My 2018 XPT4 "Bailey" and her Past, Present, And Future - Polaris RZR Forum - RZR Forums.net
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post #1 of 151 Old November 27th, 2018, 07:03 PM Thread Starter
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Hey guys, I thought i might do a build thread of sorts about my 2018 XPT4 Fox edition and have some reviews and info along the line for anyone that might find it of interest or useful, or tell me it's stupid, whatever your fancy

This may be a long read, and will probably get longer, but if you got some time to kill and are interested, feel free to ask or comment about anything along the way. This forum has been a great source of information for me and i'd be happy to give any feedback in return for anyone that would like it.

I ride about 50% on the rocks, 30% wide open high speed washes and desert, 20% mountain trails, and 0% mud (less if possible). I'm not too big on dunes, and i don't have much within a reasonable distance, but I wouldn't avoid them like a mud hole if i had the opportunity. So if you're a duner or a mudder, we'd probably go entirely different directions with the build.

Anyway, i bought this machine at Jones Powersports in Durant, OK back in March. Best deal we could find outside of Abernathy's which we decided was too far of a drive. I'd recommend Jones if your in the area or market. Between me and two of my buddies, we've bought 5 machines from them in 3 trips over the last couple years, and have gotten good deals and great service each time.

I took it out as a bone stock machine twice, for about 90 miles, just to get a good baseline. First ride was a mellow break in for about 40 miles just cruising around out in the hills and getting acquainted with the much larger machine as i came from a 2012 XP 900, and the 4 seat was a huge change.

The next 50 miles were spent on the rocks and running the wide open washes around the Glade and Chokecherry Canyon in Farmington, NM, which is my backyard basically. I was impressed with abilities of the turbo as expected, and learned that the added length wasn't a nuisance as i thought it may be, i actually learned to like it quite a bit, the added wheelbase does good on the rocks as long a you can keep the belly from dragging, which takes a different line sometimes, but overall, the benefits far outweigh the downside. The length also adds great stability at speed, it handles the washes and drives like a dream at 70, and i love that about it.

My complaints were almost all about the obnoxiously high low gear, i found it easy to smoke belts and that i was unable to "crawl" really. everything had to be taken with a little more momentum than i like to use unless i have to, and i enjoy the technical aspects of crawling as much as anything, so I knew i'd have to do something about that eventually.

The day we picked her up, along with my buddies XPT4


First Day Out


Second Day Out with the future wife




... to be continued
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post #2 of 151 Old November 27th, 2018, 07:23 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

First mods were lower doors from Dragonfire to keep the sand from blasting in the cab. The fit and install of the doors was less than optimal and took a little bit of finesse to get straight. The rear doors don't have a stiffener in the middle of them like the fronts and as a results are a bit floppy. Overall they function like they should, and i eventually got them to fit somewhat decent, but I'd choose a different set if I were to do it again.

Second thing, which was planned from day 1, was wheels and tires. After a great deal of searching I decided to go with 32-10-14 Pro Armor Crawler XG's on STI HD5 beadlocks, I do quite a bit of crawling and wanted a wheel/tire combo to suit that, and they fit the budget well. The Kevlar MRT tire was just a little too pricey for me at that point, so i opted for the nylon version in the Pro Armor. I love the tires on the rocks, I run them at 10 psi and they grab excellent. Traction in the heavy wash sand is still better than anything i ever had, they're not paddles, but they do really well. Tight trail traction and control is excellent as well. The only downfall I've found grip wise is they leave a little to be desired laterally on high speed hardpack, i feel the don't have quite the side bite as they could, but I've learned to drive in a better manner to overcome that shortfall.

I did cut a sidewall on one after about 300 miles while doing a mountain trail, running about 40 through some hard pack in the dust at night, got off in the roadside drainage a bit and felt it hit something, didn't feel major, but sure enough a short ways down the road it was completely flat. I attribute part of this to me running lower air pressures, part of it to driver error, but i did feel the durability of the sidewall left a little to be desired, I've hit things like that before on Bajacross' and Bighorns and never had an issue, but i also don't know what I hit, so there's variables there, but regardless, a new tire was needed. I patched what i thought to be about a 3" gash in the sidewall, but there were two other cuts on the inner sidewall that were irreparable, so we limped it the last couple miles back the trailer that night and ordered a replacement (That's $190... the Kevlar MRT's would've been about $350 more initially... hmm... might have been worth it if the have a stronger sidewall? who knows..). I was also a little disappointed that the tires measured about 31" as opposed to 32... but..you know... tire manufacturers can't measure right these days... i wrote pro armor an e-mail, but never got a response lol.

well now with about 400 miles on the machine, it was time for the first major part of the build: what i commonly referred to as "Phase 1", and the first service, right at 26hrs

Lower Doors and Wheels/ Tires installed


Parked atop "The Garage" in Chokecherry Canyon


Tire Comparison to the Stock Bighorns


Flat!
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post #3 of 151 Old November 27th, 2018, 07:27 PM
 
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Nice ride, interested to hear more on this. I too have the same machine and love it as it is my first sxs.Click image for larger version

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post #4 of 151 Old November 27th, 2018, 07:56 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

And Phase one began... there's a lot that was done here, so I'll just give a basic rundown for now: (Feel free to ask about anything if you're curious)

Custom Cage (Cut, Bent, and Notched by @portmod7 , welded by me)

Custom Roof by Me

All my lighting and wiring, with a new accessory fuse block, A 34" Rigid DR white, a 30" Rigid DR amber, A tribal whips real multi bank bar, Rigid Dually Rock Lights, Grille and interior glow, and dome light

Street Legal Setup

TYT VHF Radio Setup

Custom Cut Lexan Windshield

Dragonfire 4 point Harnesses & pass through bezels

The bezel fit is less than optimal, and cutting your seats isn't very fun, but they work great and keep the harnesses from running off your shoulders, so i like that, i'd just liked them to be a little more formed on the backside of the seats

Factory UTV Full 1/2" Skid Plates, Trailing Arm Guards, And Rock Sliders. Hands Down best skid plates I've seen, good install, ultra tough, and slide over darn near anything @Factory UTV

PRP Door Bags - sweet door bags on all 4 doors, I wish the front had another bolt in the middle instead of the velcro attachment tho, the sticky on the back of the velcro gets dirty and starts to fall off the door frame @PRPSeats

Audio setup at the request of future wife, Kicker 300.4 Amp, MTX Bluetooth Controller, Rockville 6.5 speaker pods

Axia Fire Extinguisher

PVCX Tuner w/ AA Stage 1 tune (also have stage 2)

Aftermarket Assassins Recoil Clutch Kit

The clutch kit and tuner helped tremendously to balance out the effects of the 32's, I would definitely recommend AA for both. They are awesome to work with and willing to help with whatever you need. @AftermarketAs

Fitting in work and life, the build took me about 2 months, But I'm really happy with how Phase 1 turned out and was stoked to have a little late night thrash session to get it going to make the group ride with the guys @ Fun Center Cycles the next day in the mountains near Silverton, CO

Cage Build in Progress



Fuse and Relay Layout (Waytek wire is awesome for this stuff if you're in the market)


Center Compartment removed to house the radio and switches


Ready to Roll Out
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Help me get some info in these threads: Tire Height --- Front Diff

Last edited by RWB713; November 27th, 2018 at 10:57 PM.
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post #5 of 151 Old November 27th, 2018, 07:59 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Quote:
Originally Posted by RS4Racer View Post
Nice ride, interested to hear more on this. I too have the same machine and love it as it is my first sxs.Attachment 565564

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Get her all shined up and lookin good there man! It's my second, and I'm really happy it with it... but ya know the project never ends..because RZR lol
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post #6 of 151 Old November 27th, 2018, 08:08 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

A few pic from that mentioned group ride, was a great time! California Pass, Lake Como, Poughkeepsie Gulch, Engineer Pass, and Return through Animas Forks







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post #7 of 151 Old November 27th, 2018, 08:33 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Next Major trip was the machines first trip to Moab. We've adopted a yearly multi-family trip up that way and once again, it did not disappoint.

Before the trip I had already broken a belt (made it 572 miles, whoopy! ) so i had the idea of how to and how not to crawl with the gearing a bit, but i didn't like it so much, I knew we wouldn't be doing anything insane in Moab with all the kids and wives, but it was still in the back of my mind that i needed to further address the situation, but the Moab trip went over smoothly with no failures or issues at all. We did Fins', Hell's Revenge, and Moab Rim. We camped down the ledges toward Kane Creek, so we played around a bit in that area too.

The Camp Setup (Yes, we crammed all that into 1 spot in ledges lol)


Our Little Corner of Camp


The Crew at the Hell's Gate overlook (-2 sleeping toddlers)


Coming Up Hell's Gate


In The Escalator




Another on Hell's Revenge


Top of Moab Rim for the token night ride
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post #8 of 151 Old November 27th, 2018, 09:25 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

And that pretty much brings us up to date. She's got about 1050 miles and 62 hrs on her now. Time for the second service and Phase 2 (i really need to quit doing "Phases" in sequence with services... my bank account will start to hate me rather quickly). I'm on my 3rd belt now (Both failures i take 100% blame for), second one made it about 450 miles. I've researched and looked to the ends of the forum for what to do next, and I've got a good little project planned for the next month or so.

The To-Doo list:

Transmission Gear Reduction
Decided this to be my best solution for my desires to crawl. I'm going ultra low, with the 53.4% (as i calculate it) in Low, and 12.7% in H/R.
Big Thanks to @RZR_Joe for starting this thread: Ultimate Crawler Transmission , and to @SSGPohlman , @RZRWorks for all your time and research

4 Corner Walker Links
I still want to run sway bars, I still wanna go fast (Adolescent Ricky Bobby Voice) but I want more articulation when i crawl too. I decided stock sway bars and walker links was the best setup for me. Thanks to @craigstumph @ Pro UTV Parts for the forum hookup on these

4 Corner Rhino 2.0's
"Bring spare axles if you run Pritchett" they said... well my solution was to buy 4 Rhinos and use my stocks as spares... This was a conundrum for me... I still believe the axle should be the weakest link in the drive train, the "fuse" as myself and others have termed it, to prevent other, more expensive, and harder to change, things from failing in the drivetrain, but I concluded that with 32's, the added stress at the tire hopefully will still result in the axle being the weakest link, kind of like a "return to stock" ratio as far as axle strength to tire stress. Again, @craigstumph @ Pro Utv Parts had the forum hookup

Shock Therapy Springs
Everyone loves a better ride right? And i feel the softer initial rate will be better for traction on the rocks, while still giving me the stiffer rate for the high speed hits. I have friends that run the setup, and absolutely love it, I've seen countless forum guys love it, and Shock Therapy pulled through with the forum hookup and great customer service. @Shock Therapist

Rhino U-Series Driveshaft & Carrier Bearing
I suffer from the horrible Polaris QC dept shortcoming of an incorrectly phased driveshaft from the factory, i have some wicked vibration in 4wd at any speed over about 5mph. The stock carrier bearings never were great either, so 2 birds one stone here. I went with the U-series instead of the bounty series because i don't feel you need that much stronger of a U-joint unless your building a full blown race machine with a completely upgraded drivetrain, and i don't ever see myself greasing the U-Joints after every ride like they recommend. I'm good with maintenance... but not grease my u-joints every ride good. Got this guy on the @SuperATV Black Friday special.

Viper Elite 6000lb winch
(I 100% bought this because I asked about doing Pritchett Canyon, and everyone basically told me i had to have a winch, or they would hate me if i wound up as the trail block.(ok, maybe not those exact words) I've referred to winches as "preparations for failure" on numerous occasions, I have no intentions of using it, I don't want to use it, I've never had a winch on any vehicle before, and i feel slightly defeated that i even caved and bought it. But hey, maybe I'll just use it to help other people out! and my rzrforum bros won't hate me for being the trail block on Pritchett ) @Motoalliance had the forum hookup here.

Spring Brake Thingy
Because one time, i put my tranny in park on a steep slope... a scared fiancÚ, a bottle jack, and some MacGuyver ingenuity later.. I've learned my lesson. Pro UTV Parts with the forum hookup here again

A HUNTERWORKS BELT!
Because Todd is a hell of a salesman, a great forum contributor, I had to own up to my promise on his black friday special, and I figured i might as well try it. @Hunterworks

I'll have to work with my clutching a bit after the gear change, so I'll hit Mike @AftermarketAs up and see what he thinks would be best from where I'm at, and I have about a month to get it all done, (Because My (Step)Son will have a project of his own in the garage after Christmas

Updates to come as I get to work on it! I got the garage prepped last weekend and the rzr washed, started pulling a couple things apart last night, but i'm out of town for work for a few days, so hopefully I'll get to hit it hard this weekend!

Also, Another thanks to all the forum vendors for the forum discounts and sales, you make it a lot less painful in the pocket! I think i saved around $500-600 with forum discounts on all this stuff!

I better stock up on beer too! Anybody got a forum hookup on Beer?

"I strive for a level of perfection I don't possess the skillset to achieve"
2018 XPT4 - Bailey

Help me get some info in these threads: Tire Height --- Front Diff

Last edited by RWB713; November 28th, 2018 at 05:07 PM.
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post #9 of 151 Old November 28th, 2018, 04:34 AM
 
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Good looking machine. I might suggest when your ready for suspension give Clint at Special Carriers MFG a call. You will not find better quality parts than SCM.
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post #10 of 151 Old December 3rd, 2018, 07:00 AM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Phase 2 Got a start on Saturday, decided to tackle the gear reduction first as it was the most involved.

Took a few shortcuts from the service manual to get the gear case out, and i can confirm that you do not need to pull the plastics, intake, or thermostat housing to get it out. It takes a little finesse and some of the bolts are challenging to get out, but it's really not bad. You will need a 15mm crows foot, or possibly a stubby wrench, to get to the nut on the top clutch cover bolt & hold backup, but that was the hardest part by far.

I did find that the ground wire to my starter appears to have never been connected from the factory... another thank you to the QC dept at Polaris, but its an easy fix and I didn't find anything else abnormal during tear down, so that's always nice. My clutch housing and clutches will be getting a full disassembly and cleaning before reassembly, as I still found some minor debris from the two blown belts, and it's at 1000 miles, probably time for a good going through anyway.

The gear case itself came apart well and the internals were actually less complex than i thought, I had seen videos and pictures, so i knew what to expect, but even then, I was still pleasantly surprised at the simplicity and ease of it really. No dirt, debris, or anything inside the shift housing like I had seen on a couple others either. A press and bearing separator are definitely a good thing to have around for it, and it makes taking the bearings and gears off a breeze. A little shot of heat from my heat gun and they pressed off without much effort. I would absolutely recommend doing one shaft at a time, as it makes it much easier to keep everything in order as you go along. I did replace all the bearings with SKG bearings with the exception of the snorkel gear, as they're always submerged in lube, and i didn't feel taking that assembly apart was worth the time & effort. I didn't get the case reassembled just yet, but i have everything cleaned, prepped, and ready for reassembly.

OEM Polaris Gear were used, with the following PN's:
#3235450 48T Stage 2 Gear
#3235451 25T Reverse Gear Shaft
This is the ACE 325 gearset, and nets 12.7% reduction across all ranges per my calculations

#3235232 67T Low Gear
#3236132 25T Low Gear
Low gear set from a Ranger 1000, 36.2% reduction in low gear only

Total Reduction in Low is 53.49% after gear multiplication takes effect

SKG Bearings ordered from Kombustion Motorsports, but it's the same kit the Sandcraft sells

OEM Seals were used to replace the input shaft and axle seals

Here is the calculation sheet i made in excel, i may expand this in the future if i find some free time:


Overall, the project is going pretty smoothly so far and I hopefully will find some time to work on it throughout the week

Gearcase Removed:


Starter ground wire not connected:


I didn't make a nifty stand like Roger Davis did on his youtube videos... but a couple pieces of 2x4 worked out pretty well


The internals prior to disassembly:


I haven't take any after pictures yet, but I'll do that before i get it all back together... Onward!

Current Beer Consumption count: 4
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post #11 of 151 Old December 3rd, 2018, 07:17 AM
 
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Great thread. Thanks for taking the time to share. Looking forward to the next post.
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Glad to see it's going well.
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post #13 of 151 Old December 13th, 2018, 09:32 PM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Got some time in the garage tonight to do a few things. Finished up the gear swap and got the case back together. Did the service as well, got a new air filter on and changed the oil & filter, The oil filter sure easy to get to with no clutch cover on lol. Also took apart and cleaned my secondary clutch as it still had traces of blown belt in it. I'm happy to finally get all that crap out of the secondary, still have the primary to do, but it will have to wait for next time

After picture of the gear swap, if you compare to the above, the gears are definitely a noticeable change, and low absolutely feels like the low i feel it should be now, i'm excited to get to try it out!




I spoke to mike at aftermarket assassins and decided to do the performance helix they offer as opposed to staying with the stock helix, got it all swapped in and the secondary looks a lot better now that it's cleaned out. Should give a lot better feel to the clutch and help keep my shift RPM where it needs to be after the gear change. I'm still going to add a weight to my primary as well. I also replaced the helix buttons since 1000 miles seemed like a good time and I was in there anyway,

Outer half of the secondary with belt traces left in it


After cleaning:


Inner half before cleaning & helix swap:



After cleaning and reassembly:


Helix Comparison:




That's it for tonight! Should have most of the weekend in the garage so hopefully I'll get to make major progress then.

Current total beer consumption count: 7
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Help me get some info in these threads: Tire Height --- Front Diff

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post #14 of 151 Old December 14th, 2018, 06:18 AM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

Here's a side by side of the gears changed out:

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post #15 of 151 Old December 17th, 2018, 06:57 AM Thread Starter
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Re: My 2018 XPT4 "Bailey" and her Past, Present, And Future

It was a weekend of trials lol. I got quite a bit done, but it doesn't feel like it since the machine still Isn't back together, but i suppose progress at least!

First off I decided to go ahead and install the Rhino drive shaft since i figured it would be easier before i put the gear case back in. A heads up to anyone about to tackle this project here... plan on pulling the entire inside of the machine out... cross braces, fuel tank, floor pan, the works... It was a little more involved than i had planned on, and quite a bit more work than the 2 seat 900 i had done a drive-line & bearing in before. And i'm still not completely done, I have a PM in to @SuperATV to clarify some install questions about the carrier bearing, I can get the carrier bearing to seat in the housing, but it doesn't sit straight with the housing since the carrier bearing mounts are at an angle, I'll update when I hear from SuperATV and get it figured out... but this was my issue:





There's not enough adjustment in the slots to get the housing to sit perpendicular to the bearing.... it seats in the housing the way I have it... but as you can see, the grease groove on the bearing is not inline with the grease groove on the housing.. Dimension A is not equal. And to get "A" to be equal, I need to move the housing past where the adjustment slots allow. I have the rest of the shaft installed minus this issue with the carrier bearing, but that's keeping me from putting the inside back together

Also, as you can see in the pic below, the rear shaft was indeed phased incorrectly from the factory... the solid yokes on the shaft should be parallel with each other as the Rhino is, My stock shaft is about 35░ off, I'll probably put this aside as a side project and cut and re-weld the yoke and keep the driveshaft as a good spare:



While I ran into the holdup, i figured i'd go ahead and swap out the springs on the shocks so they were ready to go, The rears went together well, but the fronts require a spring compressor to remove and install the springs... I have a Mcphereson strut type spring compressor, and that worked for getting the stock springs off.... but with the new springs, there's not enough room for the compressor arms to fit between the spring and the shock body, and I can get enough compression using just the spring area around the shock shaft to get the lower perch back on.. so I ran into another hold up while I figure out a different spring compressor.... I'm open to suggestions here... I know alot of guys have done this... what kind of spring compressor did you use? @RZR_Joe , did you run into this issue? (I failed to take a picture of this problem, but i did take a picture of the rear after i got it together)



After those two hold ups, I did manage to get some stuff done that went smoothly. The front axles, winch, and sway bar links are all together up front and looking pretty sweet.

The winch install went better than i expected, this was my first winch on a UTV (or anything really) and i was dreading working in the tight space, but it actually wasn't bad at all. I saw that most people put the fairlead in and leave the stock plastic cover off, I didn't like that look so much, so i cut out the stock plastic cover to clear the fairlead, Decently happy with how it turned out, since the inside is still gutted from the driveline install, I don't have it wired up yet, i did start on running wire and figuring out where i'm mounting the solenoid and wireless module, just waiting to complete the wiring.





The axles went in smoothly as they should. A couple things to point out, The stock torque on the wheel bearings seemes very excessive to me, and far tighter than the rears were. I couldn't get the axle nut off with a 2ft breaker bar and had to resort to the impact wrench. Upon reinstall, i took the liberty of adjusting that down a bit, they're still tighter than I've ever put a wheel bearing on in my life, but I can't imagine that much torque being good on a wheel bearing. Also, as many have experienced.. my wheel bearings were bone dry, i'll probably have to replace them sooner than i'd like because of the 1000 miles of running them like this, but for now I pumped them up with grease using my nifty Tiger Tool bearing greaser I won with ROTM in October (thanks guys!) The tool works great and I'm glad that I have it, I put about 15 pumps of grease in each wheel bearing. Also hit the front sway bar while i was there... those only took two pumps on each side

The front walker links didn't come with instruction, so if anyone sees something out of place in the pics, let me know, I felt it was a pretty straight forward install, but I've been wrong a time or two in the past.





Oh, yeah, I put the spring break thingy in...that install went great lol. took all of 5 minutes!



Hopefully I'll get in there a couple evenings this week and start going back together with the inside and the rear, but that's all for now!

Current Beer Consumption count: 17
SuperATV, RZR_Joe and 185EZ like this.

"I strive for a level of perfection I don't possess the skillset to achieve"
2018 XPT4 - Bailey

Help me get some info in these threads: Tire Height --- Front Diff

Last edited by RWB713; December 17th, 2018 at 08:15 AM.
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carrier bearing , gear reduction , walker links , winch , xp4 turbo

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