812-cc (49.6-cu in.) gasoline engine

The machine is powered by an 812-cc (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:

• 38.8 kW (52 hp*) at 6000 rpm
• 71-km/h (44-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
• 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 radiator compartment for air flow
• 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 most capable frame available in a high-performance utility vehicle, 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 front suspension features include:

• 203.2 mm (8 in.) of travel provides ample compression and wheel extension, which keep all four wheels on the ground for superior traction and vehicle control
• 17.5-mm (0.6875-in.) solid anti-roll bar with fully rubber isolated connecting links and pivots for minimal vehicle body roll and quiet operation
• Heavy-duty nodular cast-iron knuckles to support the strut, 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
• Front sway bear for balanced handling

XUV rear suspension detail

Dual A-arm independent rear suspension features include:

• Unequal length, dual A-arm construction for superior wheel control and travel
• 228.6 mm (9 in.) of total travel provides ample compression and wheel extension, which 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 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 new 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 50 percent more air vs. previous designs to reduce heat and the amount of water ingestion into the CVT system. The system will reduce belt slipping and improve durability.
• A low- and high-speed forward gear offering:
  • Low range is 0 km/h to 43 km/h (0 mph to 27 mph), 825M S4
  • Low range is 0 km/h to 24 km/h (0 mph to 15 mph), 855M S4
  • High range is 0 km/h to 71 km/h (0 mph to 44 mph), 825M S4
  • High range is 0 km/h to 51 km/h (0 mph to 32 mph), 855M S4
• 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
• Powertrain reduction ratios:
  • The complete reduction ratios range for high gear is (8.6:1 at top speed and 42:1 at initial clutch engagement
  • The complete reduction ratios range for low gear is (17.9:1 at top speed and 86.8:1 at initial clutch engagement
  • NOTE: Delivery and torque to the ground 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, MFWD, and CV shafts

Side view of CVT intake and clutch on closure (XUV855 shown)

Front differential rocker switch

Rear end shot of sway bar, suspension components, and CV shafts (XUV825M S4)

• Operator interface
  • On-demand true 4WD system with an auto-locking front differential and dash-mounted electronic rocker switch is best-in-class; when the rocker switch is in the on (4WD) position, the front differential will automatically lock for extra traction when needed, but when the rocker switch is in the off (2WD) position, the vehicle will remain in 2WD
    • Provides exceptional traction in challenging conditions
    • Maintains turf-friendly operation in 2WD mode
    • Illuminated for low light operation
• Transaxle
  • Two-speed fully enclosed oil bath transaxle allows for superior pulling ability
  • Cast aluminum design is the most robust in the industry
  • Helical forward and reverse gears are used for quiet operation
  • Rear traction assist (differential lock) is built in and can be engaged on demand
    • Allows locking the rear drive wheels together
    • Provides increased traction in tough spots
    • NOTE: Differential design reduces scuffing of the turf during turns because it allows the inside wheels to turn slower than the outside wheels
  • Neutral start safety interlock for engine ignition system
  • 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
• Mechanical front-wheel drive
  • Electronic design is auto-locking for ease of use
    • Performs like a locking differential when engaged, but like an open differential when cornering
    • Offers positive engagement of both front wheels in forward and reverse as a differential package
    • Automatic engagement on the fly—no shift linkages required
  • Protected by a skid plate and frame
• Drive shafts
  • Rear CV shaft diameter measures 27 mm (1.1 in.) and designed for peak engine and braking torque
  • Front CV shaft diameter measures 23.9 mm (0.94 in.) and designed for peak engine torque
    Propshaft (transaxle to MFWD shaft) diameter measures 23 mm (0.91 in.) and designed for peak engine torque
  • All CV Shaft and propshaft joints are maintenance free and protected by exclusive Neoprene boots for durability

Deluxe cargo box

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

Deluxe cargo box tailgate

Tailgate handle

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 flat bed

Deluxe cargo box converted to flat bed (XUV825 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

Bedmat—protects the steel floor from dents

Cargo box power lift

Optional accessories for the deluxe cargo box include:

• Factory-installed brake and taillight
• Factory-installed spray-in liner (not shown)
  • Improves skid resistance and surface abrasion protection
• Cargo box bed mat
• Cargo box power lift

Specifications

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

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

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. Engine 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

Seating for four

The XUV825M S4 and XUV855M S4 models feature seating for four. The rear seat will convert to provide a flat surface for extra payload and there is sealed under-seat rear storage for additional cargo.

Rear seat down

Storage for additional cargo under rear seat

You will feel confident and comfortable, even on tough terrain, with a full-size Gator™ Utility Vehicle. You will feel stable with a low center of gravity and a wide stance. Engine braking and four-wheel hydraulic disc brakes keep you in control on steep descents, even when fully loaded. The power steering on M- and R-Trim vehicles, is smooth and responsive.

Standard four-wheel drive with rear differential lock

Dash mounted four-wheel drive and rear differential lock switches

With standard four-wheel drive and rear differential lock, both instantly available with the flip of a switch, you can get where you are going.

Dual A-arm front and rear independent suspension

Rear suspension and ground clearance

The independent suspension provides a smooth ride as 203 mm (8 in.) of front suspension travel and 229 mm (9 in.) of rear suspension travel cushions bumps and glides over ruts. And clearing rocks and roots is no problem with up to 305 mm (12 inches) of ground clearance.

Tires for any terrain

Terra Hawk all-terrain tire

Maxxis® Bighorn® 2.0 extreme terrain radial tire

Predator Heavy-Duty all-terrain radial tire

Full-Size Gator Utility Vehicles are available with three tire options:

• Terra Hawk all-terrain tires
  • Tread pattern and wide footprint provide excellent traction with minimal impact on terrain
• Maxxis Bighorn 2.0 extreme terrain radial tires
  • Radial construction provides shock absorption, allowing for a smoother ride
  • Non-directional tread pattern provides predictable cornering and claws up roots and rocks
• Predator Heavy-Duty all-terrain radial tire
  • Radial construction provides shock absorption, allowing for a smoother ride
  • Flat profile increases footprint area, reducing ground pressure
  • 8-ply rating delivers up to three times the life of Bighorn tires

Maxxis® Bighorn® is registered trademark of Cheng Shin Rubber Ind. Co., Ltd.

Full-size Gator™ XUVs are built to work hard and go the extra mile.

Heavy-duty frame

Underside view of XUV 845M

Underside view of XUV825M S4

The hefty frame is designed to stand-up to all the bumps and bends of the trail, and the standard full-underbody skid plate protects key components from damage.

Constant velocity boot protection

Constant velocity boot protection

Constant velocity joints are enclosed to keep water and dirt out. A protector shield protects the boot from trail debris.

Automotive-grade panels and optional protection packages

XUV 845R with optional premium protection package

The hood and side panels are made of automotive-grade materials that resist scratches and dents, and the cargo box is made of tough composite material that resists dents and rust. Optional protection packages look tough and provide even more protection.

TrueTimber® is a trademark of True Timber Outdoors Holding Company, LLC.

Instrument display, shift lever, and switches (shown on XUV 845R)

When you sit behind the wheel of a full-size Gator™ Utility Vehicle, you will be reminded of your favorite pick-up truck. There are controls at your fingertips, an easy-to-read instrument panel, and outlets to recharge your phone. Comfort and convenience packages include cargo box power lift, dual-beam LED headlights, turn signals, even a winch.

Shift from park and into gear with a throw of a single lever. Power steering on M- and R- trim vehicles is smooth and responsive.

When the going gets tough, you can instantly engage four-wheel drive and rear differential lock with switches. Even at night, the backlit switches are easy to see. If a front wheel starts to slip, the front differential automatically locks to pull you through.

When you hop into the seat of a full-size two-row Gator™ Utility Vehicle, you will notice the front and rear bench seats accommodate yourself and three passengers.

Four-passenger seating with room to spare

Overhead view of XUV825M S4 (shown with half-doors)

Your entire crew will enjoy spacious seating. Passenger grab handles, hip restraints, and rear bar help everyone feel secure.

Roof, windshield, rear panel, poly door, and heater options

XUV825M S4 with optional rear panel, roof, windshield, and poly cab doors

Roof, windshield, rear panel, and half doors attachments keep you dry, shaded, and out of the dust. Poly cab doors with roll down windows and heater attachments keep you warm all winter.

The full-size Gator™ XUV can haul 454 kg (1000 lb), so load it up with confidence. You can also make fewer trips with 1814 kg (4000 lb) of towing capacity and a standard 51-mm (2-in.) receiver hitch.

Built-tough cargo box

Cargo box (shown with spray-in liner and optional taillight protectors)

Cargo box converted to flatbed (shown on one-row vehicle)

The cargo box resists dents, scratches, and rust because it is made from a tough composite material. You will have no problem securing loads with integrated tie bars and 14 tie-down points. You can also convert the cargo box to a flatbed when you need to haul big and bulky loads.

The cargo box measures 1143 mm (45 in.) long, 1320 mm (52 in.) wide, and 305 mm (12 in.) deep.

One-handed tailgate

Tailgate handle

Since your hands are always full, the tailgate can be opened and closed with one hand. You can also lower the tailgate to carry longer items or remove it for easy cleanout.

Power lift

Deluxe cargo box unloading rocks (shown on one-row vehicle)

To save your back, the optional cargo box power lift empties heavy loads with the push of a button.

812-cc (49.6-cu in.) gasoline engine and drivetrain

The XUV 845 and XUV825M S4 Gator™ Utility Vehicles are powered by an electronic fuel injection (EFI) gasoline engine with liquid-cooled, dual-overhead cams. This engine is designed to provide maximum power and fuel efficiency to muscle through tough jobs.

It also has plenty of torque in low range, and fast speeds in high range. The enclosed drivetrain automatically adjusts for fast acceleration, along with powerful hauling and hill-climbing capabilities.

Two-row full-size Gator XUVs come packed with places to store tools, gear, and beverages.

Folding rear seat and under seat storage

Folding the rear seat to increase cargo space

Rear under seat storage

The rear seat of two-row vehicles folds forward providing additional cargo space. An under-seat storage compartment is also found under the rear seat.

Cup holders and glove box

Glove box (shown on XUV825M S4)

Front cup holders and center tray (shown on XUV825M S4)

Two front and two rear cup holders, glove box, and center tray are within reach.

Green and yellow XUV 845R

Olive and black XUV 845R

TrueTimber® KANATI camo XUV 845R

You will get noticed with the distinctive styling of full-size Gator™ XUVs. Available in three colors, with various protection packages, and more than 100 attachments, you can create a custom look that will turn heads.

TrueTimber is a trademark of True Timber Outdoors Holding Company, LLC.

Large fuel tank fill opening

Full-size Gator™ XUVs have a large 42.8-L (11.3-gal.) fuel tank so you go further between fill ups. A 76-mm (3-in.) diameter fill opening reduce spills.