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.
• 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

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
• 72-km/h (45-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
• 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.

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 Value Selling Navigator

Specifications

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

The E trim has no electric power-assist steering (EPAS) and has minimal electronic connections. This trim level is open station only.

E-trim level open operator station

On E-trim vehicles, adding attachments and accessories requires additional electrical harnesses and structure. See the chart below for information regarding what is required for attachments and accessories.

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

Build-to-order options

• Roof is 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)

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 284 mm (11.2 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 XUV865M

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 front 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

TrueTimber® KANATI camo XUV865R 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 XUV835R Signature Edition)

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.

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 Gator™ Utility Vehicle, you will notice there’s seating for you, plus two.

Three-passenger seating with room to spare

40/60 split three-passenger bench seat

Operator platform

The adjustable operator’s seat and tilt steering lets drivers of all sizes get comfortable, and the passenger grab handles help everyone feel secure. The low step height and generous opening between seat base and fender is even designed to accommodate bulky work boots.

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

XUV835M with optional half doors, roof, windshield, and rear panel

XUV865M with optional cab doors with roll down windows, roof, windshield, and rear panel

Roof, windshield, rear panel, and half doors attachments keep you dry, shaded, and out of the dust. 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

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

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 XUV835 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.

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

Cup holders

Four cup holders and center tray (shown on XUV835E)

Cab door cup holder and pocket

The dash has four cup holders, and cab vehicles have a cup holder in each door.

Dash and under-seat storage

Under seat storage (shown on XUV835E)

Glove box, storage pocket, and two dash bins (shown on XUV835M cab)

The vehicles also feature an enclosed glove box, center tray, dash storage pocket and under-seat storage. Depending on the configuration, vehicles may have up to three additional dash bins and under-hood storage.

Green and yellow XUV835R Signature Edition with included Ultimate Protection Package

Olive and black XUV865M with cab and optional brush guard

TrueTimber® KANATI camo XUV865R with optional Premium Protection Package

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.