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BODY AND TRIM
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. It is easier to remove the rear body than to remove the fuel tank.
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-2.
2. Driver side rear fender:
2.1. Remove the seat.
2.2. Raise the cargo bed.
2.3. Remove rear fender frame bolt (Figure 4-15, Page 4-11).
2.4. Remove the top body and fender bolt.
2.5. Remove the two outside body and fender bolts and remove the fender from the vehicle.
3. Passenger side rear fender:
3.1. Remove the seat.
3.2. Remove the cargo bed. See Cargo Bed Removal on page 4-6.
3.3. Remove the seat back support brackets. See Seat Back Support Bracket Removal on page 4-9.
3.4. Remove rear fender frame bolt.
3.5. Remove the rear body. See Rear Body Removal on page 4-10.
3.6. Place body and fender on a clean flat surface and remove the top body and fender bolt.
3.7. Remove the two outside body and fender bolts and separate the passenger side fender from the
rear body.
REAR FENDER INSTALLATION
NOTE: If both fenders have been removed attach them to the rear body first, then install the rear body with
fenders attached.
Rear Body and Fenders
NOTE: Use the floor as a method of keeping the fenders and rear body in alignment for height.
1. Position the rear body on a large flat surface such as a concrete floor. See following NOTE.
2. Attach both fenders to the sides on the rear body and leave bolts loose.
3. Attach both fenders to the top locations on the rear body and snug bolts but do not tighten.
4. Tighten the side bolts on both fenders to 25 in-lb (2.8 N·m).
5. Tighten top bolts on both fenders to 25 in-lb (2.8 N·m).
REAR BODY INSTALLATION
NOTE: This procedure is easier using two people.
1. Position rear body with fenders attached onto the vehicle frame.
2. Position front edge of the body behind floor matt back rail and down into the side trim.
3. Install the front edge of the body to the rail with screws and tighten to 50 in-lb (5.6 N·m).
4. Install the rear bolts on both fenders and tighten to 50 in-lb (5.6 N·m).
2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual
4
Rear Body and Fenders
Page 4-13
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