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Intimidator GC 1K Owner's Manual

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2020 OWNER'S MANUAL

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Summary of Contents for Intimidator GC 1K

  • Page 1 2020 OWNER'S MANUAL...
  • Page 2 PERSONNEL INVOLVED IN THE OPERATION, TRANSPORT, MAINTENANCE, AND STORAGE OF THE EQUIPMENT. 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...
  • Page 3 On behalf of my wife Becky and myself, along with all of us at Intimidator, Inc., we would like to officially welcome you to the family. We are thrilled that you have chosen to become a part of our team. Whether you have purchased your Intimidator for commercial use on your farm, or you just wanted to have the best UTV in your neighborhood, we’d like to say...

  • Page 4: Table Of Contents

    Fuel ....................................  2 6   New Vehicle Break‐In................................  2 7   Maintenance  ..................................  2 8   Severe Use Definition ..............................  2 8   Intimidator GC1K Engine Specifications ........................  2 8   Intimidator Lubrication and Fluid Chart ........................  2 9   Periodic Maintenance Schedule ...........................  2 9   Fuse and Relay  ................................  3 1   Fault Codes ...................................  3 2  ...
  • Page 5 Troubleshooting  ................................  5 2   CVT Troubleshooting ..............................  5 3   Battery Troubleshooting  ...............................  5 4   Storage  ....................................  5 5   Transporting Your Intimidator  ............................  5 6   Accessories ..................................  5 6   Specifications  ..................................  5 7   GC1K Base  ..................................  5 7  ...

  • Page 6: Introduction

    Introduction  Read this owner’s manual.   The Intimidator is an off-road vehicle, not a toy. It can be hazardous to operate and should never be operated by anyone other than a trained adult. Failure to follow the warnings and instructions in this manual can result in severe injury or death.

  • Page 7: Safety

    Safety  For your protection, warning labels are placed on the vehicle. Read and follow the instructions on the vehicle carefully. If any label becomes illegible or comes off contact your authorized dealer to acquire a replacement. Discretionary and Age Warning – Located on vehicle dash  ...
  • Page 8 Seatbelt and Safety Warning – Located on vehicle firewall   Figure 3: Seatbelt and Safety Label Warning:  Improper Use of Off-Highway Vehicles Can Cause Severe Injury or Death. Be Prepared:  Fasten seat belts and side safety nets if so equipped. ...
  • Page 9   Figure 5: ROHVA Label 2 Cargo Bed Safety Warning – Located in the cargo bed.   Figure 6: Cargo Bed Safety Label Warning:  Improper use of cargo bed or cage/frame can result in severe injury or death from loss of control, overturn or other accidents. ...
  • Page 10 o Secure cargo so that it will not shift, affecting handling or cause the cargo to strike occupants. o Keep cargo weight centered in the bed and as low as possible to reduce the chance of rollover. o Do not tow or pull objects from any other point on the vehicle other than the trailer hitch or winch if installed.

  • Page 11: Roll Over Protective Structure (Rops) Inspection Guide

    Tire Rating and Pressure Chart Tire Size Max Load Rating (lb.) at Max Max Pressure Position Pressure (PSI) Front 27x10R14 Rear 27x12R14 1275 Front 28x10.5R14 1000 Rear 28x10.5R14 1000 Front 30x10.5R15 1000 Rear 30x10.5R15 1000 Roll Over Protective Structure (ROPS) Inspection Guide  ROPS, 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 12: General Safety

    When a ROPS is removed or installed, mounting hardware must be examined for signs of over-stressing. Damaged mounting hardware must be replaced with proper specification hardware before placing the ROPS back into service. Properly maintained seatbelts are essential to compliment the operator crush protection designed into the ROPS.
  • Page 13  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.  Always inspect the vehicle before each use to make sure it is in safe operating condition.
  • Page 14 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 excessive tire wear and may adversely affect the handling of the vehicle and could result in loss of control, accident, or overturn.

  • Page 15: Safe Riding Gear

    The warranty of the Intimidator will void if any unauthorized equipment is added to the vehicle, or if any modifications are made to the vehicle that increase the speed or power.

  • Page 16: Features, Controls, And Operation

      Figure 10: 4.5" Display Your Intimidator is equipped with a digital LCD screen. The 7” display boasts touchscreen capability (if equipped). General maintenance is not required. However, a soft cloth can be used for cleaning. Window cleaner or alcohol can also be used to clean the glass portion of the display.
  • Page 17 When the gauge boots up it will open to the home screen. Displayed on the screen are the following:  Engine Revolutions Per Minute (RPM)  Speed in Miles Per Hour (MPH)  Fuel Level (percentage remaining)  Current Gear ...

  • Page 18: Engaging And Disengaging 4 Wheel Drive (4Wd)

    Switches   Figure 12: GC1K Switches From left to right: 1. Light Switch 2. 2 Wheel Drive/ 4 Wheel Drive Switch 3. Rear Differential Lock Switch 4. Electric Bed Dump Switch Lights All models come equipped with automotive style headlights. Press the switch down to turn on the low beam lights.

  • Page 19: Locking Rear Differential

    To disengage 4wd, press the 4wd dash switch so that the switch light 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 restrictions.

  • Page 20: Electrical

    Adding Switches and In-Dash Accessories The Intimidator is designed to allow the dealer to add more switches for accessories and “built-in” accessories like a light bar or sound system. There are two open slots in the switch panel of stock GC1K machines to allow for additional accessories.

  • Page 21: Parking Brake

    Never rely on the parking brake alone. See “Transporting Your Intimidator.” Your Intimidator is equipped with a “Park” gear. While your vehicle is in “Park” with the engine off, both rear wheels will lock. Your vehicle’s transmission should be set in “Park”...

  • Page 22: Shifting Gears

     Always come to a complete stop and hold the brake before attempting to shift into a new gear. The Intimidator is equipped with a gear selection icon shown on the instrument cluster’s digital display. To shift, bring the vehicle to a complete stop, depress the brake, and move the shift lever to the desired gear.

  • Page 23: Rollover Protective Structure (Rops)

    The ROPS on this vehicle meets American National Standards Institute (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 Half Doors   ...

  • Page 24: Tilt Steering

      Figure 16: Steering Column 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 pressing it down. The tilt steering lever is located on the steering column, directly behind the steering wheel.

  • Page 25: Cargo Bed

     Reduce speed and allow greater distances for braking when hauling cargo.  Always load the cargo box with the load as far forward and as low as possible.  When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
  • Page 26 To use the cargo 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. Safely place the transmission into “Park.” (Engage the stand-alone parking brake if equipped.) 3.

  • Page 27: Electric Dump Bed

    Electric Dump Bed    Figure 19: Single Electric Dump Bed Actuator Press and hold the rocker switch on the side with the arrow pointing up to dump the cargo bed. Quickly release the switch when the actuator starts to make a clicking sound. To lower the bed, press and hold the rocker switch on the side with the arrow pointing down.

  • Page 28: Adjusting Rear Shock Position

    Notice:  A special tool is required to adjust the shock spring.  Authorized Intimidator dealers are equipped to make these adjustments for you. All four shock absorbers have adjustable features that increase or decrease their stiffness.

  • Page 29: Fuel

    be mounted in the near-vertical position. For light-to-medium size loads and a smoother ride, the shocks can be mounted at a steeper angle which will also increase wheel travel. Fuel  Danger:  Handle fuel carefully  Do not fill the fuel tank with the engine running. ...

  • Page 30: New Vehicle Break

    The first 20 hours of riding are the most important hours in the life of your engine. Read the and follow these instructions to properly break-in your new Intimidator. Do not put an excessive load on the engine for the first 20 hours. During this time the various parts of the engine wear and polish themselves to optimal operating tolerances.

  • Page 31: Maintenance

    Inspect, clean, lubricate, adjust, and replace parts as recommended by the periodic maintenance chart in this manual. When inspection reveals the need for replacement parts, use genuine Intimidator parts, available from your authorized Intimidator dealer. Maintenance intervals in the periodic maintenance chart are based upon average riding condition.

  • Page 32: Intimidator Lubrication And Fluid Chart

    Intimidator Lubrication and Fluid Chart  Recommended factory fluids Item Lubricant Quantity Brake Fluid DOT 3 Between min and max Front Differential Oil Shell Spirax S3 TLV 18 ml Rear Differential Oil Shell Spirax S4 AX 80w90 550 ml Transmission/Gearbox Oil Valvoline SYN 75W-140 750 ml Periodic Maintenance Schedule ...
  • Page 33 Fuel, Oil Level Pre-ride Inspect, adjust Steering Pre-ride Inspect, adjust Front Suspension Pre-ride Inspect, adjust Rear Suspension Pre-ride Inspect, adjust Tires Pre-ride Inspect, adjust Wheels/Fasteners Pre-ride Inspect, adjust Frame Pre-ride Inspect Headlights, Tail Lights Pre-ride Inspect, adjust Axle, Steering Joint Boots Pre-ride Inspect, adjust Air Filter...

  • Page 34: Fuse And Relay

    CVT Belt 150hr Inspect, replace if /12 months necessary Valve Clearance 150hr Inspect, adjust /12 months Fuel System 250hr Inspect for leaks, /24 months change fuel filter Coolant 250hr Drain, replace /24 months Engine Mounts 250hr Inspect /24 months Wiring 250hr Inspect for wear, apply /24 months...

  • Page 35: Fault Codes

    Fault Codes If your vehicle is having an issue and you are able to obtain data from a fault code reader it may help to resolve the issue more quickly. Number Fault Description Code XXXXX Un defined B2225 Tilt switch diagnosis (Short Circuit Battery) B2226 Tilt switch diagnosis (Short Circuit Ground/Open Circuit)

  • Page 36: Engine Oil

    P1617 Starter 2 diagnosis (Short 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 maintenance chart. Pay attention to the oil level. A rise in oil level during cold weather can indicate contaminant collection in the oil sump or crankcase.
  • Page 37 ¼ turn past gasket contact with the housing. 10. Reinstall the drain plug and torque to 17 ft/lb. 11. Refill engine with Intimidator SYN 10W-40. Reference the specific engine manual for specific volumes. 12. Once full, check the oil level with the dipstick.

  • Page 38: Cooling System

    Spark Plug Inspection Warning:  Hot exhaust system and engine can cause burns. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 39 Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle. Adding or Changing Coolant It is recommended that coolant be drained and replaced every two years. Use a premixed, ready-to-use antifreeze that consists of 50% antifreeze and 50% distilled water.
  • Page 40 Radiator and Cooling Fan Always keep the radiator screen clean and free of mud and debris. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

  • Page 41: Transmission And Gearbox

    Transmission and Gearbox  Always check and change the transmission oil at the intervals outlined in the periodic maintenance chart. Refer to the lubrication and fluid recommendations chart for type and capacities. Gearbox Oil Change The gearbox oil drain plug is located on the underside of the machine. 1.
  • Page 42   Figure 25: Carefully Moving Shifter When the system is operating properly, the exclamation point will display when the shift lever is directly on the tooth above the slot for “Neutral” gear. If the exclamation point displays when the lever is just moved out of the neutral slot, or does not display until the lever is almost in the slot for “Reverse,”...

  • Page 43: Differentials

    If shifting problems persist, or the vehicle continues to slip out of “Park,” take it to an authorized Intimidator dealer for service. Differentials  The front and rear differentials are the transfer point from the engine to the axles. Check and change the differential oil at the intervals outlined in the periodic maintenance chart.

  • Page 44: Continuously Variable Transmission (Cvt)

    Continuously Variable Transmission (CVT)    Figure 27: CVT Housing Danger:  Only qualified personnel are to perform installation, maintenance, adjustments, and repair operations on the variable speed transmission system.  Your vehicle is equipped with a CVT which rotates at high speed, creating large amounts of force on clutch components.
  • Page 45 3. Remove the CVT cover. 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 service if any seals appear to be damaged. 6.

  • Page 46: Throttle System

    Notice:  If your vehicle becomes immersed in water, major engine damage can result.  Intimidator warranty does not cover vehicles submerged in water over the floor board.  If your vehicle does become submerged above the engine, thorough inspection is necessary.

  • Page 47: Battery

    Battery    Figure 29: Battery Location Under Hood Danger:  The battery emits explosive gases. Keep away from any source of flame or spark.  The battery contains sulfuric acid which can cause serious chemical burns. Wear goggles and rubber/latex gloves to avoid any chemical contact with skin.
  • Page 48 Jump Starting Danger:  The battery contains sulfuric acid that can cause severe burns and produce highly explosive hydrogen gas.  Do not touch the positive and negative cables together while they are connected to the battery.  Do not lean over the battery. ...

  • Page 49: Headlights

    Battery Storage Whenever the vehicle is not in use for any extended period of time, disconnect the negative battery cable from the battery after ensuring that the battery is fully charged. A battery tender can remain connected to the battery during the storage period. Headlights ...

  • Page 50: Tires

    5. Apply the brake forcefully for a few seconds and inspect for fluid leakage around the fittings. Brake Pressure Switch and Safety Switch For safety, the brake must be applied to start the Intimidator. The brake pressure switch is located on the master cylinder. Brake Inspection To inspect the brake system: 1.

  • Page 51: Steering

    Wheel Alignment Notice:  Installing unauthorized accessories, such as larger tires or a lift kit, may damage the vehicle and cause control problems. It is recommended that tire alignment be performed by an authorized dealer. To adjust tire alignment: 1. Ensure that the vehicle is safely parked on flat surface. 2.

  • Page 52: Power Steering (If Equipped)

    3 seconds to avoid overheating the electric motor and controller. The Intimidator GC1K Stage 2 and Stage 3 come equipped with power steering made by Demon Powersports. If the system is not operating as intended, follow the troubleshooting procedures below.
  • Page 53 Fault Code Table Code Diagnosis Content Fault Code Wave Main torque sensor disconnection Main torque sensor output error (voltage too high or low) Vice torque sensor disconnected Vice torque sensor output error (voltage too high or low) Main and vice torque difference is too large Main torque sensor inner fault Motor disconnected Current of ECU is over the limit...

  • Page 54: Washing And Maintaining Appearance

    Keeping your 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 cleaners that can scratch the finish.

  • Page 55: Troubleshooting

    Troubleshooting  Symptom Cause Action Key switch is not in the Make sure the key is in “ON” position Engine is difficult to proper position start or will not start Wiring Clean corroded connections, tighten loose connections Starter switch or solenoid By-pass switch or solenoid with a jumper wire.

  • Page 56: Cvt Troubleshooting

    Clogged air filter Clean/replace air filter Overloaded Reduce cargo/tow load Exhaust fumes are colored (black, dark gray) Low grade fuel Refill with recommended fuel Clogged air filter Clean/replace air filter Excessive engine oil Drain oil to specified level Exhaust fumes are colored (white, blue) Piston ring is worn/stuck Consult your dealer...

  • Page 57: Battery Troubleshooting

    Battery Troubleshooting  Symptom Cause Action Overused battery Charge/replace battery Starter does not function Dead battery Charge/replace battery Poor terminal Clean/tighten connections connection Insufficient Add distilled water to proper level, charge Terminals appear electrolyte battery white Overused battery Charge/replace battery Expired battery Replace battery Recharging is impossible...

  • Page 58: Storage

    Storage  Notice:  Do not store the vehicle in direct sunlight. Preparation for Storage: 1. Thoroughly clean the entire vehicle. 2. Run the engine for five minutes to warm the oil. If you do not intend to use a fuel stabilizer, run the engine outdoors until the motor stops from lack of fuel.

  • Page 59: Transporting Your Intimidator

     Do not attach a strap or chain to the suspension arms. The best way to transport your Intimidator to different locations over the road is to load it onto a trailer or flatbed truck. Below are some considerations while transporting your machine: ...

  • Page 60: Specifications

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 1,561 lb. (708.1 kg) Length 113” (287.0 cm) Width 63”...

  • Page 61: Gc1K Base Crew

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 2,216 lb. (1,005.2 kg) Length 157” (398.8 cm) Width 64”...

  • Page 62: Gc1K Stage 1

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 1,834 lb. (831.9 kg) Length 122” (309.9 cm) Width 64”...

  • Page 63: Gc1K Crew Stage 1

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 2,212 lb. (1,003.3 kg) Length 157” (398.8 cm) Width 64”...

  • Page 64: Gc1K Stage 2

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 1,873 lb. (849.6 kg) Length 122” (309.9 cm) Width 64”...

  • Page 65: Gc1K Crew Stage 2

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 60 MPH (96.6 KPH) Measurements Curb Weight 2,250 lb. (1,020.6 kg) Length 157” (398.8 cm) Width 64”...

  • Page 66: Gc1K Stage 3

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 65 MPH (104.6 KPH) Measurements Curb Weight 1,920 lb. (870.9 kg) Length 122” (309.9 cm) Width 64”...

  • Page 67: Gc1K Crew Stage 3

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 65 MPH (104.6 KPH) Measurements Curb Weight 2,268 lb. (1,028.7 kg) Length 157” (398.8 cm) Width 64”...

  • Page 68: Gc1K Truck

    Starting Electric Start MAX Horsepower 83Hp (61.9 kW) Fuel Type 87 Octane Gasoline (10% Ethanol Max) 91+ Recommended Engine Oil Type Intimidator SYN 5W-40 Speed Up to 65 MPH (104.6 KPH) Measurements Curb Weight 2,300 lb. (1,043.3 kg) Length 157” (398.8 cm) Width 64”...

  • Page 69: Warranties

    CV Joints, driveshafts and their subcomponents and differentials 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-transferrable to a 2 party and will be subject to certain limitations.

  • Page 70: Battery Warranty

    Battery Warranty  The batteries used to power the Intimidator, Inc. will carry a 6-month free replacement warranty. These warranty claims will be handled by the battery manufacturer, Interstate Battery. Intimidator, Inc. does not assume any warranty obligation, liability, or modification for this item.
  • Page 71 UTV or honor your claim within a reasonable period of time, contact Intimidator at: (866) 622-3269 for assistance. If you are not satisfied with the way in which a warranty claim is resolved by Intimidator, you may write directly to:...
  • Page 72 An emergency situation exists when an Intimidator dealership is not reasonably available, a warranted 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 control devices or system may be done by any UTV repair establishment or individual, or by the owner using any replacement part.

  • Page 73: Service Record

    Service Record  Number Date Hour Meter Reading Dealer Stamp 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 First Name Address City State Postal Code Day Phone Evening Phone 70   ...

  • Page 74: Pre-Ride Checklist

    Pre‐Ride Checklist  Complete this checklist before every operation of the Intimidator to ensure a safe and enjoyable ride.  Tires and Wheels o Check condition for cuts or gouges o Check for adequate tread o Check air pressure and ensure that it is even in all tires o Check wheel lugs for tightness ...

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