2009-2010 HUV 4214, HUV
4414, and HUV 4414X
Maintenance and Service
Manual
Gasoline Utility Vehicles
Manual Number 525 88 85-02
Edition Code 0309C0211B
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 ...
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Page 3: ... 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 WARNING Read See 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 manu...
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Page 5: ...e Deformations 4 2 Minor Scratches and Surface Blemishes 4 2 Small Scratches That Cannot Be Buffed Out 4 3 Touch Up Paint Color Chart 4 3 Gouges Punctures Tears Large Scratches and Abrasions 4 3 Front Body 4 4 Front Fascia Removal 4 4 Front Fascia Installation 4 5 Front Cowl Removal 4 6 Front Cowl Installation 4 9 Instrument Panel Removal 4 10 Instrument Panel Installation 4 11 Front Fender Remova...
Page 6: ... 6 16 Vacuum Bleeding of Brakes on a DOT 5 Fluid Filled System 6 17 Manual Bleeding of Brakes on a DOT 5 Fluid Filled System 6 17 Refilling the Hydraulic System 6 18 Park Brake System 6 19 Park Brake Cable Removal 6 19 Park Brake Cable Installation 6 23 Park Brake Handle Removal 6 25 Park Brake Handle Installation 6 25 Park Brake Adjustment 6 25 SECTION 7 STEERING AND FRONT SUSPENSION 7 1 Steering...
Page 7: ...on and Daily Safety Checklist 10 2 Performance Inspection 10 3 Periodic Service Schedule 10 3 Periodic Lubrication Schedule 10 5 Brake Fluid Reservoir 10 6 Engine Oil 10 6 Engine Oil Level Check 10 6 Engine Oil and Filter Change 10 7 Oil Viscosity 10 10 Spark Plugs 10 10 Spark Plug Cleaning And Inspection 10 10 Spark Plug Gap Inspection 10 10 Gearcase Lubrication 10 10 Lubrication Level Check Fron...
Page 8: ...harge Coil 12 9 Ignition Coil And or Charge Coil Removal 12 9 Oil Pressure Sensor 12 9 Headlights 12 10 Headlight Bulb Removal 12 10 Headlight Bulb Installation 12 10 Wire Harness Diodes 12 11 Diode Removal 12 11 Diode Installation 12 11 Battery 12 12 General Information 12 12 SECTION 13 ENGINE 13 1 Engine Removal 13 1 Engine Installation 13 5 Engine RPM Adjustment 13 5 Vehicle Creep 13 5 Idle Spe...
Page 9: ...al Lock Cable Adjustment 17 9 SECTION 18 CLUTCHES 18 1 Clutch Troubleshooting 18 1 Outer Clutch Cover 18 2 Outer Clutch Cover Removal 18 2 Outer Clutch Cover Installation 18 3 Drive Belt 18 3 Drive Belt Removal 18 3 Drive Belt Installation 18 5 Drive Clutch 18 5 Drive Clutch Removal 18 5 Drive Clutch Cleaning and Inspection 18 6 Drive Clutch Disassembly 18 7 Drive Clutch Component Inspection 18 7 ...
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Page 11: ...RED WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death The color associated with Warning is ORANGE CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury The color associated with Caution is YELLOW MACHINE SAFETY CAUTION A CAUTION without the safety alert symbol indicates a po...
Page 12: ...ab Do not run the engine in a parked vehicle without proper cab ventilation Move to fresh air if you feel nausea headache dizziness drowsiness or weakness Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle Only trained technicians should service or repair the vehicle Anyone doing even simple repai...
Page 13: ...ck the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The four wheel drive system may engage any wheel s front or rear depending on the mode select...
Page 14: ...ove positive battery cable Connect battery cables in reverse order 821 Figure 1 1 Battery Cable Removal 795 Figure 1 2 4x4 Drive Warning CONNECTING THE BATTERY GASOLINE VEHICLES 1 Connect the battery cables positive cable first 2 Tighten battery terminals to 80 in lb 9 N m 3 Coat terminals with Battery Terminal Protector Spray P N 603 00 00 03 to minimize corrosion 4 Connect the spark plug wire s ...
Page 15: ...ke pads and discs on each wheel with separate hand operated park brake BODY CHASSIS Frame Chassis Box tube steel Side and rear body Polypropylene Cargo bed Powder coated steel Front body TPO ThermoPlastic Olefin Tires All Terrain 25 x 9 12 front and rear tubeless 4 ply rated load range Mud 25 x 9 12 front and rear tubeless 4 ply rated load range Tires All Terrain 25 x 9 12 front 25 x 11 12 rear tu...
Page 16: ...y 925 lb 420 kg Maximum gross vehicle weight fully loaded vehicle including accessories 2135 lb 968 kg Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase with filter SAE 10W 30 API classification SJ 1 5 qt 1 4 L Front differential 80W90 gear oil 5 5 oz 170 mL Rear transaxle 10W 30 SF SG SH 1 gal 3 79 L Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml Fuel tank unleaded gasoline 5 2 g...
Page 17: ...tion Warranties MODEL IDENTIFICATION SERIAL NUMBER The serial number of the vehicle is printed on a bar code decal mounted on the frame below the steering wheel Example DH0601 123456 Figure 3 1 Page 3 2 There is also a second serial number decal mounted on the rear body frame above the engine See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries T...
Page 18: ...from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Turn the fuel shut off valve 1 the closed OFF position Figure 3 2...
Page 19: ...sition Figure 3 2 Page 3 3 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 823 Figure 3 2 Fuel Shut off Valve 4 4 Disconnect the fuel vent line from the fuel tank vent nipple 4 5 Plug the fuel tank vent nipple so that it is air tight The manufacturer recommends using a slip on vinyl cap 5 Remove both spark plugs a...
Page 20: ...hoke can result in a fouled spark plug and engine failure 5 Place the Forward Reverse handle in the NEUTRAL position Crank the engine until fuel is pumped into the carburetor and the fuel lines and the engine starts Turn the engine off See following NOTE NOTE Due to the oil added to the gasoline engine in preparation for storage the engine may smoke excessively for a short time when it is run for ...
Page 21: ...ke Chock the front wheels 3 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 4 If removing wheel loosen the rear wheel lug nuts 5 Lift rear of vehicle and support on jack stands Figure 3 4 Page 3 5 See WARNING Lift only one end in General Warning on page 1 2 6 Remove the wheel 1024 Figure 3 4 Rear Jack Stand Placement 2009 2010 HUV 4214 HUV 4414 ...
Page 22: ...ervicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries When jumping from a booster battery make the final connection the negative cable Do not jump start or charge a frozen or damaged battery Unplug charger before connecting or disconnecting cables to the battery Never lean over battery while boosting testing or charging If it is necessary to use a booster...
Page 23: ...led vehicle battery Figure 3 7 Page 3 7 7 Start the engine After the engine has started remove the cable from the negative terminal of the disabled vehicle battery first Next remove the other end of the cable from the negative terminal of the booster battery Then remove the cable from the positive terminal of the solenoid followed by the other end of the cable from the positive terminal of the boo...
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Page 25: ...mponents to moisture Moisture entering electrical components can result in water damage and subsequent component failure The seats of the vehicle will last longer with proper cleaning To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth Use a soft bristle brush to clean areas that are especially soiled Use the following guidelines Light Soilin...
Page 26: ...pact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape returns Under no circumstance should the gun be held closer than 6 inches 15 cm to the body See precedin...
Page 27: ...ilable from the Service Parts Dept see following color chart apply paint to the scratch Multiple layers of paint may be required to fill the scratch 4 Allow paint to dry completely approximately 10 20 minutes then lightly buff the imperfection 5 Apply wax to the entire body part to restore luster and weather protection TOUCH UP PAINT COLOR CHART COLOR PART NUMBER Beige 101997201 White 101997202 Re...
Page 28: ... 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 1 2 1392 Figure 4 2 Front Fascia Hardware Removal 2 Remove the lower two bolts 1 from front fascia Figure 4 2 Page 4 4 3 Remove the upper two bolts 2 from front fascia Page 4 4 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual ...
Page 29: ...remove front fascia from vehicle FRONT FASCIA INSTALLATION 1 Move front fascia in place and connect headlight wiring Figure 4 4 Page 4 5 2 Carefully insert molded in lower front fascia retaining hook into receiving slot in the fascia mounting frame 3 Secure the fascia to the fascia mounting frame using four bolts Tighten the hardware to 22 in lb 2 5 N m 4 Secure the front of the each fender to the...
Page 30: ...soline Vehicles on page 1 4 2 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 1135 Figure 4 6 Front Cowl Removal removing under hood bolts 3 Remove bolts located under hood inside front cargo compartment on front top edge Figure 4 6 Page 4 6 Page 4 6 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual ...
Page 31: ... 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 5 Remove upper front fascia mounting frame bolts Figure 4 8 Page 4 7 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual Page 4 7 ...
Page 32: ...ghtly 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 7 Lift cowl slightly and continue to disengage edges of cowl from dash Figure 4 10 Page 4 8 Page 4 8 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual ...
Page 33: ...val lift off cowl 9 Lift off cowl and remove from vehicle Figure 4 12 Page 4 9 FRONT COWL INSTALLATION 1 Front cowl installation is reverse of cowl removal 2 Tighten fascia mounting frame bolts to 11 ft lb 15 N m 3 Tighten front fascia bolts to 22 in lb 2 5 N m 4 Tighten lower corner of the fascia torx head screws to 22 in lb 2 5 N m 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Servic...
Page 34: ... Disengage 6 Remove wire ties that secure the choke cable to the frame 7 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 15 Page 4 10 and removing the two bolts that secure the bottom of the instrument to the frame Figure 4 16 Page 4 10 1174 Figure 4 15 Instrument Panel Hardware screws 1177 Figure...
Page 35: ...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 1174 Figure 4 17 Instrument Panel Hardware screws 1177 Figure 4 18 Instrument Panel Hardware bolts NOTE It may NOT be necessary to completely remove the instrument panel from vehicle in order to remove fro...
Page 36: ...Pull the instrument panel back enough to free front fender 7 Remove front fender from vehicle FRONT FENDER INSTALLATION 1 Install front fender in the reverse order of removal 2 Tighten front fender hardware to 22 in lb 2 5 N m UNDER PEDAL CLOSEOUT PANEL REMOVAL 1 Drill out rivets that secure the closeout panel to the frame Figure 4 21 Page 4 13 Page 4 12 2009 2010 HUV 4214 HUV 4414 and HUV 4414X M...
Page 37: ...PANEL REMOVAL 1 Raise the cargo bed and engage the cargo bed lock pin 1 located at the driver side cargo bed hinge 2 Figure 4 22 Page 4 14 2 Remove seat bottom from vehicle 3 Locate the center closeout panel Flex closeout panel to disengage front lower lip that rests behind seat belt anchors and rotate up and back towards rear of vehicle Remove center closeout panel from vehicle Figure 4 23 Page 4...
Page 38: ... the frame Figure 4 24 Page 4 14 6 Manipulate and flex outer closeout panels to unclip them from the lower seat support frame Figure 4 25 Page 4 14 1073 Figure 4 24 Closeout Panel Removal remove side panel bolts 974 Figure 4 25 Closeout Panel Removal unclip from lower seat support frame 7 Rotate each outer closeout panel until it can be easily removed from the seat back support frame Figure 4 26 P...
Page 39: ...rom vehicle UNDER SEAT CLOSEOUT PANEL INSTALLATION 1 Install under seat closeout panels in the reverse order of removal Tighten bolts to 22 in lb 2 5 N m 2 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual Page 4 15 ...
Page 40: ...7 3 Loosen the cross tube hardware 12 13 15 16 and forward support hardware 5 4 Remove the top rear cross tube hardware and the top rear cross tube 14 from the vehicle 5 Remove the top front cross tube hardware and the top front cross tube 11 from the vehicle 6 Remove the hardware and the top front cross tube 11 from the vehicle 7 Remove the seat back support hardware 7 8 8 Remove the hardware 9 1...
Page 41: ...ND TRIM ROPS Roll Over Protective Structure 4 1 15 16 15 x 14 14 16 11 18 9 10 12 13 21 20 5 8 7 K 00107 eps Figure 4 28 ROPS 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual Page 4 17 ...
Page 42: ...E NOTE Make sure the bolt heads are oriented to the inside of the ROPS structure It may be necessary to tap the ROPS with a rubber mallet in order for it to align properly 5 Loosely secure the bottom of the side tube to the two tabs 18 on the vehicle with two M10 x 1 5 65 black flanged head bolts 9 and two M10 x 1 5 flanged locknuts 10 Figure 4 28 Page 4 17 6 Repeat steps 2 1 through 2 5 on the pa...
Page 43: ...L 1 2 1 Locking Pin 2 Bed Locking Pin Holes K 00221 Figure 4 31 Bed Locking Pin 1 Raise the cargo bed and engage the cargo bed lock pin 1 located at the driver side cargo bed hinge 2 Figure 4 31 Page 4 19 1073 Figure 4 32 Side Panel Removal 2 Remove the four bolts that secure the side panel to the frame Figure 4 32 Page 4 19 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and Service Manual ...
Page 44: ...l side panel in the reverse order of removal 2 Tighten side panel bolts to 22 in lb 2 5 N m Tighten cargo bed rubber bumper bolts to 84 in lb 9 5 N m 3 Install ROPS See ROPS Installation on page 4 18 UNDER SEAT CENTER PANEL See General Warning on page 1 2 UNDER SEAT CENTER PANEL REMOVAL 1 Remove seat bottom from vehicle 2 Remove bolts from under seat center panel Figure 4 34 Page 4 21 3 Remove cen...
Page 45: ...se order of removal Tighten bolts to 22 in lb 2 5 N m REAR FENDER See General Warning on page 1 2 REAR FENDER REMOVAL 1 Raise the cargo bed and engage the cargo bed lock pin located at the driver side cargo bed hinge Figure 4 36 Page 4 22 2 Remove the four bolts that secure the fender to the underside of the cargo bed Figure 4 37 Page 4 22 2009 2010 HUV 4214 HUV 4414 and HUV 4414X Maintenance and ...
Page 46: ...of removal 2 Tighten bolts to 35 in lb 4 0 N m CARGO BED See General Warning on page 1 2 NOTE Cargo bed removal and installation will be easier with an assistant CARGO BED REMOVAL 1 Raise the cargo bed and engage the cargo bed lock pin 1 located at the driver side cargo bed hinge Figure 4 38 Page 4 23 2 Loosen the cargo bed pivot bolts 2 but do not remove Page 4 22 2009 2010 HUV 4214 HUV 4414 and ...
Page 47: ... of an assistant lift the cargo bed and place it in the lowered position on the vehicle Align the cargo bed hinge tabs with mounting holes in the frame rails Secure the cargo bed using the two cargo bed mounting lock nuts washers and bolts Install bed locking pin into hinge to keep the bed from falling Tighten the hardware to 15 ft lb 20 4 N m 2 Place bed locking pin in the storage holes and then ...
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Page 49: ...nts as a result of the drilling operation 3 Disconnect the Z shaped end 1 of the accelerator cable from the pedal Figure 5 2 Page 5 1 See following NOTE NOTE If the accelerator cable does not have enough slack to allow disconnection at the pedal it may be necessary to disconnect the accelerator cable at the engine 1179 Figure 5 1 Pedal Group closeout panel 952 Figure 5 2 Pedal Group accelerator ca...
Page 50: ...osen cable clamp that secures accelerator cable Figure 5 6 Page 5 2 This will allow additional travel so that the cable can be disconnected at pedal 982 Figure 5 5 Detach Accelerator Cable Extension Spring s later models have a second spring attached to tall cable end bolt 983 Figure 5 6 Accelerator Pedal Removal pedal assembly hardware 8 Remove bow tie locking pin and washer securing each end of ...
Page 51: ...hardware 1191 Figure 5 9 Accelerator Pedal Removal pedal assembly hardware 11 With pedal group loose maneuver it to a position that will allow the accelerator pedal return spring to be detached from the bracket Loosen spring retaining nut if necessary 12 Slide accelerator pedal out of pedal group bracket ACCELERATOR PEDAL INSTALLATION 1 Installation is reverse of removal procedure 2 Check return s...
Page 52: ...TOR CABLE REMOVAL See General Warning on page 1 2 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 3 Raise the cargo bed and engage the cargo bed lock pin 1 located at the driver side cargo bed hinge 2 Figure 5 11 Page 5 5 4 Remove the two screws securing the heat shield to the exhaust...
Page 53: ...l so that the cable can be disconnected at pedal 982 Figure 5 13 Detach Accelerator Cable Extension Spring s later models have a second spring attached to tall cable end bolt 983 Figure 5 14 Loosen Cable Clamp 7 Remove the bolt securing the cable end to the bellcrank Figure 5 15 Page 5 6 8 Under the front cowl disconnect the Z shaped end of the accelerator cable from the pedal Figure 5 16 Page 5 6...
Page 54: ...ng replacement accelerator cable P N N A perform these additional steps 2 1 Remove front cowl to access cable mounting bracket See Front Cowl Removal on page 4 6 2 2 Move the hydraulic brake hose located directly beneath the cable mounting bracket to prevent accidently puncturing the hose while drilling Loosen the hose clamp and rotate the brake hose out of the way to allow sufficient clearance fo...
Page 55: ... spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 3 Raise the cargo bed and secure with the bed locking pin See Cargo Bed Section 4 Page 4 22 4 Remove the exhaust pipe heat shield 5 Place a 3 4 inch 19 mm thick spacer between the accelerator pedal and the floorboard 6 Push accelerator pedal down against the spacer and hold 7 Fully turn the engine throttle bellcrank aga...
Page 56: ...ttery Gasoline Vehicles on page 1 4 2 Remove the under pedal closeout panel Drill out rivets and carefully pull the panel out and down over the pedals Figure 5 19 Page 5 8 CAUTION Be sure not to damage any components as a result of the drilling operation 3 Remove rue pin and clevis pin securing master cylinder push rod to brake pedal Figure 5 20 Page 5 8 1179 Figure 5 19 Remove Closeout Panel 1193...
Page 57: ...nstall under pedal closeout panel with new rivets 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 BRAKE PEDAL ADJUSTMENT 1 Loosen the master cylinder rod and clevis jam nut 2 Rotate the master cylinder rod to extend or retract the clevis and brake pedal to the desired position 3 Tighten the jam nut to 168 in lb 19 N m 4 Perform all brake system insp...
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Page 59: ...OOTING See General Warning on page 1 2 BRAKE SYSTEM TROUBLESHOOTING The procedures used in making the checks provided in the following troubleshooting guide can be found in the referenced sections of this maintenance and service manual TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM COMPONENTS SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Excessive clearance between the disc and brake pads See Brake Pads and C...
