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Part of the John Deere Repair Manuals.
This is the John Deere 825i Technical Manual (TM107119), the factory service documentation for the XUV Gator utility vehicle built from 2010 through 2014. It is a 430-page PDF covering the SQR372 FI gas engine and every major system on the machine, from safety and specifications through engine, electrical, power train, steering, and brakes.Written for experienced technicians, it gives you the diagnostics, tests, adjustments, and repair procedures John Deere uses, plus torque values and capacities you need for accurate work. You can trace a fault, tear down and rebuild the CVT drive, chase an electrical problem through the wiring, or set steering and brake specs by the book.The file is fully text-searchable with bookmarks, so you jump straight to the section you need. Download it once and print any page you want for the shop bench.
What's Inside This John Deere 825i Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-8 | - |
| Specifications and Information | 9-20 | O-Ring Seal Service, General Information, Coolant, Serial Number Locations |
| Engine - Gas | 21-100 | Cylinder Head, Valves and Springs, Crankshaft, Camshafts, Piston, Connecting Rod, Cylinder Bore, Timing Belt |
| Electrical | 101-228 | Park Brake, Warning Buzzer, Oil Pressure Light, Cooling Circuit, 4WD Drive Circuit, Light Circuit, Headlight Circuit, Electronic Controller |
| Power Train | 229-314 | Emfwd Driveshaft, Front Differential, Rear Axle Halfshaft, Cv Joint and Boots, Front Drive Gear Box, Transaxle, Differential, Primary Clutch |
| Steering | 315-354 | Steering Knuckle, Front Wheel Bearing, Ball Joint, Steering Wheel, Steering Shaft, Steering Gearbox, Front Coilover Shock Absorber, Rear Coilover Shock Absorber |
| Brakes | 355-390 | Brake System, Park Brake Components, Park Brake Housing Components, Hydraulic Brakes, Park Brake, Master Cylinder, Brake Pedal, Brake Calipers |
| Miscellaneous | 391-424 | Wheel, Occupant Protective Structure (Ops), Hood Latch, Hood, Headlight, Front Bumper/Skid Plate, Front Grille, Front Fender |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Oil Capacity (with filter) | 2.2 L (2.3 qt) | p. 23 |
| Cooling System Capacity (Including recovery tank) | 5.0 L (5.2 qt) | p. 23 |
| Fuel System Pressure | 315 - 345 kPa (45.6 - 50.4 psi) | p. 23 |
| Spark Plug Gap | 0.9 - 1.05 mm (0.035 - 0.041 in.) | p. 23 |
| Connecting Rod End-Cap Nut Torque | 40 N•m (30 lb-ft) | p. 25 |
| Battery Voltage | 12V | p. 107 |
| EMFWD Differential Capacity | 580 mL (19 oz) | p. 227 |
| Front Wheel Toe-In | 4 ±3 mm (0.16 ±0.12 in.) | p. 313 |
| Brake Rotor Thickness (Minimum) | 4.76 mm (0.19 in.) | p. 353 |
| Fuel Tank Capacity | 20.1 L (5.3 gal) | p. 389 |
| Wheel Lug Bolt Torque (Aluminum Alloy Wheel) | 142 N•m (105 lb-ft) | p. 389 |
| Steering Wheel Nut Torque | 38 N•m (28 lb-ft) | p. 313 |
John Deere 825i Common Problems This Manual Covers
CVT belt and clutch overheating under load
Owners who tow heavy or climb hills report the 825i losing pulling power as the CVT belt and clutch overheat and wear. The Power Train section covers belt, clutch, and drive service.
Manual Section: Power Train p. 229Machine loses drive after hours
A worn or burned CVT drive belt, clutch damage, or belt slippage can leave the Gator refusing to move after extended use. Power Train diagnostics and repair walk through inspection and replacement.
Manual Section: Power Train p. 229Loss of steering control
Affected power-steering units had a recall for steering shaft separation from the rack assembly, which can cause a sudden loss of steering. The Steering section covers shaft, rack, and linkage service.
Manual Section: Steering p. 315Intermittent starting or electrical failure
Hard-start or no-start conditions often trace to a blown 40 amp fuse, a weak battery, or poor connections. The Electrical section covers fuses, the 12V battery, and circuit diagnostics.
Manual Section: Electrical p. 101Rough running from intake gasket leak
A bad intake or carb gasket lets unmetered air in and upsets how the gas engine runs. Engine service in this manual covers gasket replacement and fuel system checks.
Manual Section: Engine - Gas p. 21Brake rotor and pad wear
Vehicles worked hard wear brake rotors down toward the 4.76 mm minimum thickness, reducing stopping power. The Brakes section gives rotor specifications, inspection, and replacement steps.
Manual Section: Brakes p. 355Frequently Asked Questions
Which machine does this manual cover?
It covers the John Deere 825i XUV Gator Utility Vehicle with the SQR372 FI gas engine, built from 2010 to 2014. This is the factory technical manual, publication TM107119.
What causes the 825i to lose pulling power?
Heavy towing and sustained uphill work overheat the CVT belt and clutch, which wear and slip until the machine loses drive. The Power Train section covers belt, clutch, and drive inspection and repair. p. 229
Does the manual cover the electrical system and wiring?
Yes. The Electrical section covers the 12V battery, fuses, wiring, and circuit diagnostics for the 825i, so you can trace faults instead of guessing. p. 101
What is the engine oil capacity for the 825i?
With a filter change the engine holds 2.2 L (2.3 qt) of oil. Fill capacities and specifications are listed in the Engine section. p. 21
What do I get after purchasing this John Deere 825i manual?
Checkout delivers a 430-page searchable PDF, downloadable right away. Open it on your laptop, tablet, or phone and carry it straight to the shop floor.
Can I print this John Deere 825i manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are there wiring harness diagrams in this John Deere 825i manual?
Complete wiring diagrams are included, covering all electrical circuits, harness routing, and connector pinouts for the John Deere 825i.
