Front end rattle when going over small rock at slow speed…. Help!

[Boston801]

Hey everyone!

I bought a 2025 Xpedition ADV5 a few weeks ago, brand new. And we took it out yesterday and over slow chatter/ small rock I am hearing a rattle, not a clunk, in the front end sounds like it might be driver front. We had it out the day before and did not hear this so not sure what the deal is. We did just get shock therapy springs installed on it a few days before hand and everything seems tight due to install. The first day taking out the rig with new springs we did not hear this little rattle in the front end.

Any ideas what it may be? This machine has 250 miles on it

Any questions I will do my best to answer quickly.

 

[JTBarlow]

Do you have shackles on the front bumper?

Some rattling is typical on these machines. It could be the spring separator rubbing on the shock tube. You can check the spring tails on the separator and see how they’re aligned. They need to be either 180° from each other or about a 1/2” overlap on the spring separator or they’ll put uneven pressure on it that can twist it into the tube.
It could be the CV axle. They do have a little play in the connection with the differential.
If everything on the front end is torqued up properly, it may be a little annoying, but nothing to worry about.

 

[Boston801]

Do you have shackles on the front bumper?

Some rattling is typical on these machines. It could be the spring separator rubbing on the shock tube. You can check the spring tails on the separator and see how they’re aligned. They need to be either 180° from each other or about a 1/2” overlap on the spring separator or they’ll put uneven pressure on it that can twist it into the tube.
It could be the CV axle. They do have a little play in the connection with the differential.
If everything on the front end is torqued up properly, it may be a little annoying, but nothing to worry about.

Thanks for the reply, I do not have any shackles on the bumper. I will look at the spring tails again on the separator when I can go look at it but I’m pretty sure they are as you say they should be.

It’s just a little annoying no doubt, I could understand this noise when flexing or something but this is going over like 2” rock on hard pack at maybe 5 mph. Maybe I need to just full send my throttle so I can’t hear anything but the engine and all will be good…. Till it isn’t!

 

[JTBarlow]

The louder the stereo, the less noise!

I’d definitely check that everything is tight and secured but if the rattle persists after that, I’d just roll with it

 

[Keyster]

Polaris has had issues with brake calipers/pads rattling on other machine models. It's most noticeable when going slow. Not sure if these issues would extend to Expeditions, but I wouldn't rule it out.

 

[BADXP]

Hey everyone!

I bought a 2025 Xpedition ADV5 a few weeks ago, brand new. And we took it out yesterday and over slow chatter/ small rock I am hearing a rattle, not a clunk, in the front end sounds like it might be driver front. We had it out the day before and did not hear this so not sure what the deal is. We did just get shock therapy springs installed on it a few days before hand and everything seems tight due to install. The first day taking out the rig with new springs we did not hear this little rattle in the front end.

Any ideas what it may be? This machine has 250 miles on it

Any questions I will do my best to answer quickly.

I have the same issue as you describe. Also running ST springs but the rattle predates the install of those. It sounds like the upper shock mount bolt in drivers side but I’ve been through the front suspension about a dozen times disassembling/reassembling and checking/tightening everything in the front end. My next step is to install ST schrader caps on the shock bypass and ensure nitrogen fill to spec. I’ve been told low nitrogen won’t make this sound but have come across several guys on the Rzr forums where this fixed a similar sound. Will report back please do the same if you find a fix!

 

[Boston801]

I have the same issue as you describe. Also running ST springs but the rattle predates the install of those. It sounds like the upper shock mount bolt in drivers side but I’ve been through the front suspension about a dozen times disassembling/reassembling and checking/tightening everything in the front end. My next step is to install ST schrader caps on the shock bypass and ensure nitrogen fill to spec. I’ve been told low nitrogen won’t make this sound but have come across several guys on the Rzr forums where this fixed a similar sound. Will report back please do the same if you find a fix!

That’s interesting, I am wondering if maybe it is the sway bar links, if they indeed go out that fast (250 miles)? I’m at a loss as well when it comes to this little suspension rattle. I have also read other posts about the steering rack, but find that not being my problem with so little of miles on it, but again, they throw these things together as cheaply as possible too. Who knows. If I discover an answer to our issue, I will definitely report back.

 

[BADXP]

That’s interesting, I am wondering if maybe it is the sway bar links, if they indeed go out that fast (250 miles)? I’m at a loss as well when it comes to this little suspension rattle. I have also read other posts about the steering rack, but find that not being my problem with so little of miles on it, but again, they throw these things together as cheaply as possible too. Who knows. If I discover an answer to our issue, I will definitely report back.

Agree. My sway bar got thrown in the trash 2,000 miles ago so I eliminated that from the equation early on

 

[Boston801]

Agree. My sway bar got thrown in the trash 2,000 miles ago so I eliminated that from the equation early on

You don’t run a sway bar at all!? How’s the body roll with all the glass we have in these?

 

[BADXP]

You don’t run a sway bar at all!? How’s the body roll with all the glass we have in these?

My rear sway bar is still on. I only really notice additional roll when running a road at speed. Trail articulation is improved. I find it’s a preference thing. You can disconnect one end and test it out for your riding style. For me it started with chasing the rattle and liked it enough I took the front off.

 

[Boston801]

My rear sway bar is still on. I only really notice additional roll when running a road at speed. Trail articulation is improved. I find it’s a preference thing. You can disconnect one end and test it out for your riding style. For me it started with chasing the rattle and liked it enough I took the front off.

Well, I won’t be running out and buying ST bar end links to try and fix my rattle issue. I may disconnect and run it to see what it’s like.

 

[Ryan]

Def report back on your troubleshooting. I have learned to live with the rattle. I have SRS springs which love but the strange rattle or clicking pre-dates the springs.

 

[Boston801]

Def report back on your troubleshooting. I have learned to live with the rattle. I have SRS springs which love but the strange rattle or clicking pre-dates the springs.

Will do! Wish me luck haha!

 

[XpeditionMoe]

Hey everyone!

I bought a 2025 Xpedition ADV5 a few weeks ago, brand new. And we took it out yesterday and over slow chatter/ small rock I am hearing a rattle, not a clunk, in the front end sounds like it might be driver front. We had it out the day before and did not hear this so not sure what the deal is. We did just get shock therapy springs installed on it a few days before hand and everything seems tight due to install. The first day taking out the rig with new springs we did not hear this little rattle in the front end.

Any ideas what it may be? This machine has 250 miles on it

Any questions I will do my best to answer quickly.

Not sure if this is the problem but on FB, there is a guy who just had a replaced on warranty and it got rid of his front end noise. Looks to be a little heavier but shorter than the first one that came with factory build. The first photo says, "Image not available" but it is part of a bigger photo, so click on it for the part number. The guy is Canadian, so that is why it is priced in CAD.

 

[BADXP]

Not sure if this is the problem but on FB, there is a guy who just had a replaced on warranty and it got rid of his front end noise. Looks to be a little heavier but shorter than the first one that came with factory build. The first photo says, "Image not available" but it is part of a bigger photo, so click on it for the part number. The guy is Canadian, so that is why it is priced in CAD.

Ya I think the post you found is for the driveshaft rattle which is different than what we are chasing here. I had that issue too and went to an aftermarket driveshaft to address it.