Aftermarket Assassins '24+ Polaris Xpedition Stage 2 Lock & Load Kit

Aftermarket Assassins '24+ Polaris Xpedition Stage 2 Lock & Load Kit

Lock and load your 2024+ Polaris Xpedition and get ready for some serious kick. The Xpedition is a fun machine, but Polaris left room for improvement on the table. This simple kit is the best way to wake up your Xpedition as it comes with our proven ECU flash. The ECU flash adds some amazing horsepower from low end to high end RPM and really gives your machine that "snap" you're looking for. Our AA Stage 3 clutch kit compliments the tuning perfectly by more efficiently transferring power to the wheels and ridding yourself of the very lazy factory clutching setup and poor belt grip. Finishing off our kit is our newly developed Dual Suppressor Slip-On Exhaust which helps bring your Xpedition to life with a great deep tone.

Kit includes: AA Dual Suppressor Exhaust, S3 Clutch kit with primary limiter, & the AA ECU flash for Xpedition Models. Requires ECU to be sent in for programming/unlocking unless choosing to purchase ECU outright

This really is the ultimate kit for your Xpedition! Okay, maybe the turbo kit is one step up... but for the cost and gains, this kit can't be beat. With the ECU flash and our dual muffler exhaust, the motor now makes power at a much lower RPM. This means we can clutch for 7600-7800 RPM with our cruiser setup and still make +12 RWHP over the factory Xpedition at 8200-8400 RPM. That's nearly 15-16 crank HP and doing it at a lower RPM.

With our dual muffler design, this exhaust sounds amazing with a nice deep tone but not significantly louder than the OEM exhaust. The power gains are significant over a single muffler exhaust as these motors LOVE the increased exhaust volume. No single muffler will compare. At idle, off idle and wide open throttle you will notice a bit more rumble but when cruising, this exhaust is quieter than the stock exhaust.

AA's performance tunes are now available to gain horsepower and torque. Through our advanced ECU tuning we are able to modify parameters correctly to gain you the power needed. We are highly experienced in tuning UTVs and this will show.

The Xpedition uses a new Bosch MG1 ECU. Currently no programmers are available that flash without first having the ECU unlocked. The HP Tuners Remote Tuning Device (RTD) allows the ECU to be flashed remotely at any time using the AA/HP Tuners RTD and your smartphone once the unlock process has been completed from AA.

HP Tuners Remote Tuning Device (RTD) upgrade option: Upgrades to HP Tuners RTD which includes the RTD, OBDII to Polaris Diagnostic Port cable, necessary credits to flash your ECU, one AA custom tune (more tunes optional), and ECU Unlock performed at the AA facility.

Requires ECU to be sent in to be unlocked unless purchasing ECU outright: After the initial unlock, the ECU can now be flashed remotely at any time using the HP Tuners RTD and your smartphone. See links at bottom of product page for flashing your vehicle and data logging.

We have been tuning UTV's with CVT clutches for a long time, longer than almost anyone in our field going back to the 800 RZR. Tuning a CVT vehicle properly is not an easy task as you have so many variables at one time. We spend the time to wheel dyno(with actual UTV tires) correctly per modification, and have advanced ECU calibration and clutching knowledge to do so. Every change in horsepower can result in us changing clutching several times. We also develop most of our supporting mods so we know everything works correctly, and build parts to fit the vehicles needs. Lastly and honestly the most important; we then back up our results with real world data logging on local trails and our facility on 110 acres. It's this combination that truly makes the difference and why AA normally has a faster vehicle with the same or less rated tune horsepower. We left nothing on the table on the Xpedition bolt-on parts, if others claim more power/gains for the same mods use caution in believing it.

Stage 3 Clutch Kit includes: Setup/Installation sheet, AA Recoil magnetic adjustable clutch weights, primary spring, primary limiter washer, secondary spring and AA helix. The initial setup guideline shows the best setups for dunes, mud, or all around trail riding. This also has brief instructions on installing your clutch kit among other important information.

The biggest problem with the Xpedition clutching is they do not have enough belt grip, they gain RPM too quickly and yet peak RPM is not achieved quickly. Our kit helps combat this with a stiffer secondary spring over factory for even better belt grip and the right primary weight/spring to get proper RPM at the right time. Our S3 clutch kit includes primary weights, spring, primary limiter, secondary spring and helix. The helix adds more aggressive shift to the secondary clutch which gives you big acceleration gains and feels more like your throttle is locked to the rear wheels. The Performance helix is the most acceleration gain, while the High Load is a little more than stock, but less aggressive for excessively heavy/large tires, crawling, or mud riding.

Our "Cruiser" option is for those looking for less cruising RPM and less noise. The Xpedition has a higher running RPM from the factory which makes them loud. Polaris released their own cruiser setup as well and is found in some models, BUT this kit goes too far and really cuts down power. Our clutch kit with cruiser setup is the perfect happy medium that transfers power better, and holds much better belt grip. The AA Cruiser option loads the primary clutch weights heavier with our slug magnets. These magnets are like 5 magnets in one large slug, whereas with our standard magnets only 3 fit in each hole. This allows for running more weight in the arms without having to purchase a completely different kit. This kit option drops peak RPM down from the factory 8300 to roughly 7400-7700 RPM. This does lose a bit of horsepower, but if that's not your concern, this add-on option works extremely well. This setup also has even smoother engagement, crawls very well, and still has plenty of acceleration. Think more of a cross between a Ranger and RZR as far as acceleration and feel. The best part is you are not stuck with this option, you can simply revert back to our standard clutch setups whenever wanting more performance. Switching the weights takes 15-30 minutes for most and gives you a chance to clean up/inspect your clutches.

High Load Helix 1062: Slightly less aggressive than the performance helix with good acceleration gains/power transfer over the OEM helix. Designed to work better for heavier vehicles, heavier tires, overly aggressive tread, heavy sand load or crawling type riding in mind. Works on 2 & 4 door models with 30-35" heavier/aggressive tread tires over 44lbs each or 30-33" paddles. Works well for this tire size on 2 and 5 seat models.

Performance Helix 1065: Aggressive helix with acceleration/higher horsepower/aggressive fast pace drivers in mind. Works best with a tuned vehicle. Works well with 30-33" lighter tires that are under 44lbs each and on 2 or 5 seat models.

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 decal whine.
• Remove EBS: Removes the EBS pocket in the helix. Gets rid of the roller clunk noise but there is a decal whine. Most faster pace trail riders/racers or dune riders will choose to remove it.

Features:

• Big horsepower gains depending on the level of tune/modifications (see tune descriptions below for more details)
• Much quicker throttle response and power delivery giving a whole new feel to the vehicle
• Throttle by wire limiters disabled
• Seatbelt speed limiter removed
• Start in any gear (factory will only start in park)
• Fan on/off at 186/185 degrees Fahrenheit (Stock is 201/200) which is just above the thermostat opening temp.
• Speed limiter removed in low and high gears (Stock speed limit in high is 68 MPH and 27 MPH in low for crew models)
• Start in any gear with brake
• More throttle % in low gear and reverse (Stock limits your throttle for torque limitation)
• Rev limit at a safe 9200 RPM (stock is 8500). Ideal peak RPM @ 55 MPH is 8200-8500 with the flash, but 9200 is for ramp up overshoot/top speed.
• AA's wicked timing curve is safe for the fuel octane recommended, but we do a much better job of finding timing limits for ramp up/more torque. Many others simply focus on wide open throttle timing/fueling. AA's tunes are developed for 91 octane unless specified otherwise.
• AA's modified fuel curve will still get decent mileage cruising, but is corrected over the factory lean AFR when needed most on higher throttle inputs.
• Included Level 2 Tune: This tune is developed for an Xpedition with aftermarket exhaust on 91-93 octane. This tune adds +7-8 RWHP.
• We were also, but unfortunately we found no real power increase by adding octane. Certainly a little extra octane is never a bad thing to keep your ECU from pulling timing based on engine knock, but we tried various attempts to make more power with no significant results.
• Dyno graph is shown with 32" tires which showed a gain on the dyno due to building speed quicker. See a list of power levels on 32" tires below.
  • Stock with OEM Heavy Clutch Weights (some 2024's and all 2025+ models) = 80rwhp estimated
  • Stock with 32" Tires (light weights, 8300 peak RPM) = 96 RWHP
  • Stock with Cruiser clutch setup (7500-7800 RPM) = 86 RWHP
  • S3 Cruiser clutch kit + L1 Flash = 88 RWHP
  • S3 Clutch Kit (not Cruiser) with stock ECU = 100 RWHP
  • S3 Clutch Kit (not Cruiser) and L1 Flash = 103 RWHP
  • S3 Cruiser Clutch Kit + Exhaust + L2 Flash = 108 RWHP
  • S3 Clutch Kit (not Cruiser) + Exhaust + L2 Flash = 110 RWHP
• Evap (50 State/Cali model) or Non Evap (STD) 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 factory HVAC (air/heat) or the standard model without
• ECU Must Be Sent in for Programming/unlocking: Aftermarket Assassins, 2348 75th Ave, Osceola, WI 54020. (If selecting option to purchase ECU outright, disregard shipping notes as we will ship a new flashed/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 Flash, 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 flash with the correct AA tune.
  • 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.
  • Models with the dump bed include a cable to slightly shorten the throw of the bed damper to prevent the tailgate from hitting when down

Installation Instructions: