Length: 6:32
Date: Nov 1, 2024
What’s up, guys! Braden here with SuperATV, and today we’re walking you through how to install a SuperATV full windshield on a Polaris Expedition. This windshield provides excellent protection from wind, rain, and trail debris—perfect for riders who want added comfort and safety on rugged terrain.
The first step is to remove all contents from your SuperATV windshield kit. Lay the windshield up against the machine to confirm fitment. Once confirmed, remove the protective film from both sides of the windshield to prevent scratching during install.
Now grab your bulb seal. You’ll apply it along the edge of the windshield so that the bulb portion faces away from the SuperATV logo, ensuring it makes solid contact with the machine for a tight seal.
Locate the two pre-drilled center holes near the base of the windshield—this is where you’ll want to start installing the seal. Use a soft tool like a dead blow hammer to tap it in place without damaging the material. Continue pressing the bulb seal all the way around the windshield’s edge.
Next, gather the M8 Allen-head bolts, flat washers, and spacers. These will secure the lower brackets to the frame. If there’s a factory T40 Torx bolt in place, remove it—this machine had a previous windshield, so that step was already done.
Install the bracket using the factory-threaded holes. Loosely thread in the bolts for now—this allows for positional adjustment later once the windshield is aligned.
Now move up the roll cage. Inside the cab, you’ll find factory-threaded holes for your upper brackets. Take the small M6 hex-head bolts (Part A) and install them through the brackets into these threaded holes.
Note: These holes may have corrosion if they’ve never been used before. You may need to thread in the bolts slowly, possibly using a ratchet, to clear the threads without stripping them.
Again, only tighten these bolts enough to hold the brackets in place while still allowing movement for alignment.
Carefully lift the windshield and place it into position on the machine. Use the loosely mounted brackets to adjust alignment. Apply gentle pressure to ensure the windshield seals firmly against the frame, then rotate the brackets by hand into their ideal positions.
Once aligned properly, begin tightening the bracket hardware using your tools. This ensures a snug and accurate fit.
With the windshield in place, drop the shoulder bolts into the designated mounting points. The kit includes six Nylock nuts—four will have matching head sizes, and two will be slightly different. Use the four matching nuts here for the shoulder bolts.
At this stage, do not fully tighten the hardware. First, confirm that the windshield latches and locks into place correctly.
Now that everything is aligned and loosely installed, lock the windshield into position. Make sure all brackets and mounting points are seated properly and that the windshield fits flush against the machine.
Grab the remaining hardware and install the center top bracket. This adds additional support and helps the windshield stay secure during off-road conditions. Line it up as shown and tighten the bolts accordingly.
Once you’re satisfied with the alignment and latching performance, go through and fully tighten all remaining hardware. This includes:
That’s all there is to it! You’ve now successfully installed SuperATV’s full windshield on your Polaris Expedition. This windshield improves your ride comfort and protection no matter where the trail takes you. Check the description below to order your windshield today. While you’re there, be sure to like, comment, and subscribe for more UTV installs and upgrades. Thanks for watching, and we’ll catch you on the next one!
