Husqvarna Huv4210 2005 series Manual

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2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual Page i

FOREWORD

Husqvarna vehicles are designed and built to provide the ultimate in performance efficiency; however, proper

maintenance and repair are essential for achieving maximum service life and continued safe and reliable

operation.

This manual provides detailed information for the maintenance and repair of the Husqvarna 4210 series vehi-

cles, and should be thoroughly reviewed prior to servicing the vehicle. The procedures provided must be

properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.

This manual was written for the trained technician who already possesses knowledge and skills in electrical

and mechanical repair. If the technician does not have such knowledge and skills, attempted service or

repairs to the vehicle may render the vehicle unsafe. For this reason, Husqvarna advises that all repairs and/

or service be performed by an authorized Husqvarna distributor/dealer representative or by a Husqvarna fac-

tory-trained technician.

It is the policy of Husqvarna to assist its distributors and dealers in continually updating their service knowl-

edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-

resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and

other service publications also represent Husqvarna’s continuing commitment to customer support.

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.

This manual effective June 13, 2005.

Page ii 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual

ý WARNING

• Read Section 1 – Safety before attempting any service on the vehicle.

• Before servicing vehicle, read complete section(s) and any referenced information that may

be relevant to the service or repair to be performed.

NOTE: This manual represents the most current information at the time of publication. Husqvarna is con-

tinually working to further improve its vehicles and other products. These improvements may affect

servicing procedures. Any modification and/or significant change in specifications or procedures

will be forwarded to all Husqvarna dealers and will, when applicable, appear in future editions of

this manual.

Husqvarna reserves the right to change specifications and designs at any time without notice and

without the obligation of making changes to units previously sold.

There are no warranties expressed or implied in this manual. See the limited warranty found in the

vehicle Owner’s Manual.

2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual Page iii

CONTENTS

SECTION 1 – SAFETY

General Warning ............................................................................................................................... 1-1

SECTION 2 – VEHICLE SPECIFICATIONS

SECTION 3 – GENERAL INFORMATION

Serial Number Identification .............................................................................................................. 3-1

Storage – Gasoline Vehicle .............................................................................................................. 3-2

Preparing the Gasoline Vehicle for Extended Off-Season Storage .............................................. 3-2

Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-3

Storage – Electric Vehicle ................................................................................................................. 3-4

Preparing the Electric Vehicle for Extended Off-Season Storage ................................................ 3-4

Returning the Stored Electric Vehicle to Service .......................................................................... 3-5

SECTION 4 – BODY AND TRIM

Cleaning the Vehicle ......................................................................................................................... 4-1

Seat Cleaning ............................................................................................................................... 4-1

Front and Rear Body Repair ............................................................................................................. 4-2

Minor Scratches and Surface Blemishes ...................................................................................... 4-2

Small Scratches That Cannot Be Buffed Out ............................................................................... 4-2

Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2

Touch-Up Paint Color Chart ......................................................................................................... 4-3

Front Body ........................................................................................................................................ 4-3

Bumper Removal .......................................................................................................................... 4-3

Bumper Installation ....................................................................................................................... 4-3

Brush Guard Removal .................................................................................................................. 4-4

Brush Guard Installation ............................................................................................................... 4-4

Front Body Removal ..................................................................................................................... 4-4

Dash Removal .............................................................................................................................. 4-4

Dash Installation ........................................................................................................................... 4-5

Front Body Installation .................................................................................................................. 4-5

Cargo Bed ......................................................................................................................................... 4-6

Cargo Bed Removal ..................................................................................................................... 4-6

Cargo Bed Installation .................................................................................................................. 4-6

Bed Latch Assembly ..................................................................................................................... 4-6

Bed Latch Assembly Installation ................................................................................................... 4-8

Page iv 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual

Seat Back Support Brackets ............................................................................................................ 4-8

Seat Back Support Bracket Removal ........................................................................................... 4-9

Seat Back Support Bracket Installation ........................................................................................ 4-9

Rear Body and Fenders ................................................................................................................... 4-10

Rear Body Removal ..................................................................................................................... 4-10

Forward/Reverse Switch .............................................................................................................. 4-11

Rear Fender Removal .................................................................................................................. 4-13

Rear Fender Installation ............................................................................................................... 4-13

Rear Body Installation .................................................................................................................. 4-13

Floor Mat .......................................................................................................................................... 4-14

Floor Mat Removal ....................................................................................................................... 4-14

Floor Mat Installation .................................................................................................................... 4-14

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP

Brake Pedal and Park Brake ............................................................................................................ 5-1

Brake Pedal Removal ................................................................................................................... 5-1

Brake Pedal Installation ................................................................................................................ 5-2

Park Brake Removal .................................................................................................................... 5-3

Park Brake Installation ................................................................................................................. 5-4

Accelerator Pedal – Gasoline Vehicles ............................................................................................ 5-5

Accelerator Pedal Removal .......................................................................................................... 5-5

Accelerator Pedal Installation ....................................................................................................... 5-7

Accelerator Pedal – Electric Vehicles .............................................................................................. 5-8

Accelerator Pedal Removal .......................................................................................................... 5-8

Accelerator Pedal Installation ....................................................................................................... 5-10

Pedal Group Adjustment – Gasoline Vehicle ................................................................................... 5-11

Pedal Group Adjustment – Electric Vehicles .................................................................................... 5-16

SECTION 6 – WHEEL BRAKE ASSEMBLIES

Brake Shoe Removal ....................................................................................................................... 6-1

Brake Assembly Cleaning ................................................................................................................ 6-5

Brake Shoe Installation .................................................................................................................... 6-6

Brake Adjustment ............................................................................................................................. 6-8

Brake Cluster Removal and Installation ........................................................................................... 6-8

Brake Cluster Installation ............................................................................................................. 6-9

Brake Cable Removal and Installation ............................................................................................. 6-9

SECTION 7 – STEERING AND FRONT SUSPENSION

General Information ......................................................................................................................... 7-1

2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual Page v

Steering Wheel ................................................................................................................................. 7-1

Steering Wheel Removal .............................................................................................................. 7-1

Steering Wheel Installation ........................................................................................................... 7-2

Steering Column ............................................................................................................................... 7-2

Steering Column Removal ............................................................................................................ 7-2

Steering Column Disassembly ...................................................................................................... 7-4

Steering Column Assembly .......................................................................................................... 7-4

Steering Column Installation ......................................................................................................... 7-5

Steering Adjustment ......................................................................................................................... 7-6

Rack and Pinion ................................................................................................................................ 7-7

Rack and Pinion Removal ............................................................................................................ 7-7

Rack and Pinion Disassembly ...................................................................................................... 7-7

Rack and Pinion Assembly ........................................................................................................... 7-10

Rack and Pinion Installation ......................................................................................................... 7-12

Tie Rod and Drag Link ...................................................................................................................... 7-12

Tie Rod and Drag Link Removal ................................................................................................... 7-12

Tie Rod and Drag Link Installation ................................................................................................ 7-12

Front Suspension .............................................................................................................................. 7-13

Lubrication .................................................................................................................................... 7-13

Wheel Alignment ........................................................................................................................... 7-13

Front Suspension Components ........................................................................................................ 7-15

Tapered Leaf Spring Removal ...................................................................................................... 7-15

Tapered Leaf Spring Installation ................................................................................................... 7-15

Kingpin and Steering Spindle Removal ........................................................................................ 7-16

Kingpin and Steering Spindle Installation ..................................................................................... 7-16

Delta A-Plate Removal ................................................................................................................. 7-16

Delta A-Plate Installation .............................................................................................................. 7-19

Shock Absorber Removal ............................................................................................................. 7-19

Shock Absorber Installation .......................................................................................................... 7-19

Front Wheel Bearings and Hubs ....................................................................................................... 7-19

Front Wheel Free Play Inspection ................................................................................................ 7-19

Front Hub Removal ....................................................................................................................... 7-19

Front Hub Installation .................................................................................................................... 7-20

SECTION 8 – WHEELS AND TIRES

General Information .......................................................................................................................... 8-1

Wheels .............................................................................................................................................. 8-1

Wheel Removal ............................................................................................................................ 8-1

Wheel Installation ......................................................................................................................... 8-1

Page vi 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual

Tires ................................................................................................................................................. 8-1

Tire Removal ................................................................................................................................ 8-1

Tire Repair .................................................................................................................................... 8-2

Tire Installation ............................................................................................................................. 8-3

SECTION 9 – REAR SUSPENSION

General Information ......................................................................................................................... 9-1

Shock Absorbers .............................................................................................................................. 9-1

Shock Absorber Removal and Inspection .................................................................................... 9-1

Shock Absorber Installation .......................................................................................................... 9-1

Leaf Springs ..................................................................................................................................... 9-1

Leaf Spring Removal .................................................................................................................... 9-1

Leaf Spring Installation ................................................................................................................. 9-4

SECTION 10 – PERIODIC MAINTENANCE

General Information ......................................................................................................................... 10-1

Periodic Service Schedules ............................................................................................................. 10-1

Periodic Lubrication Schedules ...................................................................................................... 10-4

Batteries – Electric Vehicles ............................................................................................................. 10-6

Battery Care ................................................................................................................................. 10-6

Battery Charger – Electric Vehicles .............................................................................................. 10-6

Charging Batteries ........................................................................................................................ 10-7

Plug and Receptacle .................................................................................................................... 10-8

Receptacle Fuse Link ................................................................................................................... 10-9

Battery – Gasoline Vehicles ............................................................................................................. 10-9

Engine Oil – Gasoline Vehicles ........................................................................................................ 10-10

Engine Oil Level Check ................................................................................................................ 10-10

Engine Oil And Filter Change ....................................................................................................... 10-11

Oil Viscosity .................................................................................................................................. 10-13

Fueling Instructions – Gasoline Vehicles ......................................................................................... 10-14

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHI-

CLE

Troubleshooting Guide ..................................................................................................................... 11-1

Electrical System .............................................................................................................................. 11-5

Lockout Cam .................................................................................................................................... 11-5

Wiring Diagrams ............................................................................................................................... 11-6

Circuit Testing .................................................................................................................................. 11-8

Test Procedures ............................................................................................................................... 11-8

Index of Test Procedures ............................................................................................................. 11-8

2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual Page vii

SECTION 12 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES

Starter/Generator .............................................................................................................................. 12-1

Voltage Regulator ............................................................................................................................. 12-11

Diode ................................................................................................................................................ 12-12

Key Switch ........................................................................................................................................ 12-14

Solenoid ............................................................................................................................................ 12-15

Fuse .................................................................................................................................................. 12-16

Lockout Cam Limit Switch ................................................................................................................ 12-17

Lockout Cam ..................................................................................................................................... 12-17

Reverse Warning Buzzer .................................................................................................................. 12-18

Reverse Buzzer Limit Switch ............................................................................................................ 12-19

Oil Warning Light .............................................................................................................................. 12-20

Fuel Gauge/Hour Meter .................................................................................................................... 12-21

Fuel Level Sending Unit .................................................................................................................... 12-22

RPM Limiter ...................................................................................................................................... 12-22

Ignition Coil ....................................................................................................................................... 12-23

Oil Level Sensor ............................................................................................................................... 12-26

Headlights ......................................................................................................................................... 12-27

Headlight Diode ................................................................................................................................ 12-28

Light Switch ...................................................................................................................................... 12-28

Battery .............................................................................................................................................. 12-29

Ground Cables .................................................................................................................................. 12-32

SECTION 13 – FE290 AND FE350 ENGINES

General Information .......................................................................................................................... 13-1

Before Servicing ........................................................................................................................... 13-1

Engine Rotation ............................................................................................................................ 13-1

Spark Plug .................................................................................................................................... 13-1

Cylinder Head ................................................................................................................................... 13-3

General Information ...................................................................................................................... 13-3

Breather Valve (Reed Valve) ........................................................................................................ 13-3

Crankcase ......................................................................................................................................... 13-3

Engine Removal ........................................................................................................................... 13-3

Crankcase Cover Removal ........................................................................................................... 13-3

Oil Level Sensor ........................................................................................................................... 13-5

Crankcase Cover Installation ........................................................................................................ 13-5

Ignition Coil and Flywheel ................................................................................................................. 13-6

Flywheel Installation ......................................................................................................................... 13-8

Page viii 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual

Engine Installation ............................................................................................................................ 13-9

Torque Specifications ................................................................................................................... 13-10

Adjustments and Settings ............................................................................................................ 13-10

SECTION 14 – FUEL SYSTEM: GASOLINE VEHICLE

General Information ......................................................................................................................... 14-1

Carburetor ........................................................................................................................................ 14-1

Main Jet Elevation/Size Chart ...................................................................................................... 14-2

Changing the Main Jet ................................................................................................................. 14-2

Engine Control Linkage .................................................................................................................... 14-5

General Information ...................................................................................................................... 14-5

Accelerator Rod ............................................................................................................................ 14-6

Governor Cable ............................................................................................................................ 14-8

Accelerator Cable ......................................................................................................................... 14-9

Closed Throttle or Idle Adjustment ............................................................................................... 14-11

Engine RPM Adjustment .............................................................................................................. 14-11

Choke and Air Intake System ........................................................................................................... 14-12

Choke Button Removal ................................................................................................................ 14-12

Choke Button Installation ............................................................................................................. 14-12

Air Box Removal ........................................................................................................................... 14-12

Air Box Installation ........................................................................................................................ 14-12

Intake Duct Removal .................................................................................................................... 14-13

Intake Duct Installation ................................................................................................................. 14-13

Air Filter ........................................................................................................................................ 14-15

Fuel Filters ....................................................................................................................................... 14-15

Fuel Filter Removal ...................................................................................................................... 14-15

Fuel Filter Installation ................................................................................................................... 14-17

Fuel Pump ........................................................................................................................................ 14-17

General Information ...................................................................................................................... 14-17

Fuel Pump Removal ..................................................................................................................... 14-17

Fuel Pump Disassembly ............................................................................................................... 14-18

Fuel Pump Cleaning and Inspection ............................................................................................ 14-18

Fuel Pump Assembly ................................................................................................................... 14-19

Fuel Pump Installation .................................................................................................................. 14-19

Fuel Tank ......................................................................................................................................... 14-20

General Information ...................................................................................................................... 14-20

Fuel Tank Removal ...................................................................................................................... 14-20

Fuel Tank Disposal ....................................................................................................................... 14-21

Fuel Tank Storage ........................................................................................................................ 14-22

Fuel Tank Installation ................................................................................................................... 14-22

Fuel Lines ......................................................................................................................................... 14-23