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

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

Side view of CVT intake and clutch enclosure

Differential lock switch and MFWD switch

Rear view of transaxle and CV shafts

CV boot protection

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

Heating, ventilation, and air conditioning (HVAC) dash shown

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

Cab

M cab door

R cab door

• Functioning door windows – roll up and down

Side windows and front window

Venting position

• Fully opening front window with vent position

Headliner shown on an M-trim open station (with optional windshield, wipers, rear panel, and side mirrors installed)

• Available interior roof headliner factory installed on M-trim cab units and M-trim heating, ventilation, and air conditioning (HVAC) cab units

Door sealing

• Automotive-style sealing

Styled roof (R roof shown)

• Styled roof with channels designed-in to move water to the outside edges

Front roof light

Rear roof light

• Molded-in pockets for front and rear light mounting
  • Keeps lights below the roof line for protection

Inner door handle

Outer door handle

• Easy-opening door handles and mechanisms

M-trim HVAC controls

• HVAC – if equipped

HVAC details

Automotive-style controls on the center of the dash – easy and convenient to reach for the operator or passengers

• Four dash vents
  • Adjustable louvers and face plates
• Windshield vents mounted on the top of the dash
  • Fast defrost
  • Efficient air flow
• Air filter on the passenger side of the cab at foot level
• Three fan speeds
  • 0: off
  • 1: low
  • 2: medium
  • 3: high
• Temperature adjustment knob
  • Counterclockwise for cooler temperature
  • Clockwise for warmer temperature
• Four air flow modes
  • Dash vents
  • Dash and floor vents
  • Defroster vents and floor vents
  • Defroster vents
• HVAC compressor on/off button
  • Pushing the button once turns the air conditioning on – indicator light illuminates blue
  • Push the button again to turn off the air conditioning
• Air flow constant with compressor on or off
• Turn compressor off for full engine power
• Petrol machines have an idle bump to raise rpms to assist driving more power for the HVAC system
  • 1075 rpm in any gear at idle with air conditioning on
  • 1400 rpm when in neutral and the park brake is engaged
• HVAC – if equipped

HVAC controls and vents on the dash

854-cc (52.1-cu in.) diesel engine

The machine is powered by an 854-cc (52.1-cu in.), 3-cylinder, liquid-cooled, four-cycle diesel engine. It produces 48 Nm (35.5-lb-ft) of torque at 2600 rpm.

The advanced engine delivers superb starting, idling, and throttle response during operation.

The engine offers the following performance and reliability features:

• Indirect-injection diesel with glow plugs ensures fast starts in cold temperatures
• 17.1 kW (22.9 hp*) at 3600 rpm
• Overhead valve design for greater efficiency and fuel economy
• Spin-on oil filter for easy servicing
• Quiet operation through the entire rpm range
• Molybdenum-coated pistons
• High-stiffness cylinder block and gearcase
• High-flow water pump and optimized water jackets maintain a steady operating temperature and eliminate hot spots
• Full-pressure lubrication system
• In-line mechanical fuel pump
• Five-point, rubber isolated for quiet operation and minimal vibration
• Dry replaceable dual-element air cleaner with remote intake and a restriction indicator
• See-through coolant recovery tank permits the operator to check the coolant level without removing the radiator cap
• Open front grille allows proper air flow and ventilation to the radiator.

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

XUV front suspension detail

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 cargo without compromising ride quality or vehicle stability.

M-trim cab units (factory installed) and R-trim units have heavy-duty front and rear shocks installed from the factory.

• A higher spring rate and higher preload force versus standard springs prevent the vehicle from sagging with a heavy payload.
• These heavy-duty shocks help with the heavier weight of the cab and when attachments are installed, like blades.

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

XUV rear suspension detail

XUV rear suspension detail

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

Deluxe cargo box with optional light protectors

Top view of cargo box

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

Tailgate handle

Tailgate open

Tailgate lowered to 150 degrees

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

Integrated handle for manual 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

Integrated tie-down point in cargo-box bed

Additional tie-down points (TH 6X4 shown)

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

XUV835 Cab shown

XUV835M Cab shown

Optional accessories for the deluxe cargo box:

• See attachment information in the Sales Manual

Specifications

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.

Roof harness electrical port

Main vehicle harness – winch connection

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

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 system

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

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

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)