Polaris Xpedition 4" Long Travel Kit

Adventure Better with a Polaris Xpedition Long Travel KitWhen you’re setting out on an unknown route and you’re miles away from the trailer, you need to make sure your Xpedition can handle whatever you encounter. Upgrade your suspension to SuperATV’s Polaris Xpedition 4” Long Travel Kit to get more stability and room for bigger tires. With an 8” wider machine, you can handle off-camber trails more easily and run up to 33” tires to conquer any obstacle.

• Increases full width to 72” overall
• Includes 6061-T6 billet aluminum tie rods
• Fit up to 33” tires

Boost Off-Road StabilityYour Xpedition is a high-profile machine, and when you load it up with a ton of overlanding gear, it’s really top-heavy. Our Polaris Xpedition long travel kit adds 4” to each side of your machine for an 8” wider machine overall. That gives you tons of stability to load up your roof rack and ride with confidence across all kinds of terrain.

Ultra-Durable SuspensionThe extra-wide front and rear A-arms in this kit are built to take a beating. They use 1.25” by 0.138” wall steel DOM tubing. That makes all these A-arms tough enough for any adventure. To top them off, they come with preinstalled UHMW bushings and a lifetime warranty.

Includes Premium Billet Aluminum Hex Tie RodsYou get our premium billet aluminum hex tie rods to go with your Polaris Xpedition long travel kit. They look slick as hell and back up their good looks with extreme strength and lightweight construction. Plus, they use heat-treated chromoly tie rod ends to beef up the weakest point of your steering system.

Includes Unbeatable Rhino 2.0 AxlesA long travel kit of this caliber wouldn’t be complete without Rhino 2.0 Axles. The oversized CVs give you impressive articulation angles and beefed-up shafts provide incredible strength. They’re designed to withstand the demands of rough riding day in and day out. Plus, they’re backed with an industry-leading 18-month warranty.

Kit Includes:

• Front and rear high-clearance A-arms
• Billet aluminum hex tie rod kit
• Rhino 2.0 Axles
• Extended front brake lines
• Preinstalled UHMW bushings and sleeves
• New tender springs (specific models only)
• All hardware

Lift SetupMax Tire SizeLong travel kit only33"4” GDP Portals38"6” GDP Portals39”

• Adds 4” to each side (72” overall)
• Fit up to a 33” tire
• Includes preinstalled UHMW bushings
• Comes with everything you need to install and go
• Preadjusted pivot blocks for perfect camber

Billet Aluminum Hex Tie Rod Features:

• Solid 6061-T6 billet aluminum tie rods for maximum strength, performance, and style
• Uses heat-treated chromoly steel monoball tie rod ends
• Stock length replacement
• Easily adjustable without disassembling
• Tie rods backed by a lifetime warranty

Rhino 2.0 Axles Features:

• 100% stronger than stock
• Increased shaft size
• Constructed of 4340 chromoly steel and finished with a proprietary heat treatment
• Industry-leading 18-month warranty
• Field and lab tested for extreme strength and endurance
• CAD drawn for expert precision
• 18-month warranty

Frequently Asked Questions (FAQ)

What does a long-travel kit do for a Polaris Xpedition?

A long-travel kit widens your suspension and increases stability, which helps control body roll on off-camber and uneven terrain. This 4-inch kit adds 4 inches per side, making your Xpedition 8 inches wider overall for better confidence when fully loaded with overland gear.

How big of a tire can I run with the Polaris Xpedition 4-inch long-travel kit?

With this long-travel kit installed, you can run up to a 33-inch tire without additional lift components. The added width creates more clearance and stability, which is ideal for trail riding, overlanding, and rocky terrain.

Will this long-travel kit fit my specific Polaris Xpedition model?

This kit is designed to fit 2024+ Polaris Xpedition ADV and XP models, including two- and five-seat variants and NorthStar editions. Fitment depends on your exact submodel, so always check the fitment tab before ordering.

What makes SuperATV’s Polaris Xpedition long-travel kit different from others?

We engineered this kit with oversized DOM steel A-arms, billet aluminum hex tie rods, and Rhino 2.0 axles for maximum strength and reliability. Every component is field-tested and lab-tested to hold up to long-distance adventure use and heavy loads.

Does this kit improve stability when carrying overland gear?

Yes, widening the suspension significantly improves stability, especially when running roof racks, cargo, and camping equipment. The wider stance helps reduce tipping and sway on uneven trails and side hills.

Does the long-travel kit come with everything needed for installation?

The kit includes front and rear A-arms, billet tie rods, Rhino 2.0 axles, extended brake lines, preinstalled UHMW bushings, and all required hardware. Some submodels include new tender springs depending on factory suspension configuration.

How difficult is it to install the Polaris Xpedition long-travel kit?

Installation is a full suspension upgrade and is best suited for experienced DIY installers or professional shops. We provide detailed step-by-step installation instructions to guide you through the process.

Is this long-travel kit backed by a warranty?

Yes, major components such as the A-arms and billet tie rods are backed by a lifetime warranty, and the included Rhino 2.0 axles carry an 18-month warranty. This coverage reflects our confidence in the materials, design, and real-world durability of the kit.

Check out the PDF Installation guide here