You’ve seen them on the trail—those Polaris Xpeditions towering over everyone else on massive tires, crawling over obstacles like they’re not even there. You’ve probably thought to yourself, “I want that.” That commanding presence and trail-dominating capability come from one of the most popular upgrades in the off-road world: bigger tires.
In this comprehensive guide from the crew at FatBoysOffroad, we promise to break down exactly what it takes to get there. We’ll show you how to safely and effectively fit 35-inch tires on your rig, transforming its capability, durability, and looks. This isn’t just about bolting on new rubber; it’s about building a more capable machine from the ground up.
We’ll cover the incredible benefits, the essential parts you’ll need, a step-by-step overview of the process, and the common problems to watch out for. This is your complete polaris xpedition 35s guide, built for the real-world DIYer who wants to do it right.
Why Go Big? The Undeniable Benefits of Polaris Xpedition 35s
Jumping from stock tires to 35s is more than just an aesthetic choice. It’s a functional upgrade that fundamentally changes how your Xpedition interacts with the terrain. While it looks awesome, the real magic happens when the pavement ends.
Here are the core benefits of polaris xpedition 35s that have enthusiasts making the switch:
- Massive Ground Clearance: This is the number one reason. A larger tire physically lifts your entire machine—differentials, A-arms, and frame—higher off the ground. This means you can clear rocks, ruts, and logs that would have previously stopped you in your tracks or caused expensive underbody damage.
- Superior Obstacle Crawling: A larger tire has a better “angle of attack.” It can roll up and over an obstacle more easily than a smaller tire, which might get stuck against the face of it. Think of it like rolling a marble versus a basketball over a crack in the sidewalk.
- Increased Traction Footprint: When you air down your tires for off-road use, a 35-inch tire creates a much longer and wider contact patch with the ground. This translates to incredible grip in mud, sand, and on slick rock faces.
- Improved Ride Quality (in some cases): The larger sidewall of a 35-inch tire can act as an additional shock absorber, smoothing out small bumps and trail chatter for a more comfortable ride, especially when properly aired down.
- Unbeatable Trail Presence: Let’s be honest, it just looks tough. A Polaris Xpedition on 35s has an aggressive, purpose-built stance that commands respect on the trail.
Before You Buy: The Essential Parts List for a 35-Inch Tire Swap
Successfully running polaris xpedition 35s is a system, not just a single part. Simply buying the tires will lead to rubbing, broken parts, and a terrible driving experience. To do it right, you need to support the upgrade with the right components.
Lift Kits: Getting the Height You Need
You can’t fit a 35-inch tire in the stock wheel wells without major issues. A quality lift kit is non-negotiable. You’ll typically be looking at a 3-5 inch lift to create the necessary physical space.
Look for kits from reputable brands like SuperATV or High Lifter. A good kit will include not just spacers but often beefier A-arms or bracketry that corrects suspension geometry, ensuring your ride quality and CV axle angles don’t suffer too much.
Clutch Kits: Reclaiming Your Power
This is the most overlooked—and most critical—part of the upgrade. Larger, heavier tires dramatically change the gearing of your machine. Your stock clutch is calibrated for smaller, lighter tires. Without a clutch kit, you’ll experience sluggish acceleration, poor back-shifting, and you will absolutely burn up your CVT belt.
A clutch kit, like those from Gilomen Innovations or RVS Performance, includes new weights and springs for your primary and secondary clutches. This recalibrates the system to handle the extra rotating mass, restoring your low-end torque and protecting your belt. Do not skip this step.
Wheels & Offsets: The Perfect Stance
You’ll need new wheels to go with your tires. Pay close attention to the offset. A wheel with a more negative offset (like a 4+3 or 5+2) pushes the tire further out from the hub. This provides more clearance between the tire and your suspension components, like shocks and springs, preventing rubbing at full steering lock.
Reinforced Drivetrain Components
The added leverage and weight of 35s put a massive strain on your entire drivetrain. While not always required on day one, it’s wise to budget for future upgrades. The most common failure points are:
- Axles: Stock axles can snap under the increased torque load. Upgrading to heavy-duty chromoly axles from brands like RCV or Turner is a smart investment for aggressive drivers.
- Ball Joints: The extra weight will wear out factory ball joints prematurely. Heavy-duty, adjustable ball joints are a must-have for long-term reliability.
How to Fit Polaris Xpedition 35s: A Step-by-Step Overview
This section provides a general overview of the installation process. Always follow the specific instructions that come with your lift kit and clutch kit. Safety is paramount. Use jack stands, wear safety glasses, and if you’re ever unsure, consult a professional mechanic. This is a big job, but it’s a rewarding one for a careful DIYer.
Step 1: Install the Lift Kit
Start by safely lifting and supporting your Xpedition on jack stands. Remove all four wheels. Following your kit’s instructions, you’ll typically remove the stock shocks and A-arms to install the new brackets, arms, and hardware. A spring compressor may be needed for some kits. Pro Tip: Use blue Loctite on all suspension bolts and torque them to the manufacturer’s specification using a torque wrench.
Step 2: Fender Trimming and Clearance Checks
Even with a lift, you may have some rubbing. With the new lift installed, temporarily mount one of your new front wheel/tire combos. Turn the steering from full lock to full lock. Have a friend help you compress the suspension (carefully!) to check for any points where the tire makes contact with the fender plastic or frame. Use a utility knife or a small cutting tool to trim away small amounts of plastic for clearance. This is one of the most important polaris xpedition 35s tips for a clean setup.
Step 3: Mounting Your New Wheels and Tires
Once you’ve confirmed clearance, mount all four of your new wheels and tires. Tighten the lug nuts in a star pattern to ensure the wheel is seated evenly. Lower the machine off the jack stands and torque the lug nuts to the factory spec (check your owner’s manual).
Step 4: The Critical Clutch Kit Install
This is often the most intimidating part. You’ll need to remove the CVT cover and use specialized clutch tools to remove the primary and secondary clutches. Once they’re on a workbench, you’ll disassemble them to swap the stock weights and springs with the new ones from your kit. Pay extreme attention to the orientation of every part. Reinstall the clutches, a new heavy-duty belt, and the cover.
Living with 35s: Your New Polaris Xpedition 35s Care Guide
Your Xpedition is now a different machine, and you need to treat it as such. Driving and maintenance habits need to adapt to ensure longevity and safety.
Impact on Performance and Handling
Your center of gravity is now higher, so be more cautious with high-speed cornering and on off-camber situations to prevent rollovers. Your braking distance will increase due to the extra rotating mass, so leave more room to stop. Acceleration, even with a clutch kit, may feel slightly less snappy than stock, but your low-speed crawling ability will be phenomenal.
Your New Pre-Ride Inspection Checklist
Before every ride, you need to be more diligent. Your inspection should now include:
- Torque Checks: Check the torque on your lug nuts and key suspension bolts. The added leverage can cause things to loosen over time.
- CV Boot Inspection: The steeper angles on your axles make the CV boots more vulnerable. Look for any rips, tears, or grease spray.
li>Ball Joint and Tie Rod Check: With the front end jacked up, grab the tire at the top and bottom and try to wiggle it. Any play indicates a worn ball joint. Do the same from side-to-side for tie rods.
Common Problems with Polaris Xpedition 35s and How to Solve Them
Putting in the work upfront prevents most issues, but it’s good to know what to watch for. Here are the most common problems with polaris xpedition 35s and their solutions.
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Problem: Shredded CVT Belt.
- Cause: Almost always caused by not installing a clutch kit or using the wrong setup.
- Solution: Install a quality clutch kit calibrated for your tire size and riding style. Always carry a spare belt and the tools to change it on the trail.
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Problem: Broken Axles.
- Cause: Too much throttle in high-traction situations or when a wheel is bound up.
- Solution: Learn to drive with finesse. Use momentum and a smooth throttle, don’t just “send it.” If you break them often, upgrade to heavy-duty aftermarket axles.
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Problem: Prematurely Worn Wheel Bearings and Ball Joints.
- Cause: The increased weight and leverage of the larger, offset wheel/tire combo.
- Solution: This is a wear-and-tear issue. Accept that they will need to be replaced more often than stock. Using high-quality aftermarket parts will extend the service interval.
Sustainable Off-Roading: Eco-Friendly Polaris Xpedition 35s Best Practices
Bigger tires don’t have to mean a bigger impact on the environment. In fact, a more capable machine allows you to navigate trails more responsibly. This is where sustainable polaris xpedition 35s practices come in.
The increased ground clearance helps you avoid dragging your skid plates, which tears up the trail bed. The superior traction from a larger contact patch means less wheel spin, which prevents trail erosion. By airing down appropriately, you not only improve grip but also soften the tire’s impact on the ground.
Following Tread Lightly! principles is key. Stay on designated trails, cross obstacles straight on instead of creating bypasses, and pack out everything you pack in. Building a durable machine with quality parts also reduces waste from broken components. This is what being an eco-friendly polaris xpedition 35s owner is all about.
Frequently Asked Questions About Polaris Xpedition 35s
Do I absolutely need a clutch kit for 35-inch tires?
Yes. 100% yes. Without one, you are guaranteeing poor performance and a very short life for your CVT belt. It’s the most important supporting modification you can make.
What tire pressure should I run in my 35s?
This depends on your tire construction, wheel type (beadlock or not), and terrain. For general trail riding, start around 10-12 PSI. For rock crawling or sand, you might go as low as 5-8 PSI, but this increases the risk of de-beading the tire on a non-beadlock wheel.
Will installing 35s void my factory warranty?
It can. Any failure directly attributed to the aftermarket parts (like a broken axle due to the stress of 35s) will likely not be covered. The Magnuson-Moss Warranty Act protects you from a dealer voiding your entire warranty for one modification, but they can deny claims on related systems. Talk to your dealer to understand their specific policies.
How much will this entire conversion cost?
Be prepared for a significant investment. Between quality tires, wheels, a lift kit, and a clutch kit, you should budget anywhere from $3,000 to $6,000 or more, especially if you include upgraded axles and professional installation labor.
Stepping up to polaris xpedition 35s is a serious upgrade that transforms your machine into an absolute beast. It’s not just a purchase; it’s a project. It requires research, the right combination of parts, and a willingness to learn more about how your UTV works.
By following this guide, you understand the system-wide approach needed for success. You know the benefits, the requirements, and the risks. Do the work, be safe, and get ready to conquer trails you used to drive around.
Now you have the map. We’ll see you out there!
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