The John Deere Gator XUV 590i is a popular mid-size utility vehicle known for its nimble handling, 4WD capabilities, and fuel-injected twin-cylinder engine. Designed for both work and recreation, it strikes a balance between durability and affordability. However, like all machines, it isn’t immune to problems—especially as it ages or sees rough terrain use.
This in-depth guide covers:
- Common problems and their causes
- Fixes and maintenance tips
- Technical specifications
- Reliability and performance insights
🔧 Common John Deere 590i Problems and Fixes
1. Hard Starting or No Start Condition
Symptoms:
- Cranks but won’t fire
- Only starts with throttle pressed
- Cold-weather failures
Causes:
- Weak battery or poor ground
- Faulty fuel pump or clogged filter
- Dirty throttle body or IAC valve
- Failing spark plugs or coils
Fixes:
- Replace battery if voltage drops under load
- Clean or replace fuel filter (inline or tank-side)
- Inspect fuel pump PSI (should be ~39 PSI)
- Clean throttle body with non-chlorinated cleaner
- Replace spark plugs with OEM NGK or Champion types
2. Stalling at Idle or During Acceleration
Causes:
- Dirty fuel injectors
- Faulty idle air control (IAC)
- Bad engine sensors (MAP, TPS)
Fixes:
- Use fuel injector cleaner additive
- Replace or test IAC valve
- Scan ECU for fault codes (e.g., MAP sensor voltage)
- Check intake boot and vacuum hoses for leaks
3. Transmission Issues (CVT Problems)
Symptoms:
- Belt squeal or burning smell
- Jerky acceleration
- No movement in forward/reverse
Causes:
- Worn CVT belt
- Dirty or glazed clutch
- Misaligned or sticking secondary clutch
Fixes:
- Replace belt with John Deere OEM or Gates G-Force
- Clean clutches with Scotch-Brite + brake cleaner
- Inspect sheave alignment and spring tension
- Consider upgrading to heavy-duty clutch kits for severe duty use
4. Overheating Problems
Causes:
- Low coolant or airlocks
- Dirty radiator fins or debris in fan
- Thermostat stuck closed
- Faulty coolant temp sensor or fan relay
Fixes:
- Flush and refill with proper JD coolant
- Pressure wash radiator (from rear side)
- Replace thermostat (OEM recommended temp)
- Use multimeter to test fan circuit
5. Electrical Problems (Dash Lights, Intermittent Power Loss)
Symptoms:
- No power to dash
- Headlights flicker
- Intermittent stalls
Causes:
- Corroded ground or battery terminals
- Blown fuses or shorted relays
- Worn ignition switch or wiring harness rub-through
Fixes:
- Clean and grease all grounds (chassis and engine block)
- Test fuses and relays with continuity tester
- Replace ignition switch if key feels loose or erratic
- Wrap exposed harness near frame contact points
6. Excessive Engine Noise or Vibration
Causes:
- Engine mounts worn or loose
- Misfiring due to plug or coil
- CV joint or driveline out of balance
Fixes:
- Inspect and tighten engine mounting bolts
- Replace spark plugs and verify firing order
- Check U-joints and driveshaft angles
7. 4WD Not Engaging
Causes:
- Blown 4WD fuse or switch
- Faulty actuator motor
- Dirty front differential
Fixes:
- Test 4WD switch continuity
- Power actuator directly to test function
- Change front diff fluid (use JD Hy-Gard or equivalent)
⚙️ John Deere 590i Technical Specs
| Feature | Specification |
|---|---|
| Engine | 586cc DOHC EFI 2-cylinder (gas) |
| Horsepower | 32 HP |
| Top Speed | ~48–50 mph |
| Transmission | CVT with Hi/Lo/Neutral/Reverse/Park |
| Drive Type | On-Demand 4WD |
| Fuel Capacity | 7.4 gallons |
| Ground Clearance | 10.5 inches |
| Towing Capacity | 1,100 lbs (trailer), 1,500 lbs (with brakes) |
| Payload Capacity | 800 lbs (bed), 1,200 lbs (total) |
| Dry Weight | ~1,370 lbs |
| Brakes | 4-wheel hydraulic disc |
| Suspension | Independent dual A-arm front and rear |
🧰 Maintenance Schedule Overview
| Item | Interval |
|---|---|
| Engine Oil & Filter | Every 100 hours or annually |
| Air Filter | Clean every 25h, replace every 100h |
| CVT Belt | Inspect every 100 hours |
| Coolant | Replace every 2 years |
| Spark Plugs | Every 200 hours |
| Brake Fluid | Check every 100 hours |
| Valve Clearance | Every 400 hours |
💡 Tips to Extend Lifespan
- Use fuel stabilizer if storing over 30 days
- Keep radiator and CVT intakes clean from grass/debris
- Store indoors or cover to avoid electrical corrosion
- Use only OEM or high-quality aftermarket parts
- Warm up the engine before aggressive driving
🧩 Common Aftermarket Upgrades
| Upgrade | Benefit |
|---|---|
| Heavy-duty CVT belt | Prevents slippage and extends life |
| Clutch kit | Better power delivery on hills |
| Skid plates | Protection for rocky terrain |
| LED light bars | Improves night visibility |
| Roof and windshield kits | Comfort and protection |
📌 Final Thoughts: Is the John Deere 590i Reliable?
The John Deere XUV 590i is a solid machine when properly maintained. Most of the problems are minor and preventable with timely service. It’s an ideal UTV for moderate workloads, trail riding, and recreational users who want John Deere dependability without stepping up to the larger XUV 835 or Gator HPX series.
For those willing to keep up with basic maintenance and occasional sensor replacements, the 590i can run trouble-free for thousands of hours.
I’m David man behind Lawn Mowerly; I’ve been dealing with lawnmowers and Tractors with my father since I was a kid. I know every make and model and what each one is capable of and love helping people find the perfect equipment for their needs.