XUV855M S4 Cross-over Utility Vehicles

XUV855D engine

Remote intake and restriction indicator

The XUV855D is powered by an 854-cc (0.854-L), three-cylinder, liquid-cooled, four-cycle diesel engine.  

The advanced engine delivers superb starting, idling, and throttle response during operation. With minimal noise vibration and harshness (NVH), the 855D is the smoothest and quietest running diesel in its class.

The engine offers the following performance and reliability features:

• Indirect injection diesel with glow plugs ensures fast starts in cold temperatures
• Rated 16.1 kW (21.9 hp) at 3400 rpm using standard ECE-R24
• Overhead valve design for greater efficiency and fuel economy
• Tier 2/IV (U.S.A.) and EC (European) emission compliant
• 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
  • Sealed radiator compartment keeps trash and debris on the outside of the grille

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, 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

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
• Rear sway bar for lateral stability

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 CVT (Continuously Variable Transmission) air intake draws in 50 percent more air versus previous designs, to reduce heat and the amount of water ingestion into the CVT system. The system reduces belt slipping and improves durability.
• A low- and high-speed forward gear offering:
  • Low range is 0 km/h to 43 km/h (0 mph to 27 mph) XUV825i
  • High range is 0 km/h to 71 km/h (0 mph to 44 mph) XUV825i
  • Low range is 0 km/h to 24 km/h (0 mph to 15 mph), XUV855D and XUV855D S4
  • High range is 0 km/h to 51 km/h (0 mph to 32 mph), XUV855D and XUV855D S4 (limited to 40 km/h [25 mph] with EEC homologation kit)
• Ability to creep along slowly to maneuver in tight spaces
• Standard full clutch enclosure with high speed fan provides longer belt and clutch life
  • Provides greater access through water up to 56 cm (22 in.) high
• 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 tyre size which is a function of nominal size and pressure. These ratios will vary depending on the vehicle model.

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

Top view of engine (XUV855D shown)

Side view of CVT intake and clutch on closure (XUV855D shown)

Front differential rocker switch

Rear end shot of transaxle/CV shafts (XUV625i)

• 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 visibility in low light conditions
• 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 now 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

Deluxe cargo box converted to flat bed

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

Accessories

Brake and taillight with protector

Bedmat—protects the steel floor from dents

Cargo box power lift

Cargo box power lift

Standard accessories for deluxe cargo box include:

• Brake and taillight
• Factory-installed spray-in liner (not shown)
  • Improves skid resistance and surface abrasion protection 
    

Optional accessories for the deluxe cargo box include:

• Brake and taillight protector
• Cargo box bed mat
• Cargo box power lift

Specifications

The XUV855D S4 features 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.