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:
As engine speed increases, the spring-loaded drive clutch is closed by weights being forced out by centrifugal force.
As the drive clutch closes, the belt rides up to the largest diameter of the drive clutch and forces open the driven clutch.
With the belt running in the smallest diameter of the driven clutch, the speed being transferred to the transaxle is increased.
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:
HPX615E
HPX815E
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
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.
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 Value Selling Navigator
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.
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
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
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)
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
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
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:
Torque sensor
Electronic control unit (ECU)
Fail-safe relay
Current/thermal control circuit
Reduction gears
DC motor
Rack and pinion
Function/warning light
Key power and ground
Vehicle speed sensor
Instrument cluster
Relay module
Brakes
Type
Front/rear hydraulic disc with twin piston front calipers
Four cup holders (two additional for cab units) In dash Under seat: 56.69 L 2 cu ft Glovebox: 3.85 L 0.136 cu ft Optional under hood - except for HVAC units or units with dealer-installed heater kit
Power steering
No on E Trim; Yes on M and R Trim
Seating
Bench (available bucket seats on E and M Trim)
Instrumentation
Digital display (gear position, system diagnostic light, speed, rpm, 4WD indicator, rear differential indicator, fuel level, coolant temperature, hour meter, miles, and service interval warning light)
Headlights
Single-beam halogen (single-beam LED on R Trim)
Key Specs
Rear suspension
Fully independent dual A-arm with adjustable coils and sway bar; 231.14 mm (9.1 in.) of travel
Final drive
Park, high, low, neutral, reverse transaxle
Cargo box capacity (weight)
454 kg 1000 lb
Four wheel drive
Dash switch actuated four-wheel drive system with limited slip front differential plus locking rear differential
Fuel capacity
42.4 L 11.2 U.S. gal.
Cargo box dimensions
1143 x 304.8 x 1320 mm 45 x 12 x 52 in.
Engine power
17.0* kW 22.8 hp
Front suspension
Fully independent dual A-arm with adjustable coils; 200.7 mm (7.9 in.) of travel
Towing capacity
907 kg 2000 lb
Suspension
Front
Fully independent dual A-arm with adjustable coils; 200.7 mm (7.9 in.) of travel
Rear
Fully independent dual A-arm with adjustable coils and sway bar; 231.14 mm (9.1 in.) of travel
Tires / Wheels
Rear
25x11-12 Terrahawk AT, 27x11-R14 Maxxis Bighorn radials on alloy rims, or Maxxis Bighorn radials on steel rims
Front
25x9-12 Terrahawk AT, 27x9-R14 Maxxis® Bighorn® radials on alloy rims, or Maxxis Bighorn radials on steel rims