XUV835MCrossover Utility Vehicle

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 stays 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 reduces belt slippage and improve durability.
• A two-range transmission provides:
  • Ability to maneuver in tight spaces and increased pulling torque in low range
  • Faster speeds and reduced transport time in high range
• 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

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, four-wheel drive (4WD), and constant velocity (CV) shafts

Side view of CVT intake and clutch enclosure (XUV835M shown)

Differential lock and 4WD switches

Rear view of transaxle, suspension components, and CV shafts (XUV865M shown)

CV boot protection

Operator interface features:

• Selectable 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 a factory-installed option. A secondary brake attachment is not available for field installation.
• Large, sealed bearings are located inside the housing for better protection and durability
• Contains gear case for transferring power to the 4WD
• Splined shaft interfaces for maximum torque transfer and durability
• All drive gears machined from highest grade gear steel
• Protected by a skid plate

4WD 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 (XUV835M, XUV835R, XUV865M, and XUV865R models only; S4 models do not have tilt steering)

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 those 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

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, four-wheel drive (4WD), and differential lock switches on the dash
• Tilt steering
• Available 40/60 split three-passenger bench seat with driver adjustment

Gear shift control with differential lock and 4WD switches (R Trim)

Tilt steering

Tilt steering (up position)

Tilt steering (down position)

Driver adjustment shown on 40/60 split three-passenger bench

Three-wide seating

812-cm³ (49.6-cu in.) gasoline engine

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
• 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 easy access for service
• 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.

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 no cargo to maximum cargo without compromising ride quality or vehicle stability.

M-trim vehicles with factory-installed cabs and R-trim vehicles 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:

• 203 mm (8 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 (shown on XUV865M)

Dual A-arm independent rear suspension features include:

• Unequal length and dual A-arm construction for superior wheel control and travel
• 229 mm (9 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 brake lights, taillights, and light protectors

Top view of deluxe cargo box with optional spray-in liner

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 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

XUV835M Cab shown

XUV835M Cab shown

The deluxe cargo box easily converts to a flat bed. The flatbed configuration allows loading larger cargo.

Optional accessories

Brake and taillight with optional protector

Cargo bed mat

Cargo box power lift

Optional accessories for the deluxe cargo box include:

• Factory-installed brake lights and taillights
• Taillight protectors
• Factory-installed spray-in liner that improves skid resistance and surface abrasion protection
• Cargo box bed mat to protect the steel floor from dents
• Factory-installed cargo box power lift

Specifications

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

Factory-installed options

Several popular attachments can be ordered with the vehicle:

• Roof on E- and M-trim open station vehicles (included with cab)
• Front glass windshield on M-trim open station vehicles (included with cab)
• Rear glass panel on M-trim open station vehicles (included with cab)
• Brush guard (standard on Honor and Signature Edition)
• Brush guard extensions
• Rear bumper (standard on Signature Edition)
• Front fender guards
• Rear fender guards and rear fender flares (standard on Signature Edition)
• Cargo box power lift (standard on Honor and Signature Edition)
• Deluxe cargo box with spray-in liner, brake lights, and taillights (standard on Honor and Signature Edition)
• Winch on M- and R-trim vehicles (except Honor and Signature Editions)

Electric power-assist steering (EPAS)

E-trim vehicles have manual steering; an M-trim or R-trim vehicle is needed for power steering.

Factory cabs

E-trim vehicles are only built in an open-station configuration. M-trim vehicles are built in both open-station and cab configurations. Cab components can be purchased as attachments for field conversion, however an M-trim vehicle with a factory-installed cab is recommended. All R-Trim vehicles are built with a factory cab.

Attachment-ready electrical system

All vehicles include wires and connectors for attachments like cargo box lift, brake lights, and taillights. Adding attachments to M- and R-trim vehicles is simplified because the base vehicle’s wiring harness includes connectors for additional attachments. See the following chart for details.

Headlights

E- and M-trim vehicles have single beam halogen headlights. R-trim vehicles have single beam light-emitting diode (LED) headlights. The following attachments can be used to upgrade vehicles to dual beam LED headlights.

XUV835E and XUV865E

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

XUV835M and XUV865M:

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

XUV835R and XUV865R:

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