XUV590M S4 Crossover Utility Vehicle

The Gator™ XUV Mid-Size Crossover Series Utility Vehicles have 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 (shown on XUV590 engine)

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:

• Ability to creep along slowly to maneuver in tight spaces
• Standard full-clutch enclosure with a high intake and exhaust ensures a dry belt when crossing water
  • High-speed fan on drive clutch provides longer belt and clutch life by keeping components cool
• TEAM® industry clutches provide high performance and longevity 

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.

Four-wheel drive (4WD), transaxle, mechanical front-wheel drive (MFWD), and constant-velocity (CV) shafts

XUV590 transaxle

XUV560/XUV590 MFWD

4WD

• Selectable 4WD system with a limited slip front differential and dash-mounted electronic rocker switch
  • Provides exceptional traction in challenging conditions
  • 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

• Low, high, neutral, reverse, and park transaxle
• Automotive-style, integrated park position in transmission
• 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.
• Low range for maximum torque delivered to the wheels for hauling, pushing, and pulling
• High range for maximum vehicle speed
• Cast-aluminum design for lower weight
• Helical forward and reverse gears are used for quiet operation
• Rear traction assist (differential lock) is controlled with an electronic rocker switch
  • NOTE: Locked differential design may increase scuffing of the turf during turns because the rear wheels are turning at the same speed through a turn.
• 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
• Vertically oriented oil drain for easy maintenance
• Protected by a skid plate

MFWD

• Electronically selectable by the operator
  • Offers limited slip functionality for precision steering and great traction while pointing and shooting out of a corner.
• Near instantaneous torque to the front wheels after engaging switch
• Vertically oriented oil drain for easy maintenance
• Protected by a steel skid plate and frame

Drive shafts

• Front and rear CV shaft diameter measures 23 mm (0.9 in.) and designed for high engine torque
• Propshaft (transaxle to MFWD shaft) diameter measures 23.8 mm (0.94 in.) and designed for high engine torque
• All CV shaft joints are maintenance free and protected by exclusive inboard and outboard thermoplastic elastomer (TPE) boots for durability. TPE material is more puncture resistant than neoprene, which is used by many competitors.

TEAM is a trademark of TEAM Industries.

586-cc (35.8-cu in.) gasoline engine

Radiator

The Gator™ XUV590M Crossover Series Utility Vehicle is powered by a 586-cc (35.8-cu in.), inline twin-cylinder, electronic fuel-injected (EFI) gasoline engine. The engine is electronically controlled through an engine control unit (ECU) to ensure optimal engine performance.

The engine offers the following performance and reliability features:

• 23.8 kW (32 hp*) at 5600 rpm
• 77 km/h (48 mph) top speed
• Electronic fuel injection (EFI) with engine control unit (ECU)
• Liquid cooled
• Designed for cold-weather starting (tested to -28.9°C [-20°F])
• Wet-sump lubrication system
• Spin-on oil filter and oil pan drain accessible through skid plate for easy servicing
• High air-flow air filter
• 875-W (65 maximum amp) charging system for accessory capability (see engine section for alternator output curve)
• Spark-arresting muffler is United States Forest Service (USFS) approved
• Low fuel consumption and large 28-L (7.4-U.S. gal.) fuel tank
• Environmental Protection Agency (EPA) and California Air Resources Board (CARB) compliant

* The engine horsepower information is provided by the engine manufacturer to be used for comparison purposes only. The actual operating horsepower will be less.

Instrument panel and backlit switches

Sealed under-hood storage

Ergonomically placed controls

In-dash cup holders and sealed glove box

S4 optional under-seat storage

• Display features include:
  • Speed
  • rpm
  • Fuel
  • Mechanical front-wheel drive (MFWD)/rear diff-lock
  • Gear position
  • Hour meter
  • Service interval warning light
• Operator-centric design provides class-leading ergonomics and comfortable seats
  • Easy entry/exit and pass through for operator and passenger
  • Optimal seating position provides more legroom
  • Automotive-like ergonomics
  • Excellent comfort while driving
• Best-in-class sealed storage volume of 34 L (9 gal.) with a large in-dash glove box and under hood storage. An additional 34 L (9 gal.) of under-seat storage is available on the S4 models.
• Hinged hood rotates open without tools for access to storage
• Side-by-side seating provides ample room for one operator and one passenger
  • Seats tilt forward for ease of service and to keep dry during outdoor storage
• Two cup holders are located within reach of the operator's station
• Standard 12-V direct current (VDC) outlet is conveniently located on the instrument panel
• Seven predrilled dash switch locations with snap out caps for various electrical accessories
• Occupant protective structure (OPS) with three-point seat belts and passenger side grab handle located on front post
• Start in gear, neutral, or park position for quick starting. The service brake must be engaged to start when in gear, neutral, or park.

The cargo box consists of a high-density polyethylene copolymer composite material that eliminates rust, dents, and reduces noise. This large, one-piece design has rounded inside corners to ensure material removal when tilted. The composite box is highly ribbed and supported with a welded, steel-ladder structure to ensure hard-driving performance and longevity. The three highly styled exterior pieces are made of TPO for extra durability.

Cargo box tailgate

Tailgate handle

Tailgate pivot and removal feature

Removable lanyards

The tailgate can be opened or removed for easier cleanout and to carry longer items. It features truck-like performance and can be operated with one hand.

The tailgate’s pivot point is made of hardened steel for durability and designed for tool-free removal. The standard lanyards can also be disconnected without tools to remove the tailgate for convenient loading and unloading tasks.

Cargo box tilt and removal

Integrated handle for manual cargo box tilt (both sides)

Tilted cargo box

The cargo box ease of use is critical to performing tasks quickly and efficiently. Starting with the truck-style tailgate, the removal of content in this cargo box could not be easier. The manual release also functions as the lift lever, done in a smooth, one-step motion. It can even be tilted from both sides of the vehicle. To reduce the overall effort of lift, the pivot point of the cargo box is closer to the center. The combination of easy-to-use attributes makes this cargo box best-in-class.

For servicing the vehicle’s systems, the cargo box is easily removable. With the removal of two bolts, the cargo box can easily be detached from the vehicle frame.

Integrated tie-down points

Integrated tie-down point in cargo box bed

Additional tie-down points

The cargo box offers integrated tie-down points for increased versatility. Tie-down points are located in the following areas:

• Flip-up D-shaped rings in all four corners inside the cargo box bed
• Multiple points along the edge of the cargo box side walls
• Tie-down bars on either side of the cargo box with optional cargo box rail kit. This kit also provides a mounting system using accessories that possess the 25.4-mm (1-in.) quick clamp.

Optional accessories

Cargo box rail system

Box mat

Cargo box wall extensions (shown on RSX)

Optional accessories for the cargo box include (see price pages or JDConfigurator for complete list):

• Cargo box rail system
• Cargo box mat
• Cargo box wall extensions
• Spare tire rack
• Bucket holder

Specifications

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

XUV front suspension detail

To complement the comfortable operation station, the XUV560 and XUV590 Series are equipped with four-wheel independent suspension. This unique suspension set-up provides an unparalleled ride over challenging terrain and excellent handling through corners.

The engineering team, in collaboration with engineering firms that consult with Formula 1®, NASCAR®, and INDYCAR® teams, built a capable suspension system for class-leading operator comfort no matter what the terrain.

Dual A-arm front suspension features include:

• Dual, wide arch A-arm design provides maximum front-wheel control, precise steering, and maximum ground clearance out to the wheel
• 203 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
• Adjustable coil-over shocks absorb the most demanding terrain
• Solid anti-roll bar with fully rubber isolated connecting links and pivots is tuned to provide the most agile and predictable handling
• Camber during compression to compensate for body roll and to maintain an optimal tire contact patch for improved cornering grip
• Increasing vehicle width during compression for additional stability.
• High-strength ASTM 80-55-06 ductile cast-iron knuckle and upper A-arm to support the high stresses of the shocks, constant-velocity (CV) shaft, and wheels
• Automotive-style, fully boxed and welded, high-strength steel, lower A-arms to minimize unsprung mass and maximize strength
• Maintenance-free, rubber torsional A-arm pivots for long life and quiet operation
• CV shaft protection from sticks that may puncture the rubber boot
• Anti-dive front suspension geometry provides a solid platform for confident braking
• Optimized steering geometry using ADAMS CAR simulation to minimize steering effort and maximize terrain feedback

XUV rear suspension detail

Independent rear suspension features include:

• 203 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
• Unique, independent rear-suspension design ensures a great ride and protection for the CV shafts
• Adjustable coil-over shocks absorb the most demanding terrain
• Camber during compression to compensate for body roll and to maintain an optimal tire contact patch for improved cornering grip
• Increasing vehicle width during compression for additional stability.
• High-strength ASTM 80-55-06 ductile cast-iron knuckle, lower A-arm, and upper link to support the high stresses of the shocks, CV shaft, and wheels with the toughness to survive impacts from boulders
• Maintenance-free rubber torsional A-arm pivots for long life and quiet operation

Optional Fox™ Shocks are available to factory install

Exclusive aluminum-body, high-pressure monotube FOX racing shocks

• Fully adjustable spring preload for different driving styles
• High-pressure nitrogen gas is separated from the damping oil by an internal floating piston (IFP). The separation prevents aeration (frothing) and viscosity degradation of the oil which improves damping consistency and performance fade.
• Pressure and heat generation in the monotube is less than a traditional twin-tube shock, allowing for better vehicle control in aggressive conditions.
• The single aluminum shell of the monotube design allows for more efficient heat rejection and lower overall unsprung mass.
• Mounting the shaft end of the shock to the suspension arm lowers the unsprung mass of the suspension system, leading to improved suspension response.

NASCAR is a trademark of NASCAR. INDYCAR is a trademark of Brickyard Trademarks Incorporated. Formula 1 is a trademark of Formula One Licensing BV, a Formula One Group Company.

XUV590M with power steering

The Gator™ XUV590M Utility Vehicles are equipped with rack and pinion steering with power steering. These automotive-type systems exhibit excellent handling characteristics, as well as responsive steering and low steering effort.

Automotive-type, rack-and-pinion steering features include:

Optional electric power-assist steering (EPAS) system. Features of EPAS include:

• 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.
  • Steel ball-bearings secure the steering shaft and delivers smooth, responsive operation
  • Tight turn radius of 3.7 m (12.3 ft) for excellent maneuverability
  • Completely sealed rack-and-pinion for long life
  • Low steering ratio (lock-to-lock steering wheel rotations) provides more responsive steering and less operator input
  • Shaft U-joints are phased for a smooth, uninterrupted motion of the steering wheel
  • Ackerman steering design provides more responsive steering, decreases tire wear when used on hard surfaces and is turf friendly (see description below)
  • Minimal bump steer eliminates unintended vehicle direction changes when traversing terrain and permits less feedback to the steering wheel (see description below)

The tire scrubbing, which also creates unwanted heat and wear in the tire, can be eliminated by turning the inside wheel at a greater angle than the outside one (Ackerman steering).

NOTE: Some competitors use parallel steering instead of Ackerman steering.

Bump steering defines the change in the forward steering angle (thus wheel position) as the suspension travels through its full motion. A large amount of angular change (5 degrees to 7 degrees) will alter the vehicle's direction and excessively move the steering wheel.

The exclusive, convertible cargo rack design offers rear seating for two passengers and with a flip of a lever, expands the cargo capacity of the XUV560 S4 and XUV590 S4 by 48 percent.

The convertible cargo rack design offers the ultimate in flexibility for multi-passenger seating capacity and utility.

Most of the time a vehicle is only transporting one or two people, but at any given moment a third or fourth passenger may come along. The quick and simple convertible cargo rack can be switched back and forth in seconds with a flip of a lever. It provides comfortable rear seating with choice of ample leg room or 48 percent more cargo capacity.

Up position

Down position

Some key points about the convertible cargo rack:

• Offers additional cargo volume of 0.12 m³ (4.3 cu ft) and 90.4-kg (200-lb) capacity.
• Efficient one-step conversion from rear seat to cargo rack in 2-3 seconds (and vice-versa) can be easily done by one person