We picked up our 2016 Polaris RZR XP 4 Turbo demo at Camp RZR, drove it in stock trim at Glamis and in the desert, and then built it for the kind of riding we actually do. Our dune review and desert review established a strong starting point. This project added long-travel suspension, a cage and doors, shocks, communications, lighting, and separate dirt and sand tire packages.
This is a record of our 2016 build. Parts and specifications below describe the vehicle as it was built; check with each manufacturer for current fitment and availability.
SDR Motorsports Hi-Bred long-travel suspension
We worked with SDR Motorsports in Corona, California, on the layout and fabrication. Its Hi-Bred suspension moved the front wheels forward two inches and the rear wheels back one inch, while extending the arms three inches per side. The system used RCV 300M axle shafts, FK Bearings uniballs, 4130 chromoly spindle pins and Delrin front pivot bushings. SDR combined boxed sections with tubular construction in its proprietary arm material.
We added Walker Evans Racing 2.5-inch Velocity Series shocks with position-sensitive stepped-needle damping and high- and low-speed compression adjustments. The extra stance, wheelbase and shock control made sense for our mix of dunes and desert. The original build used stock shock mounting points; confirm the precise suspension kit and shock fitment before copying this combination.
Cage, doors and occupant protection
SDR’s XPR-4 Fastback Sport Cage ends in the bed instead of wrapping around the rear of the vehicle. It incorporates cross-bracing, intrusion bars and harness bars. We paired it with SDR Hi-Bred bolt-in doors, whose formed aluminum panels attach with Dzus fasteners. A front bumper, Axia Alloys mirrors and quick-release fire-extinguisher mount finished the practical hardware.
SSV Works audio and Rugged Radios communications
Inside, the SSV Works five-speaker setup combined front 6.5-inch kick-panel speakers, rear 6.5-inch cage-mounted speakers, a 10-inch glove-box subwoofer and a four-channel amplifier. An MRB2 Bluetooth dash controller handled basic audio controls while keeping the phone stowed.
For vehicle-to-vehicle communication we installed a Rugged Radios 50-watt VHF radio and passenger intercom. Helmet headsets let the crew talk over engine and wind noise, and the music input fades during conversation. Radio frequencies and legal operating requirements depend on the equipment and location; this list describes our original installation.
Trinity Racing exhaust
A Trinity Racing Stage 5 slip-on dual exhaust added the sound and rear-end appearance we wanted. Our 2016 setup used brushed 304 stainless components with black-finished mufflers. We did not publish a measured horsepower gain for this build.
Vision X lighting and XTC power control
Seven Vision X 4.5-inch Light Cannons across the roof gave the RZR its signature look and long-distance lighting. Snap-on covers allowed different beam patterns and colors. The build also included Vision X Tantrum pods and Optimus Halo lights, plus an XTC Power Products control system and four-foot Whip Tech LED whips. See our detailed XP 4 Turbo lighting setup.
Simpson and Twisted Stitch seats
We used Simpson Vortex seats developed with Twisted Stitch and matching harnesses. The seats’ cutaway lower bolsters made getting into the four-seater easier, while the removable cushions made cleanup after a dusty ride more manageable. Our setup retained the factory seat sliders through its billet mounting hardware.
Dirt and sand wheel-and-tire packages
For dirt, we chose 32x10R15 STI Chicane RX tires on 15×7 STI HD5 beadlocks. The Chicane’s non-directional split-knob tread, eight-ply construction and DOT marking gave us an all-around desert package with more ground clearance than the original tires.
For mixed hardpack and sand, Fullerton Sand Sports recommended a custom-shaved set of Desert Traks mounted on 15-inch Method beadlocks. Their short paddles and center bars offered a different compromise from a dedicated dune paddle when our rides crossed between sand washes, dunes and firmer ground.
Complete 2016 build list
- Base vehicle: 2016 Polaris RZR XP 4 Turbo
- SDR Motorsports Hi-Bred long-travel suspension, RCV 300M axle shafts, XPR-4 Fastback Sport Cage, Hi-Bred doors and front bumper
- Walker Evans Racing 2.5-inch Velocity Series shocks
- SSV Works five-speaker audio system and MRB2 Bluetooth dash controller
- Vision X 4.5-inch Light Cannons, Tantrum pods and Optimus Halo lights
- Axia Alloys side and panoramic mirrors, fire-extinguisher mount and light mounts
- Trinity Racing Stage 5 slip-on exhaust
- STI 32-inch Chicane RX tires and HD5 beadlock wheels for dirt
- Fullerton Sand Sports Desert Traks and 15-inch Method beadlocks for sand
- Simpson/Twisted Stitch seats and harnesses
- Whip Tech four-foot LED whips and XTC Power Products power control system
- Rugged Radios 50-watt VHF radio and intercom
- Wolf Designs graphics wrap
On the trail: Idaho, Oregon, Arizona and California
This was a working project vehicle, photographed at the 2016 Idaho UTV Invasion, DuneFest, on a Mesquite-to-Grand Canyon trip, at Glamis and at Dumont Dunes. The gallery below preserves the original build and trip photos.
Idaho UTV Invasion and DuneFest
Mesquite to Grand Canyon, March 2016
Glamis, March 2016
Dumont Dunes, February 2016
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