We’ve been working on Mark’s Polaris Xpedition ADV 5 NorthStar for a while now, and it’s finally ready to roll. Built for long-haul travel, serious trail capability, and comfort in any condition, this 2025 Xpedition is loaded with smart upgrades that improve performance without overcomplicating the setup.
This walkaround breaks down every part of the build, from suspension and lighting to interior details and storage—giving you ideas for your own Xpedition or helping you understand what’s possible when everything comes together clean.
Up Front: Lighting, Suspension & Armor
The front of the build sets the tone. We color-matched the DRT front bumper and fairing gray to match the rest of the car, and tied it together with a set of Baja Designs LP4s wired into the XTC turn signal kit. These backlight indicators double as signal lights, giving the car safety and style.
Behind the bumper sits a full HCR mid-travel suspension kit, paired with Shock Therapy dual-rate springs and sway bar links for a more responsive, planted feel. SuperATV Rhino 2.0 axles and SuperATV tie rods round out the setup with durability where it counts.
Wheels, Tires & Color-Matched Details
The car rolls on 32” BFG KM3 tires wrapped around Valor beadlock wheels, with rings powder coated to match the suspension. Even the center caps were paint-matched black to tie the look together.
We added factory mirrors with Baja Designs Squadron Pro lights, and an SDR roof rack holds a full-size spare secured with a DRT Y-strap. A full half-down gray wrap completes the exterior.
We also installed Viper whip mounts with one-inch Martian amber whips, which give just enough visibility without getting tangled in the trees.
Inside the Cab: Comfort, Storage, and Function
Step inside and you’ll find custom decking from Blades, trimmed in gray and black, including custom logo floor mats. Triple X heated and cooled seats, PRP harnesses, and a Pro R steering wheel add comfort and control. The switch panel is handled by a center-mounted Switch Pros 8-panel system using an MTS bracket.
The stock dome lights were replaced with a Litt Industries dome light plate up front and a touch-controlled dome light in the rear cargo area—no need to run to the front when you’re digging through gear.
A few upgrades stand out for being genuinely useful. We added a jump lug kit behind the rear seat so Mark can jump the car or charge from an external source without removing anything. And with Beastfab door extensions, the rear doors open wider—ideal if you’ve got kids or cargo.
See the Full Gallery
This build is proof that a purpose-driven setup can look good and work even better. Every detail serves a purpose—from the wrap to the wiring.
Check out the full photo gallery and explore all the products used in this build.
