My brother and I ordered and received our Xpeditions at the same time. Both XP 5s and 1 VIN number different. I have done all the accessory installs on both. That being noted, I’ve had zero issues with my machine. It has 1” hub adapters and 4/3 offset wheels bringing it out to 72” overall width and no problems with wheel bearings or shocks. I’ve also done the Gilomen ECU Tune and performance clutch kit. There’s 1100 miles on the original belt with 600 or so miles of that pulling a 1600+Lb trailer.
My brothers Xpedition, on the other hand, has had several issues. I found the rear driveline yoke loose on the output shaft and tightened it up. Then a couple weeks ago we finally got his HCR Suspension kit. When I started disassembly, one of the ball joints in the front upper control arms was loose in its loop. I could spin it by hand and it pretty much fell out once not connected to hub assembly. Then moving to the rear, one of the lower A-arm bolts was completely missing. It tweaked the rear A-arm mount and cracked it in several places, as well as the front hole being wallowed out from however long the bolt had been in there loose.
Like you, there were only a couple days left on the factory warranty but Polaris accepted the claim and are replacing the frame. Our Polaris Dealer has been top Tier and jumped right into it. If it’s not already done, it should be soon.
My overall take is that the factory could use a little better quality control. Some machines seem to come out perfectly while others seem to not really be checked very thoroughly.
