The Gator™ XUV Crossover Series Utility Vehicle has a precision-engineered drivetrain system that fully utilizes engine power, optimizing acceleration, hauling, towing, and hill-climbing capabilities. Power is transmitted from the engine through a continuously variable clutch system to the transaxle. Key elements of the drive system include:

Variable-speed drive

The variable-speed drive consists of two clutches and a drive belt:

• Drive clutch is attached to the engine.
• Driven clutch is attached to the transaxle.

Features include:

• The engine braking system utilizes a tight belt for operation, requiring an idler sleeve on the primary clutch for neutral. The secondary clutch is a build-on-shaft design that utilizes a cam to tune the acceleration and deceleration of the vehicle. The clutch will stay engaged, providing deceleration until approximately 5 km/h (3 mph).
• The continuously variable transmission (CVT) air intake draws in cool air to reduce heat and the amount of water ingestion into the CVT system. The system will reduce belt slippage and improve durability.
• A low- and high-speed forward gear offering:
  • Low range is 0 km/h to 40 km/h (0 mph to 25 mph), XUV835
  • Low range is 0 km/h to 24 km/h (0 mph to 15 mph), XUV865
  • High range is 0 km/h to 72 km/h (0 mph to 45 mph), XUV835
  • High range is 0 km/h to 45 km/h (0 mph to 28 mph), XUV865
• Ability to creep along slowly to maneuver in tight spaces
• Standard full-clutch enclosure with high speed fan provides longer belt and clutch life
• High-ratio clutches with three cam weights for maximum belt-clamp load in high torque conditions

NOTE: Delivery of torque to the ground and top speed depends on tire size, which is a function of nominal size and pressure. How the variable-speed drive works:

1. As engine speed increases, the spring-loaded drive clutch is closed by weights being forced out by centrifugal force.
2. As the drive clutch closes, the belt rides up to the largest diameter of the drive clutch and forces open the driven clutch.
3. With the belt running in the smallest diameter of the driven clutch, the speed being transferred to the transaxle is increased.
4. The driven clutch is designed to sense varying loads (inclines, mud, etc.) and constantly adjusts drive speed upward or downward so that engine rpm remains optimal.

Transaxle, mechanical front-wheel drive (MFWD), and constant velocity (CV) shafts

Operator interface features:

• Selectable four-wheel drive (4WD) system with a limited slip front differential and dash-mounted electronic rocker switch
  • Provides exceptional traction in challenging conditions
  • Near instantaneous torque to the front wheels once rocker switch is engaged
  • Maintains turf-friendly operation in two-wheel drive (2WD) mode
  • Combined with rear traction assist (differential lock), provides excellent traction in challenging conditions
  • More control descending hills with 4WD engaged as all four wheels help slow the vehicle down
    • Clutch engagement still necessary to prevent free coasting

Transaxle features:

• Low, high, neutral, reverse, and park transaxle
• Automotive-style, integrated park position in transmission
• Low range for maximum torque delivered to the wheels for hauling, pushing, and pulling
• High range for maximum vehicle speed
• To shift out of park, service brake must be pressed to release the parking solenoid. An audible click will be heard and allows the vehicle to shift out of park into the desired gear.

NOTE: Differential design reduces scuffing of the turf during turns because it allows the inside wheels to turn slower than the outside wheels.

• Start in gear, neutral, or park position for quick starting. The service brake must be engaged to start when in gear or neutral.
• For operators living in regions with homologation requirements or certain bid language stating the need for a secondary park brake, such as governmental or municipalities, a secondary park brake is available as an option on select models:
  • XUV825 S4
  • XUV855 S4
  • XUV835M
  • XUV835R
  • XUV865M
  • XUV865R
• Large, sealed bearings are located inside the housing for better protection and durability
• Contains gear case for transferring power to the MFWD
• Splined shaft interfaces for maximum torque transfer and durability
• All drive gears machined from highest grade gear steel
• Protected by a skid plate

MFWD features:

• Electronically selectable by the operator
  • Offers limited slip functionality for precision steering and great traction while pointing and shooting out of a corner.
• Vertically oriented oil drain for easy maintenance
• Protected by a steel skid plate and frame

Drive shaft features:

• Rear CV shaft diameter measures 27 mm (1.1 in.) and is designed for peak engine and braking torque
• Front CV shaft diameter measures 23 mm (0.91 in.) and is designed for peak engine torque
• Propshaft is designed for peak engine torque
• All CV shaft and propshaft joints are maintenance free and protected by exclusive thermoplastic elastomer (TPE) boots for durability

This Gator™ XUV Crossover Utility Vehicle is equipped with power steering and a dual A-arm front suspension. These automotive-type systems exhibit excellent handling characteristics, as well as responsive steering and low steering effort:

• Steel ball-bearings secure the steering shaft and deliver smooth, responsive operation
• Completely sealed rack and pinion for long life
• Low steering ratio (lock-to-lock) provides more responsive steering and less operator input
• Shaft U-joints are phased for a smooth, uninterrupted motion of the steering wheel
• Tilt steering wheel with 15 degrees of travel

Electric power-assist steering (EPAS) system has advanced features:

• Anti-kickback feature reduces the amount of steering unwinding when traversing difficult terrain.
• The system is speed-sensing and adjusts steering effort as the speed of the vehicle changes.
  • As speed increases, there is less steering assist for improved road feel.
  • As speed decreases, steering assist increases to give lower steering efforts for improved maneuverability.
• A warning/functional light on the instrument panel provides self-diagnostics and a warning light in the situation of no assist.
• Torque sensor measures steering wheel input so the on-board computer can provide the appropriate output for various driving situations.

With the EPAS system, the operator maintains a direct mechanical linkage from the steering wheel to the front wheels. The power steering system interfaces mechanically with the steering system by being inserted between the steering wheel and the rack-and-pinion assembly. A differential torque sensor is integrated into the power steering assembly. The circuit board assembly is also integral with the power steering assembly. Power steering does not reduce turning radius but significantly reduces steering effort by approximately 85 percent compared to models without power steering.

EPAS interface diagram

The numbered descriptions refer to the EPAS interface diagram shown above:

1. Torque sensor
2. Electronic control unit (ECU)
3. Fail-safe relay
4. Current/thermal control circuit
5. Reduction gears
6. DC motor
7. Rack and pinion
8. Function/warning light
9. Key power and ground
10. Vehicle speed sensor
11. Instrument cluster
12. Relay module

Whether it is a completely open operator station or a factory-installed cab, the interior has been redesigned with comfort and ergonomics in mind.

• Gear shift control and differential switch on the dash

HVAC dash shown (R trim)

• Tilt steering

Tilt steering	Tilt steering (up position)	Tilt steering (down position)

• Bench seat with driver adjustment

Bench seat adjustment

• Three-wide seating

Seating

The machine is powered by an 812-cm³ (49.6-cu in.), 3-cylinder, dual overhead cams, liquid-cooled, four-cycle gasoline engine. It produces 6.5 kgm (47 lb-ft) of torque at 3200 rpm. The advanced electronic controls and fuel-injection system deliver superb starting, idling, and throttle response during operation. The engine offers the following performance and reliability features:

• 40.3 kW (54 hp*) at 6000 rpm
• 72-km/h (45-mph) top speed
• Electronic fuel injection for superb performance, altitude adjustment, and cold-weather starting (tested to -28.9°C [-20°F])
• Electronic ignition is continuously variable for optimum engine power and provides fast, reliable starts
• Exclusive electronic ground-speed governor and throttle body
• Auto-compensates by providing more power when going up a hill or through difficult terrain
• Eliminates top-speed degradation from belt wear
• Overhead valve design provides greater efficiency and fuel economy
• Full-pressure lubrication system
• Spin-on oil filter with drain bracket and oil drain plug enable easy servicing
• Dry, replaceable, single-element air cleaner with remote intake
• See-through coolant recovery tank permits the operator to check the coolant level without having to remove the radiator cap
• Open front grille allows air flow and proper ventilation to the radiator
• Standard high-capacity alternator – 85 amps for maximum accessory capability

*The engine horsepower information is provided by the engine manufacturer to be used for comparison purposes only. The actual operating horsepower will be less.

To complement the robust frame, the XUV is equipped with four-wheel independent suspension. A dual A-arm front and rear suspension provides a smooth ride over challenging terrain and excellent hauling characteristics. The entire suspension system has been optimized to handle no cargo to maximum cargo without compromising ride quality or vehicle stability.

Dual A-arm independent front suspension features include:

• 200.7 mm (7.9 in.) of travel provides ample wheel travel to keep all four wheels on the ground for superior traction, excellent ride quality, and vehicle control
• Heavy-duty nodular cast-iron knuckles support the constant-velocity (CV) shaft and wheel
• Maintenance-free rubber torsional A-arm pivots for long life and quiet operation
• CV shaft protection from sticks that may puncture the rubber boot
• Coil-over shocks absorb the most demanding terrain

Dual A-arm independent rear suspension features include:

• Unequal length and dual A-arm construction for superior wheel control and travel
• 231.14 mm (9.1 in.) of total travel provides ample wheel travel to keep all four wheels on the ground for superior traction, excellent ride quality, and vehicle control
• Coil-over shocks absorb the most demanding terrain
• A-arms made from square/rectangular tubing reduce weight while remaining rigid
• Heavy-duty nodular cast-iron uprights support wheel loads with a double row of ball bearings
• CV driveshaft protection from sticks that may puncture the rubber boot
• Rear sway bar for lateral stability

The deluxe cargo box consists of a 15 percent glass-filled polypropylene composite material that eliminates rust and dents and reduces noise.

Deluxe cargo box tailgate

The tailgate can be opened or removed for easier cleanout and to carry longer items. The tailgate has been improved, features truck-like performance, and can be operated with one hand. The standard-installed lanyards can also be removed to lower the tailgate to 150 degrees for convenient loading and unloading tasks.

Deluxe cargo box tilt

The deluxe cargo box is easier to latch, unlatch, raise, and lower with the integrated handle design and gas assist. A prop rod is provided to hold the box in the upright position for operator convenience, as well as limit box pivot travel.

Integrated tie-down points

The deluxe cargo box offers integrated tie-down points for increased versatility. Tie-down points are located in the following areas:

• Four corners inside the cargo box bed
• Four points on the load guard directly behind the operator station (A)
• Tie-down bars on either side of the cargo box (B)
• Six points on the underside of the cargo box frame (circled)

Converting deluxe cargo box to a flatbed

Optional accessories for the deluxe cargo box:

• See attachment information in the Sales Manual

Specifications

Length	1143 mm (45 in.)
Width	1320 mm (52 in.)
Depth	304 mm (12 in.)
Volume	0.46 m3 (16.4 cu ft)
Weight capacity	454 kg (1000 lb)
Dump angle	47 degrees

CAUTION: Carrying extra-long cargo that extends beyond the box can adversely affect stability.

On M- and R-trim vehicles, adding attachments and accessories is made easier by the inclusion of some main wiring harnesses that facilitate efficient hook-up.

Cargo box lift

Backup alarm

Brake / tail / reverse lights

Speed limiter kit

Base radio

Heater

2041-kg (4500-lb) winch

Premium radio (base radio kit needed)

LED lights – front OPS

Windshield wiper

Windshield washer

LED lights – brush guard

LED headlights

Turn signals

Horn

Beacon light

LED lights – rear OPS

Sprayers

Spreaders

AMS integration kit

E

a

a

a,c

a,c,d

a,c,d

a,c,d

a,b

a,b

a,b

a,b

a,c,e

a,c,e

a,f

a,f

a,c,e,f

M open

c

c,d

c,d

c,d

b

b

b

b

c,e

c,e

f

f

c,e,f

M cab

b

b

b

b

e

e

f

f

e,f

R

f

f

f

	= connections in base harness
a	E-spec attachment harness
b	Front attachments harness
c	Roof attachment harness
d	Front cab harness
e	Rear cab harness
f	Dash port harness
*	If blank, the base chassis harness has the connector for the attachment

If dual beam headlights are desired, the following bundles are required: XUV835E/865E:

• BM26589 – dual beam LED headlights, including three-position rocker switch
• BUC10809 – front light harness kit
• BUC10810 – E-spec attachment harness

XUV835M/865M:

• BM26589 – dual beam LED headlights, including three-position rocker switch
• BUC10809 – front light harness kit

XUV835R/865R:

• BM26589 – dual beam LED headlights, including three-position rocker switch

The M trim adds electrical power-assist steering (EPAS) and brings in the main wiring harness for easier attachment hook-up. Cabs are available in this trim level. Heating, ventilation, and air conditioning (HVAC) is also an option within the M-trim level.

Build-to-order options

• Roof standard on all units – can order less roof on open station units
• Available factory-installed winch on M- and R-trim units
• Available factory-installed front glass windshield on M-trim open station units
• Available factory-installed rear glass panel on M-trim open station units
• Available factory-installed brush guard
• Available factory-installed brush guard extensions
• Available factory-installed rear cargo box fender guards (rear bumper required, also factory installed)