Polaris General Xp Conversion: Your Ultimate Guide To Going Wider &

Ever hit a trail in your standard Polaris General and felt that pang of envy watching an XP model crawl over an obstacle you had to bypass? You love your machine, but you find yourself wishing for that extra ground clearance, that wider, more stable stance, and the beefier suspension that comes with the premium XP package.

You’re not alone. It’s a common feeling for owners who push their rigs to the limit. We’re here to promise you that you don’t need to trade in your beloved General to get that next-level capability. The solution is a polaris general xp conversion, and it’s a project you can absolutely tackle in your own garage.

In this complete guide, we’ll break down exactly what this conversion entails. We’ll cover the parts you need, the tools for the job, a step-by-step installation process, and the common pitfalls to avoid. Let’s get wrenching and transform your ride into the trail-conquering machine you know it can be.

What Exactly Is a Polaris General XP Conversion?

At its core, a Polaris General XP conversion is the process of upgrading a standard Polaris General model with the key suspension and drivetrain components from the higher-tier General XP model. This isn’t just a simple lift kit; it’s a comprehensive overhaul of your machine’s footing.

The XP models come from the factory with a wider stance (64 inches vs. the standard 60 inches) and more suspension travel, thanks to a different set of A-arms, axles, and shocks. The goal of the conversion is to replicate this factory-engineered performance on your non-XP machine.

Think of it as giving your General a factory-spec long-travel kit. You’re swapping out the shorter, standard components for their longer, more robust XP counterparts. This results in a wider, more stable machine with significantly improved suspension articulation and ground clearance.

Unlocking the Trail: Key Benefits of a Polaris General XP Conversion

So, why go through the effort? The payoff is huge, transforming how your General performs on rugged terrain. Understanding the benefits of a polaris general xp conversion makes it clear why this is one of the most popular upgrades for serious riders.

Enhanced Stability: The most immediate change you’ll feel is the increased stability from the wider 64-inch stance. On off-camber trails and high-speed corners, your machine will feel much more planted and predictable.
Increased Ground Clearance: The combination of arched A-arms and longer shocks provides a significant boost in ground clearance, allowing you to sail over rocks, ruts, and logs that would have previously hung you up.
Superior Suspension Travel: XP models boast more suspension travel, which means the wheels can move up and down further. This keeps your tires in contact with the ground on uneven surfaces for better traction and provides a much smoother, plusher ride over rough stuff.
Ability to Run Larger Tires: The added clearance and wider stance make it much easier to fit larger, more aggressive tires (like 30″ or 32″) without rubbing issues, further improving your rig’s capability.
OEM Quality and Fitment: When using genuine Polaris XP parts, you’re getting components that were designed and tested for this platform. This ensures perfect fitment and factory-level durability, unlike some aftermarket kits that can introduce compromises.

Before You Wrench: Essential Tools and Parts for Your Conversion

A successful project starts with having everything you need on hand. Rushing to the auto parts store mid-job is frustrating and kills momentum. Here’s a rundown of what you’ll need to gather before you start your polaris general xp conversion guide.

Required Parts List

The exact part numbers can vary by model year, so always double-check with your dealer or a reliable parts fiche for your specific machine. You’ll typically need the XP version of the following:

Front Upper and Lower A-Arms (Left and Right)
Rear Upper and Lower A-Arms (or Trailing Arms, depending on your model year) (Left and Right)
Front Axles (Left and Right)
Rear Axles (Left and Right)
Front Shocks (Walker Evans or FOX, depending on the XP model you’re replicating)
Rear Shocks
Longer Tie Rods or Tie Rod Ends
Possibly new, longer brake lines (check lengths to be sure)

Pro-Tip: Look for complete take-off kits from owners who have upgraded their new XP models to even bigger aftermarket suspension. This can be a cost-effective way to get all the OEM parts in one go.

Essential Tools Checklist

This is a serious garage job, but it doesn’t require a full professional shop. Here are the must-haves:

A solid floor jack and heavy-duty jack stands. Never, ever work under a vehicle supported only by a jack.
A comprehensive socket and ratchet set (metric).
A set of combination wrenches.
A high-quality torque wrench. This is non-negotiable for safety.
Breaker bar for stubborn bolts.
Ball joint press or a ball joint separator tool (pickle fork).
Dead blow hammer or rubber mallet.
Pry bars.
Needle-nose pliers for cotter pins.
Safety glasses and mechanic’s gloves.

The Ultimate How-To: A Polaris General XP Conversion Step-by-Step

Alright, let’s get down to business. This guide provides a general overview of how to polaris general xp conversion. Always refer to a factory service manual (FSM) for your specific model’s torque specs and detailed diagrams. Take your time, stay organized, and work on one corner at a time.

Step 1: Prep and Safety

Park your General on a level, solid surface like a concrete garage floor. Chock the wheels that will remain on the ground. Loosen the lug nuts on the wheels you’re about to remove, but don’t take them off yet.

Using your floor jack, lift one end of the machine and securely place your jack stands under the frame. Make sure the machine is stable before proceeding. Now, remove the wheels.

Step 2: Disassembly of a Corner

Let’s start with a front corner. The process is similar for all four, with minor differences for the rear.

Remove the Shock: Unbolt the top and bottom shock mounts and remove the shock absorber.
Disconnect Tie Rod and Brake Caliper: Remove the cotter pin and castle nut from the tie rod end at the steering knuckle. Use a mallet or separator to pop it free. Unbolt the brake caliper and hang it securely from the frame with a bungee cord or wire. Do not let it hang by the brake hose.
Separate Ball Joints: Remove the cotter pins and castle nuts from the upper and lower ball joints on the steering knuckle. Use your ball joint press or separator to pop the knuckle free from the A-arms. Be careful as the knuckle and hub assembly is heavy.
Remove the Axle: With the knuckle free, you can now pull it outwards, allowing the axle to slide out of the hub. A gentle tug should pop the inner end of the axle out of the front differential.
Remove the A-Arms: Finally, unbolt the upper and lower A-arms from where they mount to the frame. Keep track of your hardware!

Step 3: Installing the New XP Components

Installation is largely the reverse of removal. This is where your new, longer parts come into play. One of the most important polaris general xp conversion tips is to leave bolts loose until everything is assembled.

Install New A-Arms: Bolt the new, wider XP upper and lower A-arms to the frame mounts. Keep the bolts snug, but not fully torqued.
Install the New Axle: Carefully slide the inner CV of the new, longer XP axle into the differential until you feel it click into place.
Attach the Knuckle: Slide the outer end of the new axle through the hub. Re-attach the knuckle to the new A-arms by seating the upper and lower ball joints. Install the castle nuts but wait to put in new cotter pins.
Install the New Shock: Bolt the longer XP shock into the upper and lower mounts. Again, leave the bolts just snug for now.
Reconnect Tie Rod and Brakes: Attach your longer tie rod end to the knuckle and reinstall the brake caliper.

Step 4: The Final Torque-Down

With all components in place for the corner, you can now lower the vehicle so its full weight is compressing the suspension. This is a critical step for proper torqueing.

Using your torque wrench, tighten every bolt you touched—A-arm mounts, shock bolts, ball joint nuts, and tie rod ends—to the manufacturer’s specified values found in your FSM. Once torqued, install new cotter pins on all your castle nuts.

Repeat this entire process for the other three corners. Put your wheels back on, snug the lug nuts, lower the machine completely, and then torque the lug nuts in a star pattern to the proper spec.

Dodging Headaches: Common Problems with Polaris General XP Conversion

While this is a straightforward swap, a few issues can pop up. Knowing the common problems with polaris general xp conversion can save you a lot of frustration.

Axle Binding: If you pair XP suspension components with a large aftermarket lift kit, you can create extreme axle angles that cause binding and premature failure. The XP conversion is designed to work as a system; be cautious when stacking it with other lifts.
Incorrect Alignment: Your toe alignment will be way off after this install. You will need to perform a front-end alignment. A simple string alignment method can get you close, but a professional alignment is recommended for optimal handling and tire wear.
Forgetting to Torque Under Load: Failing to tighten suspension bolts with the vehicle’s weight on the wheels is a classic mistake. It can cause the rubber bushings to bind and wear out very quickly.
Brake Line and Vent Hose Issues: Double-check that your stock brake lines and differential vent hoses are long enough to accommodate the extra travel and width. You may need to install longer, braided stainless steel lines for safety and performance.

Post-Ride Care: A Simple Polaris General XP Conversion Care Guide

You’ve done the work, now enjoy the ride! But like any major modification, it requires a little follow-up. Following these polaris general xp conversion best practices will ensure your upgrade lasts.

After your first real ride (a “shakedown run”), put your machine back on jack stands and re-check the torque on every single bolt you touched. It’s common for things to settle slightly.

Regularly inspect your new components. Check ball joints for play, inspect CV boots for tears, and keep an eye on your shock seals. Because you’re likely riding harder with your new capability, routine maintenance becomes even more critical.

For a more eco-friendly polaris general xp conversion, consider selling your old, standard-width take-off parts to another owner who might need them for repairs. This is a sustainable way to keep good parts in circulation and out of the landfill, and it helps you recoup some of your project costs!

Frequently Asked Questions About Polaris General XP Conversion

Can I do this conversion with just a front or rear kit?

While technically possible, it’s not recommended. Converting only the front or rear would create an unbalanced vehicle with mismatched track widths, which could lead to unpredictable and dangerous handling characteristics. It’s best to do the full conversion.

Is a Polaris General XP conversion better than an aftermarket lift kit?

It depends on your goals. An XP conversion provides a wider, more stable stance and uses factory-engineered geometry, which is often superior for high-speed stability and overall suspension performance. A bracket lift kit only raises the vehicle, which can negatively impact the center of gravity and suspension angles. For true performance, the XP conversion is the better path.

How long does the conversion take?

For a DIYer with the right tools and moderate mechanical skill, plan for a full weekend. A seasoned mechanic could likely complete the job in 5-8 hours. Don’t rush it; take your time and double-check your work.

Completing a polaris general xp conversion is an incredibly rewarding project. It not only transforms the look of your machine but fundamentally improves its performance on the trail. You gain the confidence to tackle tougher terrain and enjoy a smoother, more stable ride. So gather your tools, order your parts, and get ready to build the General you’ve always wanted. Happy wrenching, and stay safe out there!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.