Polaris Xpedition (2024+) Skid Plate Instructions
Step 1: Remove Stock Skid
Remove two (2x) T-40 Torx bolts from each plastic side panel to help remove the stock skid plate. Keep all hardware for later use. Once removed, re-install the T-40 Torx bolts on each side panel.
Step 2: Cut Stock Skid Plate
Cut the stock skid plate with a jig saw where marked to remove the Quarter Guards. Re-install each Quarter Guard with the stock forward two (2x) T-40 Torx bolts. Leave the countersunk mounting holes empty for now.
Step 3: Install Crossmember Bracket
Use two (2x) stock bolts without washers to hold extension brackets in location (A) during skid plate installation. Ensure the extension bracket arrow points toward the front. Mount with J-clips, tips facing inward toward the vehicle. Remove and re-install bolts with washers during the main skid plate installation.
Step 4: Install Side Spacers
Install spacers along the length of the outer frame rails. Ensure that the pointed end faces the rear. Install ½" spacer with cutouts facing outward. Spacers are an interference fit; some force may be required. The spacer should sit flush with the inner frame rail. Refer to the diagram on page 3 for placement.
Step 5: Install Skid Plates
Starting with the Rear Skid and working forward, install bolts with washers loosely for adjustment. Thread locking compound is recommended.
Rear Skid Installation:
- 9x Stock Bolts in locations (A).
- 2x ¼"-20 x ¼" Self Tapping Bolts in locations (B).
- 4x M6-1.0 x 16mm Flange Bolts in locations (C).
Main Skid Installation:
- 6x Stock Bolts in locations (A).
- 4x M6-1.0 x 16mm Flange Bolts in locations (C).
- 4x M6-1.0 x 30mm Flange Bolts in locations (D).
Front Diff Skid Installation:
Align the Front Diff edge with the Main Skid. Drill, Tap, & Install six (6x) ¼"-20 x ½" Self Tapping Bolts in Front Diff Skid locations (E).
Rock Sliders Installation (Optional)
For Side Bolts / Rock Sliders: Drill, Tap, & Install ten (10x) ¼"-20 x 1½" Self Tapping Bolts in Side Bolts locations (F).
If Rock Sliders are to be installed: Replace the (F*) locations with ten (10x) ¼"-20 x 2" Self Tapping Bolts. Slide Rock Sliders in-between the Skid Plate and body plastic.
Final Check: When installation is complete, ensure all bolts are fastened securely. ⚙️
Drilling and Installation Notes
Drilling Instructions:
- Use a #7 (13/64th") drill bit. This is one size above the commonly available 3/16th" bit.
- A ¼"-20 Tap is optional for drilling and threading self-tapping bolts into the chassis frame.
- Finger thread all bolts prior to fastening securely with power tools.
- We strongly recommend the use of a "Thread Locking Compound" when installing any mounting hardware.
- When installation is complete, ensure all bolts are fastened securely.
Hardware Breakdown
Main Skids Small Bag:
- 8x M6-1.0 x 16mm Flange Bolt (#B-A:X)
- 4x M6-1.0 x 30mm Flange Bolt (#B-A:7)
- 14x Counter Sunk Washers (#W-1)
- 2x ¼"-20 x ¼" Self Tapping Bolt (#B-...)
Cross Member Bracket:
- 8x J-Clip (Installed on Bracket) (#N-13)
Oil Filter Access Plate:
- 2x M6-1.0 x 25mm Flange Bolt (#B-A:6)
- 2x Counter Sunk Washers (#W-1)
- 2x J-Clip (Installed on Plate) (#N-13)
Side Bolts Large Bag:
- 10x ¼"-20 x 1½" Self Tapping Bolt (#B-D:6)
- 10x Counter Sunk Washers (#W-1)
If Rock Sliders: Replace (F*) locations with:
- 10x ¼"-20 x 2" Self Tapping Bolt (#B-D:7)
Front Diff Skid Small Bag:
- 6x ¼"-20 x ½" Self Tapping Bolt (#B-D:5)
- 6x Counter Sunk Washers (#W-1)
