Rattle noise

[Icehog]

Usually a good greasing of the yoke will fix the issue, there is a hole in the skid plate to get to the grease zerk.

 

[ultmax]

It’s absolutely the driveshaft - I installed an aftermarket one and don’t have the rattle now. Open your center console and pop out the inner console box. Have someone drive you at 5500 rpm you can hear the rattle come directly from the carrier bearing area.

It,s the drive shaft, if you grease it will go away for a short time, there is a grease zero by the carrier bearing.

 

[jawshxpedition740]

I have a rattle noise around 5500 rpm. Goes away after 6000. Sounds like heat/exhaust shield. Can’t find anything loose. Any one else having issues. XP 2 seater. Thanks

I had the same rattle, the dealer ship greased it and I rode for a few hundred miles, and the noise is back. I will take it in shortly and see what they are going to do this time. He told me another guy had this issue and they replaced the prop shaft on his through polaris warranty. Hoping they will do the same for me.

 

[BADXP]

It,s the drive shaft, if you grease it will go away for a short time, there is a grease zero by the carrier bearing.

I’m aware of the grease zerk. Mine got to the point that grease did nothing for the rattle. My machine also gets used daily so greasing before every ride wasn’t practical.

 

[KMFB]

I'm experiencing the same issue. 2025 xp 2 seat. Polaris have a fix for this yet? Noise is getting g annoying and greasing the slip yoke does nothing .

 

[jawshxpedition740]

I had the dealership put the new updated prop shaft on under warranty. It lasted about 100 miles and now it is back. It sounds like shit. You can hear an Xpedition coming down the trails from that rattle.

 

[KMFB]

I talked with polaris customer care today and lodged my complaint about this. Everyone that is dissatisfied with this needs to call polaris and complain. Nothing will come of it if we don't. They've already admitted to having a problem by replacing some of the driveshafts with the updated one. Mine came with the updated version and it makes noise.

 

[BrunoKY25]

Having the same issue although our dealer changed out the driveshaft, etc…annoying to say the least. The rattle happens in high range and low range which should not implicate the drive shaft. Any other suggestions?

 

[KMFB]

I believe there have been people on here who have installed the sandcraft driveshaft and it cured the problem.
Has anyone had their stock driveshaft properly phased and balanced to see if that fixes it?

 

[BrunoKY25]

I believe there have been people on here who have installed the sandcraft driveshaft and it cured the problem.
Has anyone had their stock driveshaft properly phased and balanced to see if that fixes it?

Thank you for the suggestion. We have had the dealer address this issue with a new driveshaft, balanced and lubricated per Polaris directives. No change in the “tin” rattle which begins at 5000 rpm - 6000 rpm in all modes of operation.

 

[KMFB]

I refuse to spend $1500 on a driveshaft when Polaris should have a fix for this. And I won't take it to the dealer until they do. Fortunately for polaris, my warranty is up in a little over a month.

 

[JTBarlow]

Thank you for the suggestion. We have had the dealer address this issue with a new driveshaft, balanced and lubricated per Polaris directives. No change in the “tin” rattle which begins at 5000 rpm - 6000 rpm in all modes of operation.

For a tinny sounding rattle, especially if it’s coming from the rear area, I’d check the exhaust shielding. All of it from the manifold back and including the muffler cover. It’s possible the shielding bolts have come loose and allow them to vibrate.

 

[JTBarlow]

I believe there have been people on here who have installed the sandcraft driveshaft and it cured the problem.
Has anyone had their stock driveshaft properly phased and balanced to see if that fixes it?

We had one driveshaft that was actually bowed. We had a driveline shop build a new driveshaft, but they had to use the OEM yokes.
It definitely improved the machine considerably, having it properly phased and balanced, but didn’t completely fix the vibration. The splines of the slip joint in the middle have too loose of tolerances to get it completely true. And buying another OEM driveshaft will just be buying the same issues.

The Sandcraft setup is expensive, but it’s a true upgrade. The slip joint has very good tolerances, the carrier bearing and u-joints are all grease-able, it corrects the shaft angle, and it’s a much heavier duty design.

Short of having multiple major failures, I don’t see Polaris putting any effort into improving their current drivesh

 

[B B]

I refuse to spend $1500 on a driveshaft when Polaris should have a fix for this. And I won't take it to the dealer until they do. Fortunately for polaris, my warranty is up in a little over a month.

Report it now while under warranty. It's not your fault they haven't fixed the issue yet. Personally, I don't believe they have any intentions on fixing it or it would have been done by now.

 

[Jlpxpediton]

Check your drive line, 24 models have an askew angle causing the shaft to slap around in the prop. Took to the dealer they packed it full of grease called it good, I rode a few trail rides and it was back, spoke to the dealer again and long story short they replaced the entire drive line with that of a 25 year model. No noises or vibrations or anything weird so far. Hope this helps.

 

[sscappaticci68]

I'm thinking of installing a Sandcraft, seems pretty straight forward on a ADV 2 door.

 

[jawshxpedition740]

So depressing. I just bought mine used from a dealership with 300 miles on it. Wasn't allowed to take it on the side road. They said it was because of an "accident the previous week". I call BS. They did that so I couldn't drive it faster then 10 mph around the parking lot. I get home after a 3 hour drive. I get the buggy unloaded. I can't wait to drive it!! been wanting an Xpedition since the day they announced it. I get on my road and WTF! this thing sounds like heatshield/center carrier bearing. I call the dealership back and get nothing more than you bought it with no warranty. I took the skid plate off. Spent 2 hours taking the center console and dash completely apart trying to find this heat shield I thought was making the noise.

I give up. I start looking online only to discover the slip yoke rattle issue. I grease mine and it just dulls it slightly. It is SO annoying and embarrassing. I have asked Sand Craft if they are going to make a solid center carrier bearing. Nothing yet. The worst part is I paid 25k for this thing 8 months old with 300 miles and I know what ever fix there is eventually I will be on the hook for. They left the previous owners registration in the glove box. I reached out to him and discovered that was why he traded the unit back in and bought a Defender and I got shafted. I should have done more research. I love all my Polaris's I have a Turbo S and an RS1, but I am so tired of having to spend so much time and money to make them reliable. I mean how on earth could this issue not have been discovered during testing. You're telling me that polaris never put more than a 100 or 200 miles on a unit before they approved it for retail? No way. Polaris sold these units knowing full well they had a major flaw. I hope there is a class action lawsuit. And its not like this is the first time. The turbos failing and clutches exploding on Turbo S units and Pro Xp's. Come on polaris. On top of the rattle, its obvious the drive shaft is having a severe harmonic vibration issue. It vibrates so bad the output seal on the transmission is leaking. I have 18k miles on my Turbo S and have never had to replace the output seal on the driveshaft pto. Just the output hubs to the axles. ,,!,- you polaris.

It is embarrassing to hear that noise. I can tell when another xpedition is coming down the trails from that heit shield tinny noise. People ask how I knew an xpedition is coming. I can tell by the noise it makes.

 

[Jlpxpediton]

Update** just got back from WV and put some serious miles on my machines, I’m happy to report the Xpedition did so effing good! No rattles just pure enjoyment.

 

[JTBarlow]

Update** just got back from WV and put some serious miles on my machines, I’m happy to report the Xpedition did so effing good! No rattles just pure enjoyment.

That’s awesome!