2˝ rear receiver hitch Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: Never load more than 200 lbs. tongue weight on the rear towing bracket. Never load more than 300 lbs.
  • Page 29 OWNER’S MANUAL PAGE 29...
  • Page 30 Adjusting Rear Spring Position All four shock absorbers have four (4) spring position adjustments, which will tighten or loosen the spring travel rate to adjust the suspension for different terrain and payload conditions. If you plan to haul heavy cargo or have a heavy accessory, like a snow plow, you can tighten the spring rate by moving the silver ring up.

  • Page 31: Service And Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use only genuine Intimidator parts available from your authorized dealer. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten miles per hour.

  • Page 32: Periodic Maintenance

    PERIODIC MAINTENANCE ITEM MAINTENANCE INTERVAL (whichever comes first) Hours Calendar Clean engine, battery charger surroundings and components from debris Pre-Ride Seat belts Pre-Ride Shift linkage Pre-Ride Brake fluid level and pressure Pre-Ride Steering Pre-Ride Front suspension Pre-Ride Rear suspension Pre-Ride Tires Pre-Ride Wheels/fasteners...
  • Page 33 OWNER’S MANUAL REMARKS Remove all debris Check for damage and operation Make sure Park will fully engaged. Adjust if necessary Inspect. Adjust, lubricate or replace as needed Inspect. Fill if necessary Torque to 140 ft. lb. Inspect, lubricate, reapply as needed Inspect periodically Inspect level, change yearly Inspect, lubricate, change yearly...
  • Page 34 INTIMIDATOR EV ENGINE INFORMATION Make Schabmueller Type AC-powered, brushless Peak HP 30 hp Peak Torque 120 ft. lb. INTIMIDATOR LUBRICATION AND FLUID CHART Item Lube Amount Battery water level Distilled water Whatever it takes Brake fluid DOT 3 Whatever it takes...
  • Page 35 OWNER’S MANUAL Method ¼˝ above metal plates in battery Maintain level between fill lines Power Converter Fuses Located under fuse block, both are 30-amp. PAGE 35...
  • Page 36 Motor An AC-powered, 48 volt, brushless motor made by Schabmuller powers your Intimidator EV. The IP45 motor is water resistant, not waterproof. If the motor should overheat, the digital display on the right of the speedometer will display “motor hot.” Stop the vehicle and allow time for the motor to cool down before continuing.
  • Page 37 Check the terminal bolt torque monthly. It should remain 140 ft.lb. When storing your Intimidator EV, leave the charger plugged-in or charge the batteries bi-weekly to prevent self-discharging, which could ruin the batteries. It is best to store your vehicle out of below-freezing temperatures.
  • Page 38 Always use a 3-prong (with ground) 12-gauge extension cord, plugged into a 15-amp circuit breaker. Do not overload circuit by having two Intimidator EV’s, large appliances or tools plugged into the same circuit breaker. Never allow the charger to get wet while charging or plugged into an outlet.
  • Page 39 OWNER’S MANUAL Power Converter The Intimidator EV has two 48 volt-to-12 volt power converters underneath the hood to run all the 12 volt electronics. Some additional accessories, like lights, can be added. To run large accessories, like a winch, you would need to purchase an Intimidator winch battery kit from Bad Dawg Accessories.
  • Page 40 Transmission/Gearbox Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 32. Refer to the Lubrication and Fluid Recommendations chart for type and capacities. Oil Check The level check/fill plug is located on the back, passenger side of the gear case.
  • Page 41 OWNER’S MANUAL Adjusting the Shifting Linkage Shift linkage adjustment near gearbox Shift linkage adjustment under hood WARNING: The vehicles gear shift lever comes properly adjusted from the factory so that the Park gear is fully engaged and will not slip out of Park. During every pre-ride inspection, inspect that the gear shift lever is fully engaged into Park and will not slip out of Park.
  • Page 42 Front Differential Check/Fill plug Front Differential drain plug Rear Differential Check/Fill plug Rear Differential drain plug Differential Oil Check On the front differential, the check/fill plug is located on the driver’s side rear. On the rear differential, the check/fill plug is located on the passenger side rear.
  • Page 43 OWNER’S MANUAL Vehicle Submerged in Water NOTICE: Never operate in water deeper than the floorboard. If your vehicle becomes immersed in water, major damage not covered under warranty can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before turning on the engine. Headlights Depending on model, the headlights are controlled by a two-way or three-way switch in the dash.

  • Page 44: Brake Fluid

    Brakes The front and rear brakes are hydraulic disc activated by the brake pedal. Brake Fluid Inspect the level of the brake fluid before each operation. Always keep the fluid level between the minimum and maximum fill line on the reservoir. Change the brake fluid either every two years, any time the fluid becomes contaminated or if the type and brand of the fluid in the reservoir are unknown.
  • Page 45 Tires are an important part of the suspension of the vehicle. Tire construction characteristics and inflation pressure can greatly influence vehicle handling. Intimidator, Inc. always recommends that you always replace tires with standard replacement tires. It is also very important to have tires of the same type and height on all axles, and at the same inflation pressure, on each axle.
  • Page 46 To center your vehicles steering wheel: On level ground, 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. Stop the vehicle. Place the transmission in “P” (Park).

  • Page 47: Storing And Maintaining Appearance

    Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system. If any informational or warning label becomes • illegible or comes off, contact your Intimidator dealer to order a replacement label. PAGE 47...

  • Page 48: Transporting Your Intimidator

    When trailering your vehicle, ALWAYS put the transmission being 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.

  • Page 49: Specifications

    OWNER’S MANUAL SPECIFICATIONS INTIMIDATOR EV CORE COMPONENTS Frame ......Powder Coated Fusion-Bonded Solid Steel Bridge Frame Body .......Automotive Quality Acrylic Plastic Front Tires .......26x9x14 - 6 ply Rear Tires ......26x11x14 - 6 ply Wheels ......14˝ Wheels Front Suspension ....Dual A-Arm Independent Rear Suspension....Dual A-Arm Independent...

  • Page 50: Troubleshooting

    TROUBLESHOOTING Trouble Cause No engine power Key switch is not in the proper position Low or no battery charge Check error codes Motor has overheated Speed sensor malfunction Solenoid malfunction Bad battery or batteries Poor terminal connection Difficult to shift Shifter out of adjustment Shifter cable stretches Shifter cable dirty or rusted...

  • Page 51: Troubleshooting

    OWNER’S MANUAL Curtis controller error codes can be referenced at our website: www.intimidator4x4.com Countermeasure Make sure the key is in “ON” position Charge batteries See the Error Code list below Allow motor time to cool Check connection. Replace if needed Replace solenoid Clean battery cables and terminals Charge the battery...

  • Page 52: Warranties

    Intimidator 4x4 electric model. This limited warranty is non transferrable to a 2nd party and will be subject to certain limitations.
  • Page 53 This warranty gives you specific legal rights, and you may also have other rights which may vary from state to state. Any warranty issues or questions can be handled by your Intimidator 4x4 dealer or at: Intimidator 4x4 1 Bad Boy Blvd.

  • Page 54: Service Record

    SERVICE RECORD Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 1st Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 2nd Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 3rd Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ PAGE 54...
  • Page 55 OWNER’S MANUAL 4th Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 5th Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 6th Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 7th Service Date: _________________________________________ Hour Meter Reading: _____________________________ Dealer Stamp: __________________________________ 8th Service Date: _________________________________________...

  • Page 56: Registration

    INTIMIDATOR, INC. UTILITY VEHICLE OWNERS REGISTRATION & TRAINING CERTIFICATE (Keep original copy on file at your dealership) VIN/PIN _________________________________ MODEL _________________________________ DATE OF PURCHASE ________________________ DEALER _________________________________ PURCHASER LAST NAME ______________________________ FIRST NAME _____________________________ ADDRESS _______________________________ CITY ___________________________________ STATE __________________________________...

  • Page 57: Registration

    _____ I have read the above warnings, and I understand that SEVERE INJURY OR DEATH can result from ignoring these warnings or from improper use. _____ I will watch the safety/training video provided by Intimidator, Inc., before operating this vehicle. ____________________________________________________ Purchaser’s Signature...
  • Page 58 NOTES: ____________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ PAGE 58...
  • Page 59 OWNER’S MANUAL NOTES: ____________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ PAGE 59...
  • Page 60 OWNER’S MANUAL 2500 EV Electric Vehicle For additional information, please see us at www.intimidator4x4.com Intimidator, Inc. 1 Bad Boy Blvd. Batesville, Arkansas 72501 (855) 307-0933...

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