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Summary of Contents for Husqvarna HUV 4214 2009
- Page 1 2009-2010 HUV 4214, HUV 4414, and HUV 4414X Maintenance and Service Manual Gasoline Utility Vehicles Gasoline Utility Vehicles Manual Number 525 88 85-02 Edition Code 0309C0211B...
- Page 3 This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at: Husqvarna Forest and Garden, 7349 Statesville Road, Charlotte, North Carolina, 28269; Attention: Technical Services.
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Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY ............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warning ............................1-2 Disabling the Vehicle..........................1-3 Disconnecting the Battery – Gasoline Vehicles .................... 1-4 Connecting the Battery – Gasoline Vehicles ....................1-4 SECTION 2 –... - Page 6 Under seat Center Panel Installation ......................4-21 Rear Fender..............................4-21 Rear Fender Removal..........................4-21 Rear Fender Installation ........................... 4-22 Cargo Bed..............................4-22 Cargo Bed Removal ..........................4-22 Cargo Bed Installation..........................4-23 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ................5-1 Accelerator Pedal Removal ..........................
- Page 7 Front Wheel Free Play Inspection ......................7-13 Front Wheel Bearings and Hub Removal....................7-13 Front Wheel Bearings and Hub Installation ....................7-14 SECTION 8 – WHEELS AND TIRES ........................8-1 General Information ............................8-1 Wheels ................................. 8-2 Wheel Removal ............................8-2 Wheel Installation ............................
- Page 8 Neutral Switch Removal ........................... 12-1 Neutral Switch Installation ........................12-2 Carburetor Solenoid............................. 12-2 Carburetor Solenoid Removal........................12-2 Carburetor Solenoid Installation........................ 12-3 Voltage Regulator ............................12-3 Voltage Regulator Removal ........................12-3 Voltage Regulator Installation ........................12-4 Warning Lights ............................12-5 Warning Light Removal ..........................12-5 Warning Light Installation .........................
- Page 9 Carbon Canister Installation ........................14-10 SECTION 15 – EXHAUST SYSTEM ......................... 15-1 Muffler Removal ............................15-1 Muffler Installation............................15-1 Exhaust Pipe Removal..........................15-2 Exhaust Pipe Installation ..........................15-2 SECTION 16 – FRONT DIFFERENTIAL ......................16-1 Front Differential Removal ..........................16-1 Front Differential Installation ......................... 16-3 Front Halfshaft Removal..........................
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Page 11: Section 1 - Safety
SECTION 1 – SAFETY SAFETY DETAILS To ensure the safety of those servicing these vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION. These special statements relate to specific safety issues, and must be read, understood, and heeded before proceeding with procedures. -
Page 12: General Warning
General Warning SAFETY GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Service technicians should become familiar with these general safety statements. Also, other specific safety statements appear throughout this manual and on the vehicle. DANGER •... -
Page 13: Disabling The Vehicle
SAFETY General Warning WARNING • Moving parts! Do not attempt to service the vehicle while it is running. • Ensure battery connections are clean and properly tightened. See Battery on page 12-12. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns. -
Page 14: Disconnecting The Battery - Gasoline Vehicles
General Warning SAFETY DISCONNECTING THE BATTERY – GASOLINE VEHICLES Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the battery cables, negative (–) cable first, as shown (Figure 1-1). Disconnect the spark plug wire(s) from the spark plug(s). (–) 1. -
Page 15: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS SPECIFICATIONS HUV 4214 HUV 4414 HUV 4414X POWER SOURCE Gasoline Gasoline Gasoline Engine: 4-cycle OHV, 480 cc, 14.0 maximum HP @3600 RPM (per SAE J 1940/1349), • • • twin-cylinder, air-cooled, with pressure lubrication system Fuel system: Down-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump •... - Page 16 General Warning VEHICLE SPECIFICATIONS SPECIFICATIONS HUV 4214 HUV 4414 HUV 4414X Turning Radius 139 in. (354 cm) Load bed height 32 in. (81.3 cm) 34 x 47 x 10 in. Load bed size (box bed inside dimensions) (86.4 x 119.4 x 25.4 cm) (9.25 cubic feet) Maximum payload capacity (level surface only) 425 lb.
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Page 17: Section 3 - General Information
SECTION 3 – GENERAL INFORMATION DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. Throughout this manual, important features unique to each model are highlighted. The manufacturer recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s). Refer to the owner’s manual provided with the vehicle for information on the following topics: •... -
Page 18: Storage
Storage GENERAL INFORMATION SERIAL NUMBER DH0601-123456 7349 ST ATESVILLE RD. CHARLOTTE, NC 28269 Figure 3-1 Serial Number Decal STORAGE See General Warning on page 1-2. DANGER • Never attempt to drain gasoline when the engine is hot or while it is running. •... -
Page 19: Preparing The Vehicle For Extended Storage
GENERAL INFORMATION Storage CAUTION • Batteries in a low state of charge will freeze at low temperatures. PREPARING THE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that the tires are supporting only the weight of the vehicle. Store the vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician. -
Page 20: Returning The Stored Vehicle To Service
Lifting The Vehicle GENERAL INFORMATION Adjust the tires to the recommended tire pressure. See Section 2 – Vehicle Specifications. 10. Perform semiannual periodic lubrication. See Periodic Maintenance on page 10-1. 11. Thoroughly clean the front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle. 12. -
Page 21: Lifting Only The Rear
GENERAL INFORMATION Lifting The Vehicle 1026 Figure 3-3 Front Jack Stand Placement LIFTING ONLY THE REAR Place vehicle on a level surface. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake. -
Page 22: Lifting The Entire Vehicle
Using a Booster Battery (Jump Starting) GENERAL INFORMATION LIFTING THE ENTIRE VEHICLE Place vehicle on a level surface. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake. Chock the wheels. Disconnect battery and spark plug wire(s). - Page 23 GENERAL INFORMATION Using a Booster Battery (Jump Starting) Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal of the solenoid (Figure 3-6, Page 3-7). Connect the end of the second cable to the negative (-) terminal of the booster battery.
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Page 25: Section 4 - Body And Trim
SECTION 4 – BODY AND TRIM DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. CLEANING THE VEHICLE See General Warning on page 1-2. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats. -
Page 26: Front Body Repair
Front Body Repair BODY AND TRIM FRONT BODY REPAIR See General Warning on page 1-2. STRESS LINES OR STREAKS Repeatedly flexing the front body may cause white stress lines or streaks in the finish. To remove them: Hold a heat gun 12 inches (30 cm) away from the affected area, with the gun on its lowest heat setting. Slowly wave the heat gun back and forth over the affected area until the streak fades. -
Page 27: Small Scratches That Cannot Be Buffed Out
BODY AND TRIM Front Body Repair SMALL SCRATCHES THAT CANNOT BE BUFFED OUT Thoroughly clean the affected area and then dry. Using 240 grit or finer sandpaper, lightly sand scratch to feather edges. Finish sand scratch with 320 grit or finer paper to remove gloss from surface. -
Page 28: Front Body
Front Body BODY AND TRIM FRONT BODY See General Warning on page 1-2. FRONT FASCIA REMOVAL 1062 Figure 4-1 Front Fascia Removal – under side of outer ends of front fascia Remove the two torx-head screws that secure the front of the each fender to the under side outer ends of the fascia (Figure 4-1, Page 4-4). -
Page 29: Front Fascia Installation
BODY AND TRIM Front Body 1054 Figure 4-3 Front Fascia Removal – pulling fascia forward Grip fascia, lift slightly to disengage the front fascia hook and pull fascia forward slightly to expose the headlight wiring (Figure 4-3, Page 4-5). 1053 Figure 4-4 Front Fascia Removal –... -
Page 30: Front Cowl Removal
Front Body BODY AND TRIM FRONT COWL REMOVAL 1062 Figure 4-5 Front Cowl Removal – under side of outer ends of front fascia Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the two torx-head screws that secure the front of each fender to the lower corner of the fascia (Figure 4-5, Page 4-6). - Page 31 BODY AND TRIM Front Body 1158 Figure 4-7 Front Cowl Removal – loosening lower fascia mounting frame bolts Loosen, but do not remove, lower front fascia mounting frame bolts (Figure 4-7, Page 4-7). 1157 Figure 4-8 Front Cowl Removal – unbolting upper fascia mounting frame Remove upper front fascia mounting frame bolts (Figure 4-8, Page 4-7).
- Page 32 Front Body BODY AND TRIM 1137 Figure 4-9 Front Cowl Removal – separating cowl from dash groove Grip cowl and pull cowl forward slightly to disengage the cowl from the dash groove (Figure 4-9, Page 4-8). 1138 Figure 4-10 Front Cowl Removal – lift rear of cowl to disengage edges of cowl from dash Lift cowl slightly and continue to disengage edges of cowl from dash (Figure 4-10, Page 4-8).
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Page 33: Front Cowl Installation
BODY AND TRIM Front Body 1139 Figure 4-11 Front Cowl Removal – disengage cowl from fender grooves Grip cowl, lift and disengage edges of cowl from fender grooves (Figure 4-11, Page 4-9). 1140 Figure 4-12 Front Cowl Removal – lift off cowl Lift off cowl and remove from vehicle (Figure 4-12, Page 4-9). -
Page 34: Instrument Panel Removal
Front Body BODY AND TRIM INSTRUMENT PANEL REMOVAL Remove cowl. See Front Cowl Removal on page 4-6. Remove steering wheel. See Steering Wheel Removal on page 7-1. Remove knobs from shifting levers. Disconnect wiring harness from components mounted in instrument panel. At engine, loosen choke cable clamp (Figure 4-13, Page 4-10) and disengage choke cable (Figure 4-14, Page 4-10). -
Page 35: Instrument Panel Installation
BODY AND TRIM Front Body INSTRUMENT PANEL INSTALLATION Install instrument panel in the reverse order of removal. Tighten instrument panel hardware to 22 in-lb (2.5 N·m). FRONT FENDER REMOVAL Remove cowl. See Front Cowl Removal on page 4-6. Remove ROPS. See ROPS Removal on page 4-16. Loosen instrument panel by removing four screws that secure the top of the instrument panel to the top of the instrument panel support frame (Figure 4-17, Page 4-11) and removing the two bolts that secure the bottom of the instrument to the frame (Figure 4-18, Page 4-11). -
Page 36: Front Fender Installation
Front Body BODY AND TRIM 1173 Figure 4-19 Front Fender Hardware – removal Drill out rivets that secure the bottom of the front fenders to the frame (Figure 4-20, Page 4-12). 1178 Figure 4-20 Front Fender Hardware – rivet removal Pull the instrument panel back enough to free front fender. -
Page 37: Under Pedal Closeout Panel Installation
BODY AND TRIM Under Seat Closeout Panels Pull the closeout panel back and down passing it over the pedals. Remove closeout panel from vehicle. 1179 Figure 4-21 Under Pedal Closeout Panel Removal UNDER PEDAL CLOSEOUT PANEL INSTALLATION Install under pedal closeout panel in the reverse order of removal. UNDER SEAT CLOSEOUT PANELS See General Warning on page 1-2. - Page 38 Under Seat Closeout Panels BODY AND TRIM 1. Locking Pin 2. Bed Locking Pin Holes Figure 4-22 Bed Locking Pin 1134 Figure 4-23 Center Closeout Panel Removal – flex and lift front lower lip Remove the two bolts that secure the top of the side panels and the under seat closeout panels to the frame (Figure 4-24, Page 4-14).
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Page 39: Under Seat Closeout Panel Installation
BODY AND TRIM Under Seat Closeout Panels Figure 4-26 Closeout Panel Removal – rotate to remove Remove outer closeout panels from vehicle. UNDER SEAT CLOSEOUT PANEL INSTALLATION Install under seat closeout panels in the reverse order of removal. Tighten bolts to 22 in-lb (2.5 N·m). Connect battery and spark plug wire(s). -
Page 40: Rops (Roll Over Protective Structure)
ROPS (Roll Over Protective Structure) BODY AND TRIM ROPS (ROLL OVER PROTECTIVE STRUCTURE) See General Warning on page 1-2. ROPS REMOVAL See General Warning on page 1-2. NOTE: ROPS removal and installation will be easier with a assistant. Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2) (Figure 4-27, Page 4-16). - Page 41 BODY AND TRIM ROPS (Roll Over Protective Structure) K-00107.eps Figure 4-28 ROPS 2009-2010 HUV 4214, HUV 4414, and HUV 4414X Maintenance and Service Manual Page 4-17...
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Page 42: Rops Installation
ROPS (Roll Over Protective Structure) BODY AND TRIM ROPS INSTALLATION NOTE: Do not tighten the hardware until after the ROPS assembly is competed. K-00103.eps K-00104.eps Figure 4-29 Side-Tube and Front Support Figure 4-30 Side-Tube and Seat Back Support Position the ROPS side-tube (1) to the drivers-side of the vehicle (Figure 4-28, Page 4-17). Tilt the top of the side-tube (1) forward while inserting the side tube support (2) into the (vehicle) frame support (3) (to the outside of the dashboard (4) (Figure 4-29, Page 4-18). -
Page 43: Side Panel
BODY AND TRIM Side Panel CAUTION • Exceeding the maximum torque value could result in damage to the ROPS tubing and stripped thread on the hardware. SIDE PANEL See General Warning on page 1-2. SIDE PANEL REMOVAL 1. Locking Pin 2. Bed Locking Pin Holes K-00221 Figure 4-31 Bed Locking Pin Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2) (Figure... -
Page 44: Side Panel Installation
Under Seat Center Panel BODY AND TRIM Remove ROPS. See ROPS Removal on page 4-16. 1159 Figure 4-33 Side Panel Removal Remove the hardware securing the cargo bed rubber bumper. Remove the bumper to release the side panel support bracket (Figure 4-33, Page 4-20). Remove side panel from vehicle. -
Page 45: Under Seat Center Panel Installation
BODY AND TRIM Rear Fender 1040 1041 Figure 4-34 Under Seat Center Panel Removal Figure 4-35 Under Seat Center Panel Removed From Vehicle UNDER SEAT CENTER PANEL INSTALLATION Install under seat center panel in the reverse order of removal. Tighten bolts to 22 in-lb (2.5 N·m). REAR FENDER See General Warning on page 1-2. -
Page 46: Rear Fender Installation
Cargo Bed BODY AND TRIM 1. Locking Pin 2. Bed Locking Pin Holes K-00221 1154 Figure 4-36 Bed Locking Pin Figure 4-37 Rear Fender Removal Remove fender from vehicle. REAR FENDER INSTALLATION Install rear fender in the reverse order of removal. Tighten bolts to 35 in-lb (4.0 N·m). -
Page 47: Cargo Bed Installation
BODY AND TRIM Cargo Bed 1393 Figure 4-38 Cargo Bed Pivot Bolts Lower the cargo bed into the lowest position, but do not engage the cargo bed latch. Remove the two cargo bed mounting lock nuts, washers and pivot bolts. With the help of an assistant, lift the cargo bed and remove from vehicle. -
Page 49: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. ACCELERATOR PEDAL REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the under-pedal closeout panel. - Page 50 Accelerator Pedal Removal ACCELERATOR AND BRAKE PEDAL GROUP 1023 Figure 5-3 Bed Locking Pin Figure 5-4 Remove Exhaust Pipe Heat Shield Detach accelerator cable extension spring(s) (Figure 5-5, Page 5-2). See following NOTE. NOTE: Later models have a second spring attached to a unique cable end bolt that is taller and grooved. Loosen cable clamp that secures accelerator cable (Figure 5-6, Page 5-2).
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Page 51: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Installation 1195 Figure 5-7 Remove Bow-Tie Locking Pin and Washer Remove rue pin and clevis pin securing master cylinder push rod to brake pedal (Figure 5-20, Page 5-8). 10. Remove hardware securing the pedal group assembly to chassis (Figure 5-8, Page 5-3) and (Figure 5-9, Page 5-3). -
Page 52: Accelerator Cable Removal
Accelerator Cable Removal ACCELERATOR AND BRAKE PEDAL GROUP Adjust accelerator cable. See Accelerator Cable Adjustment on page 5-7. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. 2 1/4 in. (57 mm) 1287 Figure 5-10 Accelerator Pedal Return Spring Height ACCELERATOR CABLE REMOVAL See General Warning on page 1-2. - Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Cable Removal 1. Locking Pin 2. Bed Locking Pin Holes K-00221 1023 Figure 5-11 Bed Locking Pin Figure 5-12 Remove Exhaust Heat Shield Detach accelerator cable extension spring(s) (Figure 5-13, Page 5-5). See following NOTE. NOTE: Later models have a second spring attached to a unique cable end bolt that is taller and grooved.
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Page 54: Accelerator Cable Installation
Accelerator Cable Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-15 Disconnect Cable End From Engine (bolt may Figure 5-16 Disconnect Z-Shaped Cable End From Pedal differ from shown) ACCELERATOR CABLE INSTALLATION NOTE: A replacement accelerator cable (P/N N/A) is now available for vehicles that may exhibit intermittent binding or sticking during operation in cold environments if moisture gets into the cable housing. -
Page 55: Accelerator Cable Adjustment
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Cable Adjustment CAUTION • Failure to remove burrs will damage the cable bellows during installation. 2.5. Paint the inside of the enlarged hole to prevent corrosion. 2.6. Secure the hydraulic brake hose in its original location with clamp. 2.7. -
Page 56: Brake Pedal Removal
Brake Pedal Removal ACCELERATOR AND BRAKE PEDAL GROUP 2315 2316 Figure 5-17 Fully Turn Throttle Bellcrank Until It Contacts Figure 5-18 Correct Throttle Bellcrank Position With Accelerator Pedal To Floor BRAKE PEDAL REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the under-pedal closeout panel. -
Page 57: Brake Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Installation Remove bow-tie locking pins and washers securing each end of brake pedal pivot rod to bracket (Figure 5-21, Page 5-9). Slide pedal to one side and remove from vehicle. 1192 Figure 5-21 Remove Brake Pedal Bow-Tie Locking Pins BRAKE PEDAL INSTALLATION Maneuver brake pedal into position in bracket and secure with washers and bow-tie locking pins. -
Page 59: Section 6 - Brakes
SECTION 6 – BRAKES GENERAL INFORMATION DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. CAUTION • Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary. This section contains procedures for inspection, troubleshooting, removal, installation, maintenance, and regular servicing of the hydraulic brake system.