2007 Utility Vehicles Gasoline and Diesel Owner’s Manual HUV 4421-G / GXP HUV 4421-D / DXP
NOTICE Warranty information appears on the last pages of this manual. No other warranties, express or implied, are contained herein. Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Husqvarna is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
FOREWORD Thank you for choosing Husqvarna, a world leader in outdoor products. You have chosen the finest utility vehicle on the market. Please protect your investment and ensure that your Husqvarna vehicle provides years of reliable, superior performance by reading and following the maintenance instructions in this manual. Your comfort and safety are important to us, so we urge you to read and follow the step-by-step operating instructions and safety procedures in this manual.
TABLE OF CONTENTS Safety Details ............................................................................................................................................ 7 General Warnings ...................................................................................................................................... 8 General Information ................................................................................................................................... 10 Model Identification ..
Vehicle Feature Identification ALL HUV 4421 MODELS DIESEL WARNING DECAL GASOLINE WARNING DECAL (DIESEL VEHICLES ONLY, ON PASSENGER-SIDE SEAT SUPPORT) (GASOLINE VEHICLES ONLY, ON PASSENGER-SIDE SEAT SUPPORT) OPERATING INSTRUCTIONS (ON INSTRUMENT PANEL) HOT MANIFOLD WARNING DECAL (ON ENGINE VALVE COVER) WINCH CABLE WARNING DECAL (FOR VEHICLES WITH WINCH ACCESSORY) FRAME GROUND WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) (ON FRONT BODY) HOT SURFACE WARNING DECAL (ON COOLANT PIPES AND UNDERSIDE OF B
Vehicle Feature Identification ALL HUV 4421 MODELS UNDERAGE WARNING DECAL ! WARNING • Do not modify or remove Roll-over Protective Structure (ROPS). • Replace ROPS if damaged. Do not attempt repair. • Use seat belts during operation. Do not jump from vehicle. • Keep away from drop-offs, steep slopes, and unstable surfaces.
Vehicle Feature Identification Page 6 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual
Safety Details SAFETY DETAILS ý WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
General Warnings GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Safety decal identification information is also included beginning on page 4. Other specific safety statements appear throughout this manual and on the vehicle. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area.
General Warnings ý WARNING • 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. The appropriate instructions must be used when performing maintenance, service, or accessory installation. • To avoid unintentionally starting the vehicle: - Disconnect battery cables, negative (–) cable first (Figure 1). - Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs.
General Information GENERAL INFORMATION This manual includes operating procedures, maintenance, and regular servicing information for all gasoline and diesel HUV 4421-G and HUV 4421-D vehicles. All operating procedures, maintenance, and regular servicing are identical unless otherwise noted. MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted on the frame above the brake pedal (Example: RC0601-123456) (Figure 3).
Controls and Indicators 9 8 A 0 1/2 1 1 10 6 OPERATING INSTRUCTIONS 12 B OFF ON START C 14 15 13 4 5 11 7 1 3 2 Figure 4 Instrument Panel – Gasoline Vehicles 9 8 A 0 1/2 1 1 10 6 10 OPERATING INSTRUCTIONS B PREHEAT OFF ON START 12 C 13 15 11 7 4 5 1 3 2 Figure 5 Instrument Panel – Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual Page 11
Controls and Indicators KEY SWITCH – GASOLINE VEHICLES The key switch (7) is mounted on the instrument panel to the right of the steering column (Figure 4, Page 11). It has three positions: OFF, ON, and START. To start the vehicle, place the Forward/Reverse handle in the NEUTRAL position and turn the key to the START position, and hold it there until the engine starts. Activate the choke (14) as necessary. If the engine does not start after 10-15 seconds, release the key and repeat the procedure.
Controls and Indicators BRAKE PEDAL The brake pedal (2) is located to the immediate left of the accelerator pedal (Figure 4 and Figure 5, Page 11). To slow or stop the vehicle, press the brake pedal. PARK BRAKE The park brake pedal (3) is located to the left of the brake pedal (Figure 4 and Figure 5, Page 11). To engage the park brake, first apply pressure to the brake pedal, then firmly press the park brake pedal until it latches into place.
Controls and Indicators LOW OIL WARNING LIGHT The low oil warning light (9) is located on the instrument panel just to the left of the steering column (Figure 4 and Figure 5, Page 11). If the warning light lights up, oil should be checked and added to the engine as necessary before vehicle use continues. The vehicle should never be driven when the low oil warning light remains lit.
Roll-Over Protective Structure and Safety Belts ROLL-OVER PROTECTIVE STRUCTURE AND SAFETY BELTS HUV 4421-G and HUV 4421-D vehicles are equipped with a Roll-Over Protective Structure (ROPS) and safety belts for each occupant. See following WARNING. ý WARNING • The ROPS must be properly installed before operating the vehicle. Husqvarna strongly urges that the vehicle’s occupants be properly restrained at all times with the safety belts provided.
Seat Latch and Adjustment ý WARNING • After inserting the tab, make sure the tab and buckle are locked and that the belt is not twisted. • Loose fitting safety belts could increase the chance of injury due to sliding under the belt if sudden braking should occur. Keep the safety belt snug and positioned as low on the hip bone as possible. • Use a single safety belt for one person at a time. Do not use a single safety belt for two or more people – this includes children.
Pre-Operation and Daily Safety Checklist To adjust the passenger-side seat 1. Remove the seat from the vehicle. 2. Remove the four bolts and washers from the bottom of the seat mounting plate. 3. Align the mounting plate holes with holes in the seat to achieve the desired seat position. 4. Install washers and bolts, and tighten to 96 in-lb (10.8 N·m). 5. Install the seat. See preceding WARNING “Make sure seat hinges and latch...
Performance Inspection PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following list, in addition to the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle daily for proper operation. Any problems should be corrected by a dealer/distributor or a trained technician. • Forward/Reverse shifter: Check for proper operation.
Driving Instructions ý WARNING - Be sure all passengers are capable of securing themselves in a moving vehicle before allowing them to ride in one. - Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle. • Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive passengers and (or) damage to the vehicle.
Driving Instructions 5. Make sure wheels are turned in desired direction and nothing is in your path. 6. Make sure the Forward/Reverse handle is in the NEUTRAL position. 7. Press and hold the brake pedal. 8. To start the vehicle 8.1. Gasoline vehicles: Turn the key to the START position and hold it there until the engine starts. Activate the choke as necessary. If the engine does not start after 10-15 seconds, release the key and repeat the procedure.
Bed Latch and Prop Rod Under most circumstances the driver will not need to do anything to engage the AWD system; however, the front differential may become locked (rotate at the same speed regardless of the terrain) under certain conditions. If the front differential becomes locked, drive slowly in reverse for at least 10 feet (3 meters), then brake gently. See following WARNING. ý WARNING • Reduced steering control can occur if the front differential becomes locked.
Loading and Unloading Cargo ý WARNING • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in severe personal injury or death.
Vehicle Load Capacities ý WARNING • Reduce speed and avoid sudden stops when backing up. Failure to do so may cause the vehicle to overturn or flip over backwards. • Maximum cargo load must be reduced by the weight of optional equipment. Center and secure cargo as far forward as possible in the cargo bed. Do not overload the vehicle. See Vehicle Load Capacities on page 23 for vehicle capacities.
Towing with the Vehicle B D C A Figure 10 Vehicle Load Capacity – Two-Passenger Vehicles TOWING WITH THE VEHICLE ý WARNING • • • • • • Do not tow a vehicle or trailer on public streets or highways. Normal vehicle operating speed should be reduced when towing. Extreme caution should be used when towing. Do not allow riders in the vehicle or trailer being towed. Avoid sudden starts, sudden stops, and tight turns when towing. Avoid stopping on a hill when towing.
Storage ý WARNING • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Never tow a vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer. • The vehicle to be transported should be tied securely to the trailer, with the Forward/Reverse handle in the NEUTRAL position, the key switch in the OFF position, and the park brake firmly engaged.
Storage ý CAUT ION • Batteries in a low state of charge will freeze at low temperatures.
Storage 3. Make sure the key switch is in the OFF position and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels. Gasoline vehicles: 4. Prepare the fuel tank. 4.1. Fill the tank with fresh fuel. 4.2. Following the manufacturer’s directions, add a commercially available fuel stabilizer (such as StaBil®). Run the engine in a well-ventilated area to allow treated fuel to replace untreated fuel in the carburetor. 4.3.
Maintenance 5. Place the Forward/Reverse handle in the NEUTRAL position. Crank the engine until fuel is pumped into the carburetor (gasoline vehicles) and the fuel lines (all vehicles) 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 the first time after storage. 6.
Periodic Service Schedule ý WARNING - Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs. • 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. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity.
Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Monthly service by owner or trained technician First adjustment after 20 hours, additional every 100 hours of operation Semiannual service by trained technician only (or every 50 hours of operation, whichever comes first) Engine Check engine circulating air passage; visually inspect unshrouded area around engine exhaust for grass and debris and clean if necessary.
Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Annual service by trained technician only (or every 100 hours of operation, whichever comes first) Check for leaks around gaskets, fill plugs, etc. Kawasaki gasoline engines: Adjust valve clearance. See Kawasaki FH680D Service Manual. Engine Gasoline vehicles: Inspect, clean, and gap spark plug; replace if necessary. See authorized dealer or trained technician for service.
Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION POINTS RECOMMENDED LUBRICANT Gasoline vehicle: Honda engine-First change 20 hours Kawasaki engine- First change 10 hours Diesel vehicle: First change 50 hours Additional change for all engines every 100 hours of operation or annually, whichever comes first.
Periodic Lubrication Schedule 3 1 4 5 7 6 4 2 2 Figure 14 Lubrication Points – Gasoline Vehicles 3 4 1 5 7 6 4 2 2 Figure 15 Lubrication Points – Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual Page 33
Brake Fluid Reservoir BRAKE FLUID RESERVOIR FULL LEVEL MA X 1 SAFE LEVEL MA 2 X MIN MA X MIN Figure 16 Brake Fluid and Coolant Access (diesel vehicle shown) MIN LOW LEVEL Figure 17 Brake Fluid Reservoir The brake fluid reservoir (1) is located under the hood (Figure 16). Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: • The presence of brake fluid on the exterior surface of the master cylinder indicates a leak.
Engine Oil NOTE: The normal oil pressure value stated in the Honda engine manual is 28 psi at idle; however, the remote filter design causes oil pressure to be 18 psi, which is normal for this type of oil circulation design. Kawasaki engine: The Kawasaki gasoline engine has an oil filter that is mounted on a bracket between and in front of the engine and transmission. Inlet and outlet oil-carrying hoses enable oil circulation to and from the engine. See following NOTE.
Engine Oil 2 1 1 3 3 2 Full Level Full Level Safe Level Safe Level Low Level Low Level Figure 20 Engine Oil Level Check – Diesel Vehicles With Driver-side Dipstick Figure 21 Engine Oil Level Check – Diesel Vehicles With Passenger-side Dipstick ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed: • Kawasaki gasoline engine after the first 10 hours of operation. • Honda gasoline engine after the first 20 hours of operation.
Engine Oil 7. Use a socket or wrench to replace the oil drain plug (1) (Figure 22 or Figure 23). Turn the plug clockwise and tighten to 29 ft-lb (40 N·m) for Honda gas vehicles, 61 in-lb (6.9 N·m) for Kawasaki gas vehicles with plastic drain plugs,14.5 ft-lb (20 N·m) for Kawasaki gas vehicles with metal drain plugs, or 31 ft-lb (42 Nm) for diesel vehicles.
Engine Oil NOTE: An oil drip guard (1) can be used to prevent excess oil from dripping onto the engine base plate (Figure 26). Use an empty quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil filter (2) before removal. Position the port of the plastic container so oil will be directed into the oil pan (3).
Engine Oil Figure 28 Add Engine Oil – Gasoline Vehicles (Honda Shown) Figure 29 Add Engine Oil – Diesel Vehicles Engine Oil Filling 1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 28 or Figure 29). With filter change, the engine requires: • Honda gasoline engines: 1 qt. and 25 oz. (1.7 L) of oil per change. • Kawasaki gasoline engines: 1 qt. and 19 oz. (1.5 L) of oil per change. • Kubota diesel engines: 3 qt. (2.8 L) of oil per change. 2.
Gearcase Lubrication NOTE: Use engine oil with API classification SJ for gasoline engines and CF for diesel engines. Using multi-grade oils (5W-20, 10W-30, and 10W-40) may increase oil consumption. If multi-grade oil is used, check the oil level more frequently.
Gearcase Lubrication the lubricant level indicator hole (1). See Periodic Lubrication Schedule on page 32. Tighten the level indicator plug to 10 ft-lb (14 N·m). 1 1 2 2 Figure 32 Front Differential Lubrication Level Figure 33 Transmission Lubrication Level Transmission: Clean and install the drain plug (2) before filling the transmission with new lubricant (Figure 33). Tighten the drain plug to 8 ft-lb (11 N·m).
Engine Coolant – Diesel Vehicles 1 2 Figure 34 Rear Differential Lubrication Level ENGINE COOLANT – DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 16). Raise the hood to check the coolant level before every operation. 1. Check the coolant level of the reserve tank (2). If the coolant is at or below the LOW mark, add pre-mixed coolant until the level reaches the FULL mark.
Fueling Instructions Air Filter Removal 1. Raise the cargo bed, and locate the air filter canister. 2. Release both canister tab locks (Figure 35). 3. Pull the canister cap away from the canister. 4. Remove the air filter cartridge (1). See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Husqvarna part (P/N 603 00 00-10) designed for this engine. 1 Figure 35 Air Filter Cartridge Air Filter Installation 1.
Fueling Instructions NOTE: Gasoline vehicles: Use unleaded gasoline only. Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Diesel vehicles: Use only diesel fuel grade no. 2 with a cetane rating of 45 or higher. 2. Replace the fuel cap. Ensure that the cap is tightened securely. 3. Clean any spilled fuel from the cap or around the fuel cap area.
Fueling Instructions If biodiesel is used, be sure to apply the following guidelines: • Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting. • Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank. • Drain all water from the fuel filter daily before operating vehicle. See Draining Water from Fuel Filter. • Check the engine oil level daily before the engine is started. See Engine Oil Level Check on page 35.
Battery 1 Figure 38 Fuel Filter BATTERY See General Warnings on page 8. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: - External: Flush with water. Call a physician immediately.
Battery The battery in this vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 39). Electrolyte level should be checked semiannually. LEVEL INDICATOR FRONT OF VEHICLE POS NEG Figure 39 Battery BATTERY CAP PLATES ELECTROLYTE LEVEL AT LEAST 1/2-INCH (13 MM) ABOVE PLATES OR TO LEVEL INDICATOR Figure 40 Battery Electrolyte Level 1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. 2.
Using A Booster Battery (Jump Starting) USING A BOOSTER BATTERY (JUMP STARTING) ý WARNING • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. • When jumping from a booster battery make final connection (negative) at engine frame. • Do not jump start or charge a frozen or damaged battery. Unplug charger before connecting or disconnecting cables to the battery.
Cleaning the Vehicle CLEANING THE VEHICLE Each vehicle is equipped with hand wash-washable front and rear bodies. The vehicle has a powder-coated steel cargo bed (or optional aluminum flat bed). Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate. To remove oxidation or discoloration from aluminum, use a commercially available aluminum cleaner paste and fine grade (No. 00) steel wool.
Subsequent Owner Registration ý WARNING • Before beginning a winch operation: - Turn key switch to the OFF position, put Forward/Reverse handle in the NEUTRAL position, and engage the park brake. - Do not use winch while persons are seated on the vehicle. • Stand to the side and away from the vehicle to operate winch. CAUT ION • Use of the winch for an extended period of time could discharge the battery.
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS HUV 4421 HUV 4421 POWER SOURCE Gasoline Diesel Engine: (Honda) 4-cycle OHV, 614 cc, 20.0 maximum HP @3600 rpm (per SAE J 1940/ 1349), twin-cylinder, air-cooled, with pressure lubrication system • Engine: (Kawasaki) 4-cycle OHV, 675 cc, 23.0 maximum HP @3600 rpm (per SAE J 1940/ 1349), twin-cylinder, air-cooled, with pressure lubrication system • Engine: 4-cycle OHV, 719 cc, 20.
Vehicle Specifications SPECIFICATIONS HUV 4421 HUV 4421 BODY/CHASSIS, CONTINUED Gasoline Diesel Side and rear body: Plastic • • Cargo bed: Powder-coated steel or aluminum • • Front body: Geloy XTWM206 • • Tires: All Terrain: 25 x 10.5 – 12 front and rear; tubeless, 4-ply rated load range Mud: 25 x 11 – 12 front and rear; tubeless, 4-ply rated load range • • DIMENSIONS/WEIGHT NOTE: Items marked with an asterisk (*) indicate approximate values.
Vehicle Specifications SPECIFICATIONS Engine coolant: mixture of 55% propylene glycol and 45% water HUV 4421 HUV 4421 n/a 2 gal. (7.8 L) Brake fluid: DOT 5 (silicone) brake fluid 8 oz. (240 ml) 6.5 gallons (24.6 L) Fuel tank: unleaded gasoline 6.5 gallons (24.6 L) Fuel tank: diesel grade no.2 with cetane rating of 45 or higher TIRE PRESSURE All-terrain tread and mud tires 20 - 22 psi (1.38 - 1.
HUSQVARNA® LIMITED TWO YEAR WARRANTY FOR 2007 TRANSPORTATION AND UTILITY VEHICLES 1. WARRANTY: Husqvarna, INC.
6. DISCLAIMER: THIS LIMITED WARRANTY IS EXCLUSIVE. HUSQVARNA MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY HUSQVARNA AND EXCLUDED FROM THIS WARRANTY. THE PURCHASER AND HUSQVARNA EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER.
TECHNICAL & CONSUMER INFORMATION (GASOLINE ENGINES) Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen and hydrocarbons.
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your new Husqvarna, Inc. ("Husqvarna") vehicle engine complies with both the U.S. EPA and State of California emission regulations. YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board ("CARB") and Husqvarna are pleased to explain the emission control system warranty on your 2007 vehicle engine. In California, new small off-road engines (SORE) must be designed, built and equipped to meet the State's stringent anti-smog standards.
Husqvarna Part Number 531 30 81-86 Edition Code 0706C0307B CCI P/N 103218307
