TPR Industries Big Brake Kit Review: Ultimate Polaris Xpedition Brake Upgrade

If you've loaded up your Polaris Xpedition with accessories, upgraded to bigger tires, or installed a long travel kit, you've probably noticed one critical issue: stopping power just isn't what it used to be. That factory brake setup that worked fine on a stock machine suddenly feels inadequate when you're trying to bring 2,000+ pounds of fully-loaded UTV to a stop. We've tried multiple solutions over the past year, and nothing really delivered the results we were looking for until now.

TPR Industries has developed a big brake kit specifically for the Polaris Xpedition. This isn't an incremental improvement. It's a complete transformation of braking performance. We got our hands on one of the first kits available and put it through extensive real-world testing on a heavily modified Xpedition. The results were incredibly impressive. In this comprehensive review, we'll break down everything you need to know about this brake upgrade, from what's included in the kit to the dramatic performance improvements we measured in our before-and-after testing.

Why Upgrade Your Xpedition Brakes?

The Polaris Xpedition comes from the factory with a brake system that's perfectly adequate for the stock configuration. However, the reality is that most Xpedition owners don't keep their machines stock for long. Whether you're adding essential accessories or going all-out with performance upgrades, each modification adds weight, and weight is the enemy of effective braking.

Consider the typical Xpedition build: a roof rack adds 50-75 pounds, a heavy-duty bumper and winch can add another 100+ pounds, a spare tire carrier with a 35-inch tire adds significant weight, and long travel suspension kits can add 50-100 pounds or more. Then there's the cargo itself: coolers, camping gear, tools, recovery equipment, and passengers. Before you know it, you're asking your factory brakes to stop a vehicle that weighs several hundred pounds more than what Polaris engineered them for.

Add larger, heavier tires into the equation (many Xpedition owners are running 32-33 inch tires or larger) and the problem compounds. Not only is there more rotational mass to stop, but the increased tire diameter also creates more leverage against your brake system, effectively reducing your braking force.

This isn't just about convenience or performance. It's about safety. When you're navigating technical terrain with passengers aboard, towing a trailer, or descending steep grades with a load of hunting gear (or an elk in the bed), you need confidence that your brakes will stop you when you need them to. The TPR Industries Big Brake Kit delivers that confidence.

What's Included in the TPR Big Brake Kit

TPR Industries took a smart approach with this kit. Instead of reinventing the wheel, they're leveraging proven components from Polaris's high-performance Pro-R platform and engineering the adapters needed to make everything work seamlessly on the Xpedition. Here's what you get:

Front Brake Components: The heart of the system is genuine Polaris Pro-R front calipers, which are significantly larger and more powerful than the stock Xpedition units. These calipers are paired with larger-diameter rotors for increased thermal capacity and stopping power. TPR manufactures custom caliper mounting brackets that are precision-machined to adapt the Pro-R calipers to the Xpedition's front suspension geometry. These brackets are engineered specifically for this application to ensure proper alignment and optimal performance.

Rear Brake Components: Here's where TPR's engineering really shines. Rather than leaving the rear brakes stock (which would create a major imbalance), the kit relocates your factory Xpedition front brake components to the rear. This gives you a significant upgrade over the stock rear brakes while maintaining a balanced brake bias. Custom rear caliper adapter brackets are included to mount the relocated calipers properly. These brackets are machined with specific clearances to avoid any interference issues that can occur when adapting components.

Master Cylinder Assembly: The kit includes a Pro-R master cylinder with a custom-designed mounting bracket that positions everything perfectly for the Xpedition's brake pedal geometry. What makes this setup particularly clever is that it integrates your factory Xpedition plunger, maintaining the proper pedal feel and travel that you're accustomed to.

Perhaps the most important component is the built-in proportioning valve. This adjustable valve allows you to fine-tune the brake bias between front and rear, giving you the ability to dial in the perfect braking characteristics for your specific setup and use case. We'll talk more about this adjustability later, but it's a feature that sets this kit apart from simpler brake upgrades.

Everything in the kit is designed to bolt on using the factory mounting points. No cutting, welding, or permanent modifications required. It's a complete system that's been engineered to work together, not a collection of parts you have to figure out how to make compatible.

Installation Overview

The TPR Big Brake Kit is designed to be installed by enthusiasts who are comfortable working on brake systems. If you've done brake jobs before and have a basic understanding of hydraulic brake systems, this is definitely within the realm of a DIY project. That said, brakes are critical safety components, so if you have any doubts about your mechanical abilities, we strongly recommend having the kit installed by a professional.

Installation time will vary based on your experience level and how methodical you are about the process. An experienced technician can knock it out fairly quickly, while a first-timer should plan to take their time and not rush through any steps.

The basic installation process follows this sequence:

First, you'll remove the factory front brake components: calipers, rotors, and brake lines. The Pro-R calipers and larger rotors then get installed using TPR's custom mounting brackets, which bolt into the factory locations. New brake lines will need to be routed to these relocated calipers.

Next, those factory front brake components you just removed get installed on the rear. This is where the rear adapter brackets come into play, allowing you to mount the calipers in the correct position with proper clearance. Again, brake line routing is part of this step.

The master cylinder installation is straightforward but requires attention to detail. The Pro-R master cylinder mounts to the frame using TPR's custom bracket, and the proportioning valve is integrated into this assembly. You'll connect your factory Xpedition brake pedal plunger to the new master cylinder, maintaining the stock pedal feel.

After all components are installed and torqued to specification, the system needs to be bled thoroughly to remove all air from the hydraulic lines. This is critical for proper brake function and pedal feel. Take your time with the bleeding process and don't cut corners.

Finally, the proportioning valve will need initial adjustment. We'll cover the fine-tuning process in detail later, but expect to do some test stops and make adjustments to dial in the brake bias for your specific vehicle configuration.

Again, if you're not completely comfortable working on brake systems, professional installation is worth the investment. These are your brakes. They need to be installed correctly.

Real-World Testing: Before & After Results

We don't just bolt parts onto vehicles and call it a day at Jagged X. When we say we tested this kit, we really tested it. We chose Rick's Xpedition as our test vehicle for several reasons. It's a heavily modified machine with an HCR long travel kit, 33-inch Nitto tires, a full roof rack, bed rack, spare tire carrier, and numerous other accessories. In other words, it's exactly the type of Xpedition that desperately needs better brakes, and it's representative of the builds our customers are running.

We set up a controlled testing environment with two cones marking our starting point. Using a laser measuring device, we would measure the exact stopping distance from the cones to where the vehicle came to a complete stop. We conducted tests at three different speeds: 20 mph, 30 mph, and 40 mph. For each speed, we did multiple runs to ensure consistency, and we marked the pavement to document the results.

Before Installing the TPR Kit:

At 20 mph with the stock brakes, Rick's Xpedition required 25 feet to come to a complete stop. Even at this relatively low speed, there was no wheel lockup. Just steady, progressive deceleration that took more distance than you'd want in an emergency situation. The brake pedal felt mushy and required significant pressure to achieve maximum braking force.

At 30 mph, the stopping distance increased to 37 feet. Again, no wheel lockup was possible no matter how hard we applied the brakes. The vehicle just gradually came to a stop. This is concerning when you consider how often you might need to make a sudden stop on the trail.

At 40 mph, things got really eye-opening. The stopping distance stretched to 65 feet. Jamming on the brakes as hard as possible resulted in a slow, rolling stop that covered a lot of ground. If you've ever driven a heavily-loaded Xpedition and experienced that sinking feeling when the brakes just don't seem adequate, you know exactly what we're talking about.

After Installing the TPR Kit:

The transformation was immediate and dramatic. At 20 mph, the stopping distance was slashed to just 7 feet. That's an 18-foot reduction, or 72% shorter stopping distance. More importantly, we could feel the authority in the brakes. They grabbed confidently and brought the vehicle to a quick, controlled stop. This was the test that surprised us the most because it really highlighted how much improvement the kit provides even at moderate speeds.

At 30 mph, the stopping distance improved to 34 feet. We achieved complete brake lockup. Looking at the skid marks on the pavement, you could see that the tires locked up almost immediately when we hit the brakes hard. The vehicle came to a stop in a distance that was dramatically shorter than the stock setup.

At 40 mph, the results were even more impressive. The Xpedition stopped in 56 feet, a 9-foot improvement over stock. Full brake lockup was achieved nearly at the cone markers. The skid marks told the story clearly. This kit gives you legitimate emergency stopping power.

Performance Summary:

20 mph: Stock 25 feet vs TPR 7 feet (72% improvement)
30 mph: Stock 37 feet vs TPR 34 feet (8% improvement)
40 mph: Stock 65 feet vs TPR 56 feet (14% improvement)

Beyond just the raw numbers, the brake feel was transformed. The pedal was firm and responsive, with excellent modulation. You could feel exactly how much braking force you were applying, giving you precise control whether you needed a gentle slow-down or a full panic stop. The confidence this inspires when you're loaded up and heading down a steep trail cannot be overstated.

One thing we did notice was some adjustment would be needed with the proportioning valve to fine-tune the front-to-rear brake bias and minimize skidding, but that's exactly what that valve is there for. Even before optimization, the kit was delivering performance that far exceeded our expectations.

Adjustability & Fine-Tuning

One of the smartest features of the TPR Big Brake Kit is the integrated proportioning valve. This is where the kit really separates itself from simpler brake upgrades. This valve allows you to adjust the brake bias, essentially controlling how much braking force goes to the front wheels versus the rear wheels.

Why does this matter? Because your Xpedition's weight distribution changes constantly depending on how you're using it. The proportioning valve lets you adapt your brake performance to match your current configuration.

Running solo on the dunes? You can adjust the valve to optimize for a lighter rear end and more aggressive front braking. Loaded up with four passengers and gear for a weekend expedition? Dial in more rear brake bias to account for the additional weight in the back of the vehicle. Towing a trailer? Adjust accordingly. Have an elk in the bed after a successful hunt? Make another adjustment to compensate for the extra weight.

The valve is easily accessible and adjustments can be made with basic tools. Greg from TPR Industries specifically designed this system with the expectation that customers would actively tune their brake bias for different scenarios. This isn't a set-it-and-forget-it installation. It's a performance system that you can optimize for exactly how you're using your Xpedition at any given time.

The adjustment process is straightforward. Make small changes to the valve setting, do some test stops to evaluate the brake balance, and refine from there. You're looking for firm, controlled stops with all four tires contributing to the braking effort without excessive lockup. The goal is to maximize stopping power while maintaining control and stability.

Different terrain can also benefit from different settings. Street riding might call for a different balance than technical rock crawling or high-speed desert running. The beauty of the system is that you have the flexibility to optimize for whatever you're doing.

We recommend keeping notes on your preferred settings for different load conditions and uses. Once you've dialed in the valve for your typical configurations, you'll be able to quickly adjust whenever your setup changes significantly.

Who Should Consider This Upgrade?

The TPR Industries Big Brake Kit isn't necessary for every Xpedition owner, but if you fall into any of these categories, it's an upgrade you should seriously consider:

Long Travel Owners: If you've installed a long travel suspension kit from HCR, Lone Star, or any other manufacturer, you've added significant weight to your Xpedition. The factory brakes were never designed to handle this extra mass, and the TPR kit brings your stopping power back to where it needs to be, or even better than stock.

Larger Tire Runners: Running 32-inch tires or bigger? The increased rotational mass and larger diameter work against your factory brakes. This kit provides the additional power needed to effectively stop those larger, heavier tires.

Heavy Accessory Loads: Roof racks, bed racks, spare tire carriers, heavy-duty bumpers, winches, skid plates. These accessories add up quickly. If your Xpedition is decked out with gear, your brake system is working overtime. The TPR kit ensures your stopping power matches your vehicle's actual weight.

Frequent Passenger Hauling: The Xpedition is designed to carry passengers, but four adults plus gear can push the vehicle's weight significantly above its base curb weight. If you regularly have passengers aboard, this brake upgrade provides peace of mind that you can stop safely no matter the load.

Towing Applications: Planning to tow a trailer with your Xpedition? The additional tongue weight and the momentum of the trailer both demand more from your brake system. This kit provides the stopping power you need to safely tow.

Anyone Concerned About Stopping Power: Even if your Xpedition isn't heavily modified, if you've found yourself wishing for better brakes (especially during steep descents, emergency stops, or when fully loaded), this kit addresses that concern directly.

The bottom line is this: if you've ever felt like your Xpedition's brakes weren't quite up to the task, or if you've added enough weight that you know you're pushing the limits of the factory system, the TPR Industries Big Brake Kit is worth serious consideration. It's an investment in safety and performance that pays dividends every time you touch the brake pedal.

Pricing & Availability

The TPR Industries Big Brake Kit for the Polaris Xpedition is launching soon, and we're excited to offer it to our customers at Jagged X. While the product page is still being finalized, we're accepting inquiries and can provide pre-order information for those ready to upgrade.

Want to be notified the moment this kit becomes available? Subscribe below and we'll send you an email as soon as you can place your order. You'll also get early access to pricing information and any launch specials we might be running.

This kit represents a significant investment in your Xpedition's performance and safety, but when you consider what you've likely already spent on other upgrades (and the peace of mind that comes with genuinely effective brakes), it's an investment that makes sense. We've tried other solutions to address brake performance on modified Xpeditions, and nothing else has delivered results even close to what this kit provides.

The kit will be available through authorized dealers like Jagged X, ensuring you get proper support, installation guidance, and warranty coverage. We'll have both the complete kit in stock as well as the expertise to help you get it installed correctly.

For pre-order information or to discuss whether this kit is right for your specific Xpedition build, contact us directly. We're here to answer questions and help you make an informed decision about this upgrade.

Conclusion & Final Thoughts

After extensive real-world testing of the TPR Industries Big Brake Kit on a heavily modified Polaris Xpedition, we can say without hesitation: this is the brake upgrade the Xpedition community has been waiting for. The performance improvement isn't incremental. It's transformational.

The ability to achieve full brake lockup at 30 and 40 mph, the dramatically reduced stopping distances at all speeds (especially that 72% improvement at 20 mph), and the firm, confidence-inspiring pedal feel all add up to a kit that fundamentally changes how your Xpedition performs in one of the most critical areas: stopping safely.

The installation process is straightforward for those with mechanical aptitude, and the included components are clearly engineered with care and precision. TPR didn't cut corners or take shortcuts. They built a proper big brake system using proven components and custom-engineered mounting solutions.

The adjustable proportioning valve is a standout feature that adds real-world versatility. The ability to tune your brake bias for different loads, uses, and terrain types means you're not locked into a one-size-fits-all solution. This kit adapts to how you use your Xpedition.

If you're running a modified Xpedition (especially one with a long travel kit, larger tires, or heavy accessory loads), this upgrade should be at the top of your list. The factory brake system simply wasn't designed to handle the weight and demands of a fully-built machine, and the TPR kit brings your stopping power to where it needs to be.

Safety should never be an afterthought, and brakes are the most critical safety system on your vehicle. The TPR Industries Big Brake Kit delivers the performance and confidence you need to truly enjoy your Xpedition, regardless of how you've built it or how you're using it.

Ready to upgrade your braking performance? Subscribe for launch notifications, contact us for pre-order information, or stop by Jagged X to discuss your specific build and how this kit can benefit you. Your passengers (and your heart rate on steep descents) will thank you.