XUV835R Crossover 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, mechanical front-wheel drive (MFWD), and constant velocity (CV) shafts

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

Differential lock switch and MFWD switches

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

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 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 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 with model year 2021 tan interior

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 with model year 2021 tan interior (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 and R spec cab door

Side windows and front window

Venting position

• Functioning door windows – roll up and down
• 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

HVAC details

Automotive-style controls on the center of the dash are 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
• Gas 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 controls and vents on the dash

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 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.

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 units with factory-installed cabs 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:

• 201 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 (shown on XUV865M)

Dual A-arm independent rear suspension features include:

• Unequal length and dual A-arm construction for superior wheel control and travel
• 231 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

XUV835M 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 (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

The R trim is cab only and comes with a sport steering wheel, stone interior and heating, ventilation, and air conditioning (HVAC) as standard equipment. Electrical wiring for increased flexibility for attachments also comes standard.

R-trim level interior (shown in tan on a model year 2021 vehicle)

• Headliner is standard

Standard headliner (shown in tan on a model year 2021 vehicle)

• Cloth 40/60 bench seat

Cloth bench seat

• Standard single-beam light-emitting diode (LED) headlights

LED headlight

• A and B post covers

Post cover (shown in tan on a model year 2021 vehicle)

Post cover (shown in tan on a model year 2021 vehicle)

• Rear panel cover

Rear panel cover (shown in tan on a model year 2021 vehicle)

• Interior rearview mirror

Rearview mirror (shown in tan on a model year 2021 vehicle)

• Sun visors

Sun visor (shown in tan on a model year 2021 vehicle)

Sun visor (shown in tan on a model year 2021 vehicle)

• Dome light

Dome light (shown in tan on a model year 2021 vehicle)

• Windshield wiper and washer

Windshield wiper

Windshield washer

Build-to-order options

• Available factory-installed winch
• 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)