Aftermarket Assassins '24+ Polaris Xpedition Complete Turbo Kit

Aftermarket Assassins '24+ Polaris Xpedition Complete Turbo Kit

The Xpedition turbo kit is just what is needed to take these models to great, to absolutely awesome! Not only does a turbo add amazing performance that gives you the get-up & go these heavier vehicles need, but it also makes your Xpedition QUIETER by lowering cruising RPM.

We are avid Xpedition riders as the comfort and suspension is unbeatable for a trail vehicle. The problem is the loud cab/motor and high RPM motor.... and the lack of get up & go when you clutch them for a lower RPM. This kit solves this issue! The turbo kit adds a great deal of horsepower, so you can run much heavier clutch weights and still achieve good peak RPM when going full throttle. With the heavier clutch weights, you will see less cruising RPM and less noise as well as better bottom end belt grip. This combination is perfect as it gives you some major punch, and more comfort.

Turbocharger: The turbo we use is assembled/balanced in the USA and is the same that we've been using/abusing on the Pro R turbo kits running 20-25psi of boost without any issues. Running this turbocharger at only 6-10psi in this kit (depending on tune) is timid, and the turbo runs extremely cool. This is a non water cooled turbo to avoid more clutter and unnecessary coolant line splicing. The turbocharger is a little larger than a 2860 as we needed more exhaust flow to stay away from engine knock on this high 12.5:1 compression motor. It utilizes an AA internal wastegate with the crack pressure pre set, and clocked ready to bolt on. The turbocharger is rear mounted which keeps heat buildup away from the motor to reduce chances of engine knock. Mounting a turbocharger directly to the motor will not net the same results in the real world... it will decrease power faster as EGT's come up much faster. Our kit is designed to be a minimal heat system.

RTD Flash Device: We also have an AA/HP tuners RTD device that flashes with your smartphone and an application. This is done by creating an account, downloading the app, and reading your stock file. We then build your tune(s) off your stock file and you then flash the tune(s) to your ECU. You can also data log with this device, but must be connected to your phone and can only view this later... no useful live data. The benefit to this is no computer is ever needed.

See our tune list below. Keep in mind these vehicles are equipped with a knock sensor that will allow your ECU to pull up to 12 degrees of timing to protect the motor from potential failure. In testing, we abuse this protection system like crazy with high boost on pump gas and have had zero issues. However, the name of the game for maximum power is to stay off the knock protection system by having enough octane as it reduces timing/power.

We always suggest using higher octane when possible even though minimum octanes are listed. These are high compression motors and for best power, extra octane makes a huge difference. We like the use the VP octane booster (VP SKU 28555) and add 1 can per tank. Even a half can per tank works wonders on the level 1 or 2 tunes.

Level 1 (91-93 Octane - 5-7 PSI - 143 RWHP/170 crank HP): The standard! This is the tune most will love for all around riding and simply having wicked horsepower and being easy on your motor/system. It will also have the best fuel economy out of all our tunes. With this tune compared to others, you will see power fade a little bit on the top end, but still pulls wicked hard comparted to stock.

Level 2 (91-93 Octane - 5-7 PSI - 150 RWHP/180 crank HP): This tune runs the same boost as level 1, but runs best on 93 octane fuel. If you have 93 at the pump, or want to add octane booster, this tune will be at it's full potential. This will be your "standard" or sport mode tune. It's still very easy on the motor and runs well even on 91 octane, but will pull a few degrees of timing on longer pulls.

Level 3 (95 Octane - 6-8 PSI - 170 RWHP, 190 Crank HP): Take level 2 but add 2-3psi of boost. We have a boost T that bleeds air off from the wastegate line. No change in the ECU mapping as we have everything mapped our correctly for this higher boost pressure. This tune is one of our favorites as a small amount of octane boost is needed, and you gain a huge 20hp over level 2! We use 1 can of the 16oz Octane Booster (VP Racing SKU 28555)

Level 4 (98-100 Octane - 6-8 PSI - 181 RWHP, 200-210 Crank HP): Running this tune means you have to run 98-100 octane all the time, there is no way to tune back at this time. This is the same boost and configuration as level 3, but added ignition timing. With the extra octane, we can add boost and some timing back to really start gaining big power, and have big down low torque. This tune absolutely RIPS! To achieve 98-100 octane, we use a 32oz can of VP Octanium (VP SKU 29505 per RZR tank of fuel, or a mix of 110/pump gas.

• All tunes have a removed speed limiter, safe 9200 RPM rev limit, start in any gear with the brake, better throttle response, torque limits/functions corrected, lower coolant fan turn on temp, seatbelt limiter removed & more.
• Stock like drivability. This turbo kit and calibrations all work excellent for work, play and everything in-between

ECU MUST BE SENT IN FOR UNLOCK PROCESS: Aftermarket Assassins, 2348 75th Ave, Osceola, WI 54020 (If selecting option to purchase ECU outright, disregard shipping notes as we will ship a new unlocked ECU to you)

We will follow up with instructions on how to locate, remove, and send your ECU.

Customer is responsible for shipping the ECU to AA, a shipping label is not included in the price Excludes Express Unlock, which includes UPS Next Day Air label to ship ECU to AA

Programming/unlocking turnaround will vary, but is normally 1-2 business days.

Express ECU service for US main 48 states only. We'll send you a Next Day Air UPS label, and ship your ECU ONLY back via Next Day. All other parts will be shipped ground unless otherwise specified/selected during order checkout. Keep in mind we cannot guarantee same day programming/unlocking or control UPS shipping times/delays. We will do everything possible to turn the ECU around as fast as possible.

When the ECU arrives we'll read your stock file and keep a file folder for your stock/tune files. We'll then unlock it and it will return to you with the STOCK file in it until YOU flash it.

If you ever need to go back to the OEM tune we charge $95 which includes shipping back to you (shipping back for lower 48 US only). Please contact us if you need to go back to your OEM tune.

ENSURE you INSURE your ECU for $700. AA is not responsible for shipping delays or lost ECUs. While more expensive over Priority Mail or FedEx, UPS has been the most reliable carrier in our experience.

Features:

• 2-5 business day lead time for final kit assembly/packaging.
• Over 1500 hard miles on our shop Xpedition with this kit before releasing, and over 3500 miles on our shop vehicle as of Jan 2025
• 144rwhp/170 crank HP on 91 Octane (gains 50rwhp over stock)
• 181rwhp/220 crank horsepower on 100 octane!
• Stock Xpedition: 96RWHP on our dyno on 32" tires & rated at 114 Crank HP from Polaris
• Intake: Kit utilizes the stock airbox and stock intake inlet with our 3" AA tube that runs to the turbocharger inlet side. This AA intake tube has an integrated closed loop catch can to help keep fuel, water, and oil out of your intake tract. We do NOT use an intercooler. The intercooler restriction vs. gain was a complete wash at the boost pressure you can run on this high compression motor. Through many data logs in different conditions, we found no reason to complicate things and run an intercooler.
• Exhaust: The turbo kit comes with exhaust that bolts on to your OEM header pipe, heads into the turbo, then exits the turbo with our dual outlet muffler with quiet core(cap) and spark arrestor included in the price.
• No scavenge pump! Other kits will use an oil scavenge pump. With our design, no pump is needed which is important as if the pump fails, it will back up oil and oftentimes do turbocharger damage. This also keeps things much simpler.
• Installation: Installation is easy and normally takes 4-6 hours. This requires bed removal, head pipe removal from the motor, and you must remove 1 coolant line to get to the oil dipstick tube that we replace with our AA drain back tube. The rear muffler silver heat shield is removed, and you must drill 1 hole in the back frame plate for the oil drain line. The oil filter is also removed for an oil filter adapter, so it's a good time to do an oil change.
• Will NOT fit with most rear bumpers Many can modify brackets to extend the bumper slightly without issue, but this would be a custom modification.
• Clutching: This kit comes with our custom Turbo Clutch Kit which uses 65g base weights, blue/green primary spring, red secondary spring, and helix (two helix options) We have our 1065 performance helix or the 1062 high load helix which effects the shift rate of the secondary clutch.
  • 2 Seat Helix Choice: 1062 helix for those running 34-45" tires, 1065 performance helix for those running 30-33" tires.
  • 5 Seat Helix Choice: 1062 high load helix for those running 31-35" tires. 1065 Helix for those running the stock size 30" tires.
• EBS (Engine Braking) Options:
  • Keep EBS: Like factory. Most slower pace riders (mud, crawling or very hilly terrain) will keep the EBS in place. Gets rid of the chatter noise but there is a decel whine.
  • Remove EBS: Removes the EBS pocket in the helix. Gets rid of the roller clunk noise but there is some more whine on decel. Most faster pace trail riders/racers or dune riders will choose to remove it.
• Quieter! The turbo acts as a baffle, and the heavier clutch weight needed to keep RPM in check will lower RPM. Both of these combined make your Xpedition much quieter overall and even quieter when cruising.
• AA Tuned Dynojet PV3 or HP Tuners RTD : Both require your ECU to be sent in to us(AA) for an unlock unless purchasing ECU outright.
• AA PV3 Device: We prefer this device for the turbo kit as it gives you a screen to view live gauges, and requires no phone application to flash. Everything is right on the device. The only downfall here is the need for a computer to send us data logs, or to receive other tunes. Seeing live gauges is important with the turbo kit as you can keep an eye on cylinder knock retard, intake temps, and other parameters while you ride.
• Evap(50 State/Cali model) or Non Evap(STD 49 State) Model: See the sticker located in your drivers side front wheel well as it will state which one you have. Your ECU should also have a label on it stating if it's an Evap, but we like to verify with the VIN sticker also as sometimes Polaris is not correct on the ECU sticker.
• The drop down also asks if your Xpedition has HVAC(air conditioning/heat) or the standard model without
• ADV models will require removing the back half of the vehicle. You also want to make sure you align your intake tube/charge tube clamps properly so you can easily access them as they will need to be removed to access the clutch cover.
• We HIGHLY suggest running our Stryker Belt as we've found it grips much better in the clutch
• We also suggest our Revolver Billet Clutch Cover with Tower Lock for improved strength and airflow.
• Have clutch alignment issues? Use our P90X Secondary Clutch Alignment Shim Kit to set things straight

Kit Includes:

• Turbocharger (assembled with oil fittings and billet internal wastegate)
• Custom Stainless mid pipe.
• Exhaust Gaskets.
• Oil Adapters.
• Drain Line.
• Feed Line.
• Oil Filter Feed Adapter.
• Custom Dipstick for oil drain back.
• V-Band Exhaust Clamps.
• Exhaust Downpipe.
• Slip-on exhaust with quiet core & spark arrestor.
• Intake tube kit with closed loop catch can integrated.
• Charge tube kit.
• 3 Bar map sensor.
• Big Injectors.
• Lower heat iridium spark plugs.
• S3 Clutch kit designed just for the turbo kit(weights, limiter springs, helix)
• ECU Unlock.
• Flash Device (PV3 or RTD)
• Tunes & Credits.

Note:

• For best fitment of the drain line, we suggest using the RZR turbo oil filter part.

Fitment:

• Turbo Kit fits Polaris Xpedition Models 2024+

Installation Instructions:

• Xpedition Turbo Kit Instructions