Husqvarna HUV4210 2005 Series Maintenance Service Manual
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Husqvarna HUV4210 2005 Series Maintenance Service Manual

Gasoline and electric vehicles 2005-2006
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  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ......................Storage – Gasoline Vehicle ......................Preparing the Gasoline Vehicle for Extended Off-Season Storage ..........Returning the Stored Gasoline Vehicle to Service ................ Storage –...
  • Page 6 Seat Back Support Brackets ......................Seat Back Support Bracket Removal ................... Seat Back Support Bracket Installation ..................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 ........................
  • Page 7 Steering Wheel ..........................Steering Wheel Removal ......................Steering Wheel Installation ......................Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ...................... Steering Column Assembly ......................Steering Column Installation ......................Steering Adjustment ......................... Rack and Pinion ..........................Rack and Pinion Removal ......................Rack and Pinion Disassembly ......................
  • Page 8 Tires ..............................Tire Removal ..........................Tire Repair ............................ Tire Installation ..........................SECTION 9 – REAR SUSPENSION General Information ......................... Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Leaf Springs ............................. Leaf Spring Removal ........................Leaf Spring Installation ......................... SECTION 10 –...
  • Page 9 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 ......................
  • Page 10 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 ........................
  • Page 11 Fuel Shut-Off Valve .......................... 14-24 SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES Muffler ............................... 15-1 Muffler Removal ..........................15-1 Muffler Installation ......................... 15-1 SECTION 16 – UNITIZED TRANSAXLE: GASOLINE VEHICLE General Information .......................... 16-1 Lubrication ............................ 16-2 Axle Shaft ............................16-2 Axle Shaft and Oil Seal Removal ....................
  • Page 12 SECTION 18 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE General Information ......................... 18-1 Wiring Diagram ..........................18-2 Troubleshooting ..........................18-4 Troubleshooting the Vehicle with the Diagnostic Handset ............18-4 Troubleshooting Guide 1 ......................18-5 Troubleshooting Guide 2 ......................18-8 Test Procedures ..........................18-10 Index of Test Procedures ......................
  • Page 13 Charging a Battery Pack that has Low Voltage ................20-12 SECTION 21 – BATTERY CHARGER: ELECTRIC VEHICLE Refer to the battery charger maintenance and service manual (Husqvarna 603 00 28-15). SECTION 22A – MOTOR (MODEL 5BC59JBS6365) General Information .......................... 22a-1 Motor Identification ...........................
  • Page 14 SECTION 22B – MOTOR (MODEL EJ4-4001) General Information ......................... 22b-1 Motor Identification ........................... 22b-1 External Motor Testing ........................22b-1 Motor ..............................22b-2 Motor Removal ..........................22b-2 Motor Disassembly ........................22b-4 Motor Component Testing and Inspection ..................22b-6 Armature Inspection and Testing ....................22b-6 Motor Frame and Field Windings Inspection ................

  • Page 15: Section 1 - Safety

    SECTION 1 – SAFETY 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 CAU- TION.
  • Page 16 SAFETY General Warning ý WARNING • 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 repairs or service should have knowledge and experience in electrical and mechanical repair.
  • Page 17 SAFETY General Warning ý WARNING • If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death. •...

  • Page 19: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS Electric Gasoline Electric Gasoline SPECIFICATIONS HUV4210- HUV4210- HUV4210-E HUV4210-G POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure • lubrication system Engine: 4-cycle OHV, 351cc, 11.0 hp rated, single-cylinder, air-cooled, with pressure •...
  • Page 20 VEHICLE SPECIFICATIONS Electric Gasoline Electric Gasoline SPECIFICATIONS HUV4210- HUV4210- HUV4210-E HUV4210-G 800 lb. Vehicle rated capacity: Level surface only (363 kg) Forward speed 17 mph (27 km) Standard seating capacity Liquid Capacities Transaxle 22 oz. (0.67 L) Engine crankcase (without filter) 32 oz.

  • Page 21: Section 3 - General Information

    SECTION 3 – GENERAL INFORMATION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. Important features unique to the different models covered in this manual are highlighted. It is recommended that the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 22: Storage - Gasoline Vehicle

    Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry and then coat them with Battery Terminal Protector Spray (Husqvarna 603 00 00-03). 2. Store 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 23: Returning The Stored Gasoline Vehicle To Service

    GENERAL INFORMATION Storage – Gasoline Vehicle CLOSED (OFF) POSITION VENT (SELECTOR IS ALIGNED SHUT-OFF WITH OFF MARKINGS ON THE SIDES OF VALVE) VALVE TO CARBURETOR VIEWED FROM SELECTOR VENT TUBES SIDE OF VALVE Figure 3-2 Fuel Tank, Vent, and Lines Figure 3-3 Fuel Shut-Off Valve –...

  • Page 24: Storage - Electric Vehicle

    Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry and then coat them with Battery Terminal Protector Spray (Husqvarna 603 00 00-03). 3. Store vehicle in a cool, dry place. This will minimize battery self-discharge.

  • Page 25: Returning The Stored Electric Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicle 4. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications. 5. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules, Section 10, Page 10-4. 6. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. 7.

  • Page 27: Section 4 - Body And Trim

    SECTION 4 – BODY AND TRIM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. CLEANING THE VEHICLE See General Warning, Section 1, Page 1-1. CAUT ION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.

  • Page 28: Front And Rear Body Repair

    BODY AND TRIM Front and Rear Body Repair CAUT ION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first. FRONT AND REAR BODY REPAIR See General Warning, Section 1, Page 1-1. MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the body that do not penetrate the finish: 1.

  • Page 29: Touch-Up Paint Color Chart

    TOUCH-UP PAINT COLOR CHART COLOR HUSQVARNA P/N Husqvarna Orange Husqvarna 603 00 33-29 FRONT BODY See General Warning, Section 1, Page 1-1. BUMPER REMOVAL 1. Remove bolts (3) and (5) and lock nuts (4) and pull bumper (1) from vehicle frame (Figure 4-1, Page 4-3).

  • Page 30: Brush Guard Removal

    BODY AND TRIM Front Body BRUSH GUARD REMOVAL 1. Remove bolts (3) and (5) and lock nuts (4) and pull brush guard (2) from vehicle frame (Figure 4-2, Page 4-3). See following WARNING. ý WARNING • Have another person hold brush guard firmly against the frame when removing the last bolt. The brush guard weighs approximately 40 pounds.

  • Page 31: Dash Installation

    BODY AND TRIM Front Body DASH INSTALLATION 1. Pass the steering wheel through the instrument panel hole in the dash. 2. Attach the dash clips along the bottom edge of the dash onto the frame above the floor matt. 3. Install the instrument panel: 3.1.

  • Page 32: Cargo Bed

    BODY AND TRIM Cargo Bed CARGO BED See General Warning, Section 1, Page 1-1. CARGO BED REMOVAL NOTE: This procedure requires two people. 1. Raise bed and remove the rue rings on the end of each clevis pin. 2. Remove hinge clevis pins and remove bed from vehicle. See following CAUTION and WARNING. CAUT ION •...
  • Page 33 BODY AND TRIM Cargo Bed Figure 4-4 Bed Latch Link Bolt Figure 4-5 Passenger Side Catch Rods and Catch Plate Catch Rod and Catch Plate Removal 1. Remove latch springs. 2. Remove bolts and mechanical lock nuts from latch link and catch plates (Figure 4-5, Page 4-7). 3.

  • Page 34: Bed Latch Assembly Installation

    BODY AND TRIM Seat Back Support Brackets Bed Hinge and Support Bracket Removal 1. Remove steel bushings and urethane bushings from hinge brackets (Figure 4-8, Page 4-8). 2. Remove bolts from hinges and remove hinges from supports. 3. Remove support channel bolts and bushings form hinge support channel (Figure 4-9, Page 4-8). 4.
  • Page 35 BODY AND TRIM Seat Back Support Brackets Figure 4-10 Bed Latch Plates SEAT BACK SUPPORT BRACKET REMOVAL 1. Remove bolts from seat back and support brackets and remove seat back. 2. Remove seat back support bolts and bed support weldment with bed bumpers from seat back supports (Figure 4-11, Page 4-9).
  • Page 36 BODY AND TRIM Rear Body and Fenders REAR BODY AND FENDERS See General Warning, Section 1, Page 1-1. NOTE: The driver side rear fender can be removed without removing any other component. But the pas- senger side rear fender cannot be removed without either removing the fuel tank, or removing the rear body.
  • Page 37 BODY AND TRIM Rear Body and Fenders GRAY SENSE LEAD WITH FUSE GRAY WIRE FROM OBC CHARGER RECEPTACLE 10-GAUGE BLACK 10-GAUGE WIRE TO OBC RED WIRE TO BATTERY Figure 4-14 PowerDrive Charger Receptacle 6. Disconnect and remove Forward/Reverse switch. See Forward/Reverse Switch Removal on page 4-11.
  • Page 38 2.7. Connect the battery cables, positive (+) cable first, and tighten terminals to 110 in-lb (12.4 N·m). Coat terminals with Battery Terminal Protector Spray (Husqvarna 603 00 00-03). Page 4-12 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual...
  • Page 39 BODY AND TRIM Rear Body and Fenders REAR FENDER REMOVAL NOTE: The driver side rear fender can be removed without removing any other component. But the pas- senger side rear fender cannot be removed without either removing the fuel tank, or removing the rear body.
  • Page 40 BODY AND TRIM Floor Mat Rear Body Installation, Continued: 5. Driver side rear fender: NOTE: If only the driver side fender has been removed, use the following procedure for installation 5.1. Install fender in reverse order of removal. 5.2. Tighten side bolts to 25 in-lb (2.8 N·m). 5.3.
  • Page 41 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL AND PARK BRAKE See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
  • Page 42 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 4 PLACES Service part brake pedal has second TYPICAL weldment. 2 PLACES Figure 5-1 Brake and Park Brake Pedal Assembly BRAKE PEDAL INSTALLATION 1. From the top side of the floorboard, insert the brake pedal assembly through the opening in the floor, and install the brake pedal stop bumper (11) on the brake pedal assembly (Figure 5-1, Page 5-2).
  • Page 43 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 4. Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-2, Page 5-3). See following NOTE. NOTE: Brake pedal free-play is the distance the brake pedal can be pressed before the brake actuator arm moves.
  • Page 44 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake following NOTE. NOTE: New push nuts (18) and (27) must be used when reassembling the park brake (Figure 5-3, Page 5-4). 3.2. To remove the park brake pedal (1), remove the push nut (27), disconnect the torsion spring (21) (Figure 5-3, Page 5-4) and slide the pedal off of the shaft.
  • Page 45 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL – GASOLINE VEHICLES See General Warning, Section 1, Page 1-1. NOTE: This section pertains to gasoline vehicles. For electric vehicles, proceed to Accelerator Pedal – Electric Vehicles on page 5-8. ACCELERATOR PEDAL REMOVAL 1.
  • Page 46 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Accelerator Pedal Removal, Continued: FLOORBOARD REMOVED FOR CLARITY Figure 5-5 Accelerator Pedal Assembly – Gasoline Vehicles 12. Inspect the accelerator pivot rod supports (21) for wear or damage and replace as necessary. If the pivot rod supports do not require replacement, loosen, but do not remove the four bolts (22) and lock nuts (15) to make installation of the pivot rod easier.
  • Page 47 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (8), and lock nuts (15). Finger-tighten nuts at this time (Figure 5-5, Page 5-6).
  • Page 48 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. NOTE: This section pertains to electric vehicles only. For gasoline vehicles go to Accelerator Pedal – Gas- oline Vehicles on page 5-5. ACCELERATOR PEDAL REMOVAL 1.
  • Page 49 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-7 Accelerator Pedal – Electric Vehicle 2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual Page 5-9...
  • Page 50 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL INSTALLATION 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-7, Page 5-9). Finger-tighten hardware at this time.
  • Page 51 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle PEDAL GROUP ADJUSTMENT – GASOLINE VEHICLE See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2.
  • Page 52 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle Pedal Group Adjustment – Gasoline Vehicle, Continued: 3. Adjust brake pedal free play. See following NOTE. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves.
  • Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle CUTAWAY SIDE VIEW 0.060 inch (1.5 mm) BOTTOM VIEW Figure 5-13 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, and then lock the park brake (Figure 5-14, Page 5-13).
  • Page 54 5.1. Loosen the nut and bolt (Figure 5-17, Page 5-14) securing the accelerator pedal to the pivot plate. 5.2. Clamp the accelerator pedal adjustment tool (Husqvarna 603 00 18-32) to the accelerator pedal, with the end marked accelerator pedal height closest to the floorboard (Figure 5-18, Page 5-14).
  • Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle 6.2. Loosen the jam nuts (18) and disconnect the accelerator rod (17) at the accelerator pedal. Adjust the length of the rod (Figure 5-5, Page 5-6) to obtain an accelerator cable cam position of 14° as shown (Figure 5-19, Page 5-15).
  • Page 56 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2.
  • Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 3. Adjust brake pedal free play. See following NOTE. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves. 3.1.
  • Page 58 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Electric Vehicles, Continued: CUTAWAY SIDE VIEW 0.060 inch (1.5 mm) BOTTOM VIEW Figure 5-24 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, and then lock the park brake (Figure 5-25, Page 5-18).
  • Page 59 5.1. Loosen the nut and bolt (Figure 5-28, Page 5-19) securing the accelerator pedal to the pivot plate. 5.2. Clamp the accelerator pedal adjustment tool (Husqvarna 603 00 18-32) to the accelerator pedal, with the end marked accelerator pedal height closest to the floorboard (Figure 5-29, Page 5-19).

This manual is also suitable for:

Huv4210 2006 seriesHuv4210-e 2005Huv4210-exp 2005Huv4210-g 2005Huv4210-gxp 2005Huv4210-e 2006 ... Show all

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